FULLER O’BRIEN PRO 1002 User manual

OWNER’S MANUAL 308–029
Rev A
PRO 1002 Airless Paint Sprayer
3.5 Horsepower, Gasoline-Powered
Model 223–630
3000 psi (210 bar) MAXIMUM WORKING PRESSURE
TABLE OF CONTENTS
Warnings 2.
. . . . . . . . . . . . . . . . . . . .
Setup 8 . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 9 . . . . . . . . . . . . . . . . . . . . . . .
Startup 10 . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11 . . . . . . . . . . . . . . . . .
Flushing Guidelines 12. . . . . . . . . . .
Troubleshooting Guide 13. . . . . . . .
Repair 14 . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 27. . . .
Parts 30 . . . . . . . . . . . . . . . . . . . . . . .
Accessories 35 . . . . . . . . . . . . . . . . .
Technical Data 35. . . . . . . . . . . . . . .
Dimensions 35 . . . . . . . . . . . . . . . . . .
Warranty 36 . . . . . . . . . . . . . . . . . . . .
THE O’BRIEN CORPORA TION, 450 E. Grand Avenue, So. San Francisco, CA 94080
COPYRIGHT 1990, GRACO INC.
This manual contains IMPORTANT
INSTRUCTIONS and WARNINGS.
READ AND RETAIN FOR REFERENCE.
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.A void accidental trig -
gering
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
T reatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable liq -
uids
in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip -
ment,
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 ciga -
rettes,
arcs from connecting or disconnecting power cords or turn -
ing
light switches on and off.
Failure to follow this warning can result in death or serious injury .
NOTE: This is an example of the DANGER label on your sprayer .
This label is available in other languages, free of charge.
See page 35 to order .

308–029
WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating the equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid through
your
skin and into your body , and cause extremely serious bodily
injury, including the need for amputation. Also, fluid injected or
splashed
into the eyes or on the skin can cause serious damage.
NEVER point the spray gun at any one or at any part of the body .
NEVER
put your hand or fingers over the spray tip. NEVER try
to “blow back” paint; this is NOT an air spray system.
ALWAYS have the tip guard in place on the spray gun when
spraying.
ALWAYS
follow the PRESSURE RELIEF PROCEDURE , below ,
before
cleaning or removing the spray tip or servicing any sys -
tem equipment.
NEVER try to stop or deflect leaks with your hand or body .
Be
sure equipment safety devices are operating properly before
each use.
Medical Alert––Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREA T AS A SIMPLE
CUT.
T ell the doctor exactly what fluid was injected.
Note to Physician : Injection in the skin is a traumatic injury . It
is important to treat the injury surgically as soon as possible.
Do not delay treatment to research toxicity . Toxicity is a
concern with some exotic coatings injected directly into the
blood
stream. Consultation with a plastic surgeon or reconstru -
ctive
hand surgeon may be advisable .
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before
each
use. Do not remove or modify any part of the gun; this can
cause a malfunction and result in serious bodily injury .
Safety Latch
Whenever you stop spraying, even for a moment, always set the
gun safety latch in the closed or “safe” position, making the gun
inoperative. Failure to set the safety latch can result in accidental
triggering of the gun.
Diffuser
The gun dif fuser breaks up spray and reduces the risk of fluid in -
jection when the tip is not installed. Check dif fuser operation
regularly. Follow the PRESSURE RELIEF PROCEDURE, be-
low,
then remove the spray tip. Aim the gun into a metal pail, hold -
ing
the gun firmly to the pail. Using the lowest possible pressure,
trigger the gun. If the fluid emitted is not dif fused into an irregular
stream, replace the dif fuser immediately .
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. The tip guard alerts you to the fluid injection hazard
and helps reduce, but does not prevent, the risk of accidentally
placing your fingers or any part of your body close to the spray
tip.
Trigger Guard
Always have the trigger guard in place on the gun when spraying
to reduce the risk of accidentally triggering the gun if it is dropped
or bumped.
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If the
spray tip clogs while spraying, engage the gun safety latch im -
mediately. ALWAYS follow the PRESSURE RELIEF PROCE-
DURE,
below, and then remove the spray tip to clean it.
NEVER wipe of f build–up around the spray tip until the pressure
is fully relieves and the gun safety is engaged.
PRESSURE RELIEF PROCEDURE
To reduce the risk of serious bodily injury , including fluid injection,
splashing fluid or solvent in the eyes or on the skin, or injury from
moving parts or electric shock, always follow this procedure
whenever
you shut of f the sprayer , when checking or servicing
any part of the spray system, when installing, cleaning or chang -
ing
spray tips, and whenever you stop spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3.
Flip the pressure control switch to OFF .
4. Disengage
the gun safety latch. Hold a metal part of the gun
firmly to the side of a grounded metal pail, and trigger the gun
to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container ready to
catch
the drainage. 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, VER Y SLOWL Y loosen the tip guard retaining nut
or hose coupling to relieve pressure gradually , then loosen com -
pletely.
