Hitachi GM7000 User Manual
INSTRUCTIONS-PARTS LIST
308398
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
5.5 HORSEPOWER, GASOLINE–POWERED
GM7000 Airless Paint Sprayer
3000 psi (207 bar, 21 MPa) Maximum Working Pressure
Model 231326, Series D
This is a basic sprayer without a hose or a gun.
Model 231327
This is a complete sprayer with hoses and a
Contractor gun, a RAC IVt DripLesst Tip Guard,
and a 517 size SwitchTipt
Model 231800, Series B
This is a Lo-Boy sprayer without a hose or a gun.
Rev. P
Model 231382
This is a complete sprayer with hoses and a
Contractor gun, a RAC IVt DripLesst Tip Guard,
and a 517 size SwitchTipt
CAUTION
Always use a minimum hose length of 100 foot
(30.4 m) 1/4 inch ID or 50 foot (15.2 m) 3/8 inch ID.
An undersized hose may result in poor equipment
performance and damage to the clutch or pressure
control.
03466B
Model 231327 Shown
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Tube Storage 12. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 13. . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing & Connecting Rod 15. . . . . . . . . . . .
Drive Housing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion, Clutch, Clamp, Field, & Engine 18. . . . . . . . .
Pinion Housing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness 21. . . . . . . . . . . . . . . . . . . . . . .
Clamp 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Clutch Housing 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Replacement 26. . . . . . . . . . . . . . . .
Removing and Installing Pump 27. . . . . . . . . . . . . . . .
Displacement Pump 27. . . . . . . . . . . . . . . . . . . . . . . . .
Parts Lists and Drawings
Model 231326, Basic Sprayer 28. . . . . . . . . . . . . . . . .
Model 231800, Lo-Boy Sprayer 30. . . . . . . . . . . . . . . .
Models 231327 & 231382, Complete Sprayer 34. . .
Pinion Assembly 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 35. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
equipment if the you do not follow the instructions.
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 36 for the maximum working pressure of this equipment.
D Use fluids and solvents compatible with the equipment wetted parts. Refer to the Technical Data
section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Wear hearing protection when operating this equipment.
D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
3083982
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
D Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon monoxide which is colorless and odorless.
D Do not operate this equipment in a closed building.
308398 3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Disconnect all electrical equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
D Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
D Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of
charge. See page 33 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as cigarettes, arcs from connecting or disconnecting power cords or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
3083984
Component Identification and Function
B
M
53
A
51
N
C
D
K
202
L
20
204
203
202 Main hose
203 Whip end hose
204 Contractor gun with RAC IV
DripLess tip guard and 517 size SwitchTip
Fig. 1
A Pressure Control Switch ON/OFF, enables/disables clutch function
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering the carburetor
D Fuel Tank* Holds 0.95 gallons (3.6 liter) of [(R+M)/2]; 86 octane gasoline
E Muffler* Reduces noise of internal combustion
F Spark Plug Cable* Routes electrical current to spark plug
G Fuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor
H Choke* Enriches air/gasoline mixture for cold starting
J Throttle* Adjusts engine speed for large or small orifice spray tips
K Engine Switch* Enables/disables engine operation
L Secondary Fluid Outlet Second hose and spray gun is connected here
M Pressure Control Controls clutch cycling to maintain fluid pressure.
N Primary Fluid Outlet Hose and spray gun is connected here
1 Engine* 5.5 HP gasoline engine
4 Clutch Housing Transfers power from engine to drive assembly
20 Drive Assembly Transfers power from clutch to displacement pumps
28 Displacement Pump Provides fluid to be sprayed through spray gun
51 Fluid Filter Filters fluid between source and spray gun
47 Grounding Clamp and Wire Grounds sprayer system
53 Pressure Drain Valve Relieves fluid pressure when open
71 Pail Hanger Provides a hanger for paint pail
* For more detailed explanations of these controls, refer to the Honda engine manual; supplied
71
28
4
H
G
F
1
E
Model 231327 shown
47
308398 5
J
03467C
Setup
NOTE: A 55 gallon (200 liter) suction tube kit, Part No.
236951, is available.
WARNING
If you are supplying your own hoses and spray
gun, be sure the hoses are electrically conductive,
that the gun has a tip guard, and that each part is
rated for at least 3000 psi (207 bar, 21 MPa) Maxi-
mum Working Pressure. This is to reduce the risk
of serious injury caused by static sparking, fluid
injection or over-pressurization and rupture of the
hose or gun.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions.
1. Always use nylon spray hose. Never use a wire
braid hose; it is too rigid to act as a pulsation
dampener.
2. Two gun hookup. Remove the cap (56) from the
secondary hose outlet. Connect the second outlet
hoses to the sprayer as explained in Step 1,
above.
3. Fill packing nut/wetcup. Fill the packing nut/wetcup (416) 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. See Fig. 2.
4. Check the engine oil level. Refer to the Honda
engine manual, supplied. This is a summary of the
information: Remove one of the oil fill plugs (P);
the oil should be almost overflowing. See Fig. 3.
Add oil as necessary.
Recommended lubrication oil: Use a high–quality,
detergent oil, SAE 10W–40, classified “FOR
SERVICE SE or SF”, for regular use and for
breaking–in a new engine.
51
2. Always use a minimum hose length of 50 foot
(15.2 m) x 3/8 inch ID hose at each outlet.
3. Never install any shutoff device between the filter
(51) and main hose (202). See Fig. 2.
4. Always use the main filter outlet (60) for a one
gun operation. Never plug this outlet.
1. Connect hose and gun. (Refer to Fig. 2.)
a. Remove the plastic cap from the 3/8 npsm (m)
filter outlet nipple (60). Screw the 50 foot (15.2
m) main fluid hose (202) onto the nipple. Read
the CAUTION, above.
b. Connect the whip end hose (203) between the
main fluid hose and the inlet adapter of the
gun (204).
c. DO NOT use thread sealant, and DO NOT
install the spray tip yet!
60
56
202 204 203
Fig. 2
416
Model 231327 shown
03469A
3083986
Setup
5. Be sure your system is properly grounded
before operating it. Read and follow the warning
section, FIRE OR EXPLOSION HAZARD, on page
4. Use the grounding wire and clamp (47) whenever the sprayer is used as a stationary unit.
6. Fill the gas tank. See Fueling, page 8.
7. Flush the pump to remove the lightweight oil
which was left in the pump to protect it from rust.
a. Before using water–base paint, flush with
mineral spirits, followed by soapy water, and
then flush with clean water.
b. Before using oil–base paint, flush with mineral
spirits, only.
c. See Flushing on page 11 for the flushing
procedure.
8. Prepare the paint according to the manufacturer’s
recommendations.
a. Remove any skin that may have formed.
9. Keep the sprayer upright and level during
operation and whenever it is being moved. See the
last CAUTION on page 9.
L
K
47
b. Stir the paint to mix the pigments.
c. Strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove the
particles that could clog the filter or spray tip.
This is probably the most important step
toward trouble–free spraying.
Fig. 3
P
03470A
308398 7
Fueling
WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
Always turn the engine switch (K) to off before
refueling.
Refuel in a well–ventilated area.
Do not smoke or allow flames or sparks in the area
where the engine is refueled or where the gasoline
is stored.
Do not overfill the tank. Make sure the gas fill cap
(L) is securely closed after refueling.
Be careful not to spill fuel when fueling. Fuel vapor
or spilled fuel can ignite. If any fuel is spilled, make
sure the area is dry before starting the engine.
1. Fuel specifications. Use automotive gasoline
with a pump octane number [(R + M)/2] of 86 or
higher, or a research octane number of 91 or
higher. Unleaded fuel minimizes the combustion
chamber deposits.
2. Gasolines containing alcohol (gasohol). Do not
use gasohol which contains methanol, if the gasohol does not contain cosolvents and corrosion
inhibitors for methanol. Even if it does contain such
additives, do not use the gasohol if it contains
more than 5% methanol.