Now clear the tip or hose.
1,5 2 3
46

3
308–029
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other body
parts. KEEP CLEAR of moving parts when starting or operating
the sprayer . Follow the Pressure Relief Procedure on page 2
before checking or servicing any part of the sprayer , to prevent
it from starting accidentally .
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemi-
cals
and fluids, or using worn or damaged parts, can cause them
to rupture and result in fluid injection, splashing in the eyes or on
the skin, or other serious bodily injury , or fire, explosion or prop -
erty
damage.
NEVER alter or modify any part of this equipment; doing so could
cause it to malfunction.
CHECK all spray equipment regularly and repair or replace worn
or damaged parts immediately .
Always
wear protective eyewear , gloves, clothing and respirator
as recommended by the fluid and solvent manufacturer .
System Pressure
This sprayer can develop 3000 psi (210 bar) MAXIMUM WORK -
ING
PRESSURE. Be sure all spray equipment and accessories
used are rated to withstand the this pressure. DO NOT exceed
the maximum working pressure of any component or accessory
used in the system.
Fluid and Solvent Compatibility
All chemicals used in the sprayer must be chemically compatible
with the wetted parts shown in the TECHNICAL DA TA on page
35. Consult your chemical supplier to ensure compatibility .
Do
not use 1,1,1-trichloroethane, methylene chloride, other ha -
logenated hydrocarbon solvents or fluids containing such sol-
vents in this equipment, which contains aluminum and/or zinc
parts.
Such use could result in a serious chemical reaction, with
the possibility of explosion, which could cause death, serious
bodily
injury and/or substantial property damage.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear ,
damage
or misuse, the high pressure spray emitted from it can
cause a fluid injection injury or other serious bodily injury or prop -
erty
damage.
ALL FLUID HOSES MUST HA VE STRAIN RELIEFS ON BOTH
ENDS! The strain reliefs help protect the hose from kinks or bends
at or close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High
pressure
fluid can dislodge a loose coupling or allow high pres -
sure
spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the entire
hose for cuts, leaks, abrasion, bulging cover, or damage or
movement
of the hose couplings. If any of these conditions exist,
replace the hose immediately . DO NOT try to recouple high pres -
sure hose or mend it with tape or any other device. A repaired
hose
cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULL Y. Do not pull on
hoses to move equipment. Keep hoses clear of moving parts
and
hot surfaces of the pump and gas engine. Do not use fluids
or solvents which are not compatible with the inner tube and
cover
of the hose.
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
grounded
spray system. Check the electrical resistance of your
fluid hoses at least once a week. If your hose does not have a
tag
on it which specifies the maximum electrical resistance, con -
tact the hose supplier or manufacturer for the maximum resis-
tance
limits. Use a resistance meter in the appropriate range for
your hose to check the resistance. If the resistance exceeds the
recommended limits, replace it immediately . An ungrounded or
poorly grounded hose can make your system hazardous. Also
read
FIRE OR EXPLOSION HAZARD, below.
Always
read the chemical manufacturer ’ s literature before using
them in this sprayer .
FIRE OR EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump
and hose. If every part of the spray equipment is not properly
grounded,
sparking may occur , and the system may become haz -
ardous.
Sparking may also occur when plugging in or unplugging
a power supply cord or using a gasoline engine. Sparks can ignite
fumes from solvents and the fluid being sprayed, dust particles
and other flammable substances, whether you are spraying in -
doors
or outdoors, and can cause a fire or explosion and serious
bodily injury and property damage.
If you experience any static sparking or even a slight shock while
using this equipment, ST OP SPRA YING IMMEDIA TELY. Check
the entire system for proper grounding. Do not use the system
again
until the problem has been identified and corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and all
other spray equipment used or located in the spray area.
CHECK
your local electrical code for detailed grounding instruc -
tions
for your area and type of equipment. BE SURE to ground
all of this spray equipment:
1. Sprayer: connect a ground wire and clamp (supplied) to a true
earth ground.
2. Fluid hoses: use only grounded hoses with a maximum  f 500
ft (150 m) combined hose length to ensure grounding continu -
ity.
See Hose Grounding Continuity above.
3.
Spray gun: obtain grounding through connection to a properly
grounded fluid hose and sprayer .
4.
Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to local code.
Use only metal pails, which are conductive. Do not place the
pail on a non–conductive surface, such as paper or card-
board,
which interrupts the grounding continuity .
7.
To maintain grounding continuity when flushing or relieving
pressure
, always hold a metal part of the gun firmly to the side
of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce the risk of fluid injection injury , static sparking, or splash -
ing
by following the flushing procedure given on page 12 of this
manual. Follow the PRESSURE RELIEF PROCEDURE on
page
2, and remove the spray tip before flushing. Hold a metal
part of the gun firmly to the side of a grounded metal pail and use
the lowest possible fluid pressure during flushing.
GASOLINE ENGINE HAZARD
NEVER fill the fuel tank while the engine is running or hot. Fuel
spilled on a hot surface can ignite and cause a fire.
ALWAYS pour fuel in slowly to avoid spilling. Also read FIRE OR
EXPLOSION HAZARD , above, and FUELING on page 9.
NEVER operate the engine in a closed building unless the en-
gine exhaust is piped outside. The exhaust contains carbon
monoxide, a poisonous, odorless and invisible gas which can
cause
serious illness and even death of inhaled.
IMPORTANT
United States Government safety standards have been adopted
under the Occupational Safety and Health Act. These standards
– particularly the General Standards, Part 1910, and the Con-
struction
Standards, Part 1926 – should be consulted.

4308–029
AVERTISSEMENT
La pulvérisation à haute pression peut causer de blessures très graves.
Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité.
Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel.
RISQUES D’INJECTION
Consignes générales de sécurité
Cet appareil produit un fluide à très haute pression. Le fluide pul -
vérisé
par le pistolet ou le fluide sous pression provenant de fuites
ou de ruptures peut pénétrer sou la peau ou à l’intérieur du corps
et entraîner des blessures très graves, voir même une amputa -
tion. Même sans être sous pression, le fluide éclaboussant ou
entrant
dans les yeux peut aussi entraîner des blessures graves.
NE JAMAIS pointer le pistolet vers quelqu’un ou vers une partie
quelconque du corps. NE JAMAIS mettre le main ou les doigts
sur l’ajutage du pulvérisateur . NE JAMAIS essayer de “refouler”
la peinture. Cet appareil N’est P AS un compresseur
pneumatique.
TOUJOURS garder la protection de l’ajutage en place sure le
pistolet
pendant la pulvérisation.
TOUJOURS observer la Marche à Suivre Pour Détendre la
Pression
donnée plus loin, avant de nettoyer ou d’enlever l’aju -
tage du pulvérisateur, ou d’effectuer un travail quelconque sur
une
partie de l’appareil.
NE JAMAIS essayer d’arrêter ou de dévier le fuites avec la main
ou le corps.
Avant chaque utilisation, bien s’assurer que les dispositifs de sé -
curité
fonctionnent correctement.
Soins médicaux
En cas de pénétration de fluide sous la peau: DEMANDER IM -
MEDIATEMENT DES SOINS MÉDICAUX D’URGENCE. NE
PAS SOIGNER CETTE BLESSURE COMME UNE SIMPLE
COUPURE.
Avis au médecin: La pénétration des fluides sous la peau est
un traumatisme. Il est important de traiter chirurgicalement
cette blessure immédiatement. Ne pas retarder le traite-
ment
pour effectuer des recherches sur la toxicité. Certains re -
vêtements exotiques sont dangereusement toxiques quand
ils sont injectés directement dans le sang. Il est souhaitable de
consulter un chirurgien esthétiques ou un chirurgien spéciali -
sé
dans la reconstruction des mains.
Dispositifs de sécurité du pistolet
Avant chaque utilisation, bien s’assure que tous les dispositifs
de
sécurité du pistolet fonctionnent correctement. Ne pas enle -
ver
ni modifier une partie quelconque du pistolet; ceci risquerait
d’entraîner un mauvais fonctionnement et des blessures gra-
ves.
Verrou de sécurité
A chaque fois que l’on s’arrête de pulvériser , même s’il s’agit
d’un
court instant, toujours mettre le verrou de sécurité du pisto -
let
sur la position, “fermée” ou “sécurité” (“safe”), pour empêcher
le pistolet de fonctionner . si le verrou de sécurité n’est pas mis,
le pistolet peut se déclencher accidentellement.
Diffuseur
Le dif fuseur du pistolet sert à diviser le jet et à réduire les risques
d’injection accidentelle quand l’ajutage n’est pas en place. Véri -
fier
le fonctionnement du dif fuseur régulièrement. Pour cette vé -
rification,
détendre la pression en observant la Marche à Suivre
Pour Détendre la Pression donnée plus loin enlever l’ajutage
du pulvérisateur . Pointer le pistolet dans un seau en métal, en le
maintenant fermement contre le seau. puis, en utilisant la pres -
sion
la plus faible possible, appuyer sur la gâchette du pistolet.
Si le fluide projeté n’est pas dif fusé sous forme de jet irrégulier ,
remplacer
immédiatement le dif fuseur.
Protection de l’ajutage
TOUJOURS maintenir la protection de l’ajutage en place sur le
pistolet du pulvérisateur pendant la pulvérisation. La protection
de l’ajutage attire l’attention sur les risques d’injection let contri -
bue à réduire, mai n’évite pas le risque, que les doigts ou une
partie quelconque du corps ne passent accidentellement à
proximité
immédiate de l’ajutage du pulvérisateur .
Consignes de sécurité concernant l’ajutage
du pulvérisateur
Faire extrêmement attention à l’occasion du nettoyage