NOTE: The HONDA engine warranty does not cover
the damage resulting from the use of gasolines containing alcohol. See the HONDA engine manual for
more information.
3. General. Do not use any oil and gasoline mixtures
or contaminated gasoline. Avoid getting any dirt,
dust or water in the fuel tank.
4. Tank Capacity. 0.95 gallons (3.6 liter). Always
leave at least 1/2 in. at the top of the tank for
expansion.
5. Shut off the engine before refueling.
6. After refueling, tighten the fuel tank cap firmly.
Startup
Before You Start the Sprayer
1. See Flushing on page 11 to determine if you
should flush the sprayer.
2. Be sure the gas tank is full.
3. Check the engine oil level.
NOTE: The engine stops automatically, or will not
start, if it is low on oil. Refer to the oil fill procedure in
the Honda engine manual or to step 4, page 6.
4. Be sure the spark plug cable is firmly pushed
onto the plug.
Starting the Sprayer
NOTE: Refer to Fig. 1 as you start the sprayer.
1. When starting a sprayer that IS NOT PRIMED,
remove the spray tip.
2. If a secondary hose and gun is not installed,
be sure the cap is securely plugging the secondary
outlet fitting.
3. Place the suction tube into the paint, water or
solvent container, depending on whether you are
flushing or are ready to spray.
3083988
4. Open the black fuel shutoff lever by pushing it in
the direction of the arrow.
CAUTION
Never try to start the engine unless fluid pressure is
relieved and the pressure control switch is OFF.
Trying to start the engine when it is pressurized
could damage the recoil system.
5. Turn the pressure control switch to OFF.
6. To start the engine:
a. Turn the pressure adjusting knob all the way
counterclockwise to the lowest pressure setting.
b. Slide the metal throttle lever away from the
fuel tank to maximum position (fully left).
c. If the engine is cold, close the choke by mov-
ing the gray lever.
d. If the engine is warm, close the choke by
moving the gray lever only half way or not at
all.
e. Turn the engine switch to ON.
Startup
WARNING
A rope which recoils too quickly may hit someone
and cause serious injury. The rope could also jam
in recoil assembly.
f. Hold the frame of the sprayer with one hand
and pull the starter rope rapidly and firmly.
Continue holding the rope as you let it return.
Pull and return the rope until the engine starts.
g. Open the choke as soon as the engine starts,
except in cold weather. In cold weather, leave
the choke closed for 10 to 30 seconds before
opening it to keep the engine running.
7. Unlock the gun trigger safety.
8. To start the pump:
a. Open the pressure drain valve.
b. Turn the pressure control switch to ON.
c. Turn the pressure control knob about 1/4 turn
from minimum pressure. Run the pump until
fluid is flowing smoothly from the pressure
drain valve, indicating the pump is fully primed.
d. Close the pressure drain valve. Hold a metal
part of the gun firmly against a grounded metal
pail and squeeze the trigger until fluid flows
from the gun.
WARNING
To reduce the risk of serious injury from fluid injection, NEVER operate the spray gun with the tip
guard removed.
10. Install the spray tip in the gun. See the separate
tip instruction manual, 308644, supplied.
11. Adjust the engine speed and pump pressure.
Unlock the gun trigger safety. Trigger the gun onto
a test paper to check the spray pattern and atomization. Turn the pressure adjusting knob until you
get a good pattern. Then slowly lower the throttle
setting as far as you can without changing the
spray pattern.
CAUTION
Always use the lowest needed fluid pressure and the
lowest needed throttle setting, to increase the life of
the sprayer. Higher settings cause excessive clutch
cycling, premature tip wear and premature pump
wear.
e. Release the trigger. Lock the gun trigger
safety.
9. If you have not primed the sprayer with paint
yet, move the suction tube to the paint container.
Unlock the gun trigger safety. Trigger the gun into
the water/solvent pail just until paint appears.
Release the trigger and lock the trigger safety.
Repeat for the second gun if two guns are used.
CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayer to prevent fuel from flooding
the engine.
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber, which
makes startup very difficult.
308398 9
Maintenance
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
DAILY: Check the engine oil level and fill as neces-
sary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
DAILY: Check and fill the gas tank.
AFTER THE FIRST 20 HOURS OF OPERATION
Drain the oil and refill with clean oil.
CAUTION
For detailed engine maintenance and specifications,
refer to the separate engine manual, supplied.
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
D are instructed to relieve the pressure,
D stop spraying,
D check or service any of the system equipment,
D or install or clean the spray tip.
WEEKLY: Remove the cover of the air filter and
clean the element. Replace the element, if necessary.
If operating in an unusually dusty environment, check
the filter daily and replace it, if necessary.
Replacement elements can be purchased from your
local HONDA dealer.
WEEKLY: Check the level of the TSL in the displacement pump packing nut. Fill the nut, if necessary. Keep
TSL in the nut to help prevent fluid buildup on the
piston rod and premature wear of the packings.
AFTER EACH 100 HOURS OF OPERATION:
Change the oil.
MONTHLY: Oil connecting rod.
SPARK PLUG: Use only an (NGK) BPR6ES or
W20 EPR-U (NIPPON DENSO) plug. Gap the plug to
0.028 to 0.031 inch (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing the plug.
Pressure Relief Procedure
1. Lock the gun trigger safety.
2. Turn the engine switch to OFF.
3. Move the pressure control switch to OFF.
4. Unlock the trigger safety. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and
trigger the gun to relieve the pressure.
See Fig. 4, A.
5. Lock the gun trigger safety.
6. Open the pressure drain valve. Leave the valve
open until you are ready to spray again.
7. Disconnect the spark plug cable.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY
loosen the tip guard retaining nut or hose end coupling
to relieve the pressure gradually, then loosen completely. Now clear the tip or hose.
30839810
Flushing
When to Flush
1. New Sprayer. This sprayer was factory tested in
lightweight oil,which was left in to protect the pump
parts.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean water flush.
Before using oil–base paint, flush with mineral
spirits.
2. Changing Colors. Flush with a compatible solvent
such as mineral spirits or water.
3. Changing from water–base to oil–base paint. Flush
with warm, soapy water, then mineral spirits.
4. Changing from oil–base to water–base paint. Flush
with mineral spirits, followed by warm, soapy
water, and then a clean water flush.
CAUTION
When using oil–based paint, flush out the mineral
spirits with the paint to be sprayed.
How to Flush
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
NOTE: The word solvent refers to water or oil-based
solvent.
1. Relieve pressure.
2. Remove the filter bowl (A) and screen (B); see
instruction manual 307273, supplied. Install the
bowl and support (C), without the screen, to flush.
Clean the screen separately. See Fig. 5.
To prevent pump corrosion, never leave water or
any type of paint in the sprayer when it is not in use.
Pump the water or the paint out with mineral spirits.
5. Storage.
Water base paint: flush with water, then mineral
spirits and leave the pump, hose and gun filled
with mineral spirits. Shut off the sprayer, remove
the spark plug cable, and open the pressure drain
valve to Relieve the pressure. Leave the drain
valve open.
Oil base paint: flush with mineral spirits and leave
the pump, hose and gun filled with mineral spirits.
Shut off the sprayer, remove the spark plug cable,
and open the pressure drain valve to relieve the
pressure. Leave the drain valve open.
6. Startup after storage.
Before using water–base paint, flush out the
mineral spirits with soapy water, and then with
clean water.
3. Close the pressure drain valve.
4. Put the suction tube in a grounded pail of solvent.
5. Remove the spray tip from the gun(s).
WARNING
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
the gun, and hold a metal part of the gun firmly to
the side of, and aimed into, a grounded metal pail.
See Ref. A in Fig. 4.
A
Fig. 4
01024
308398 11
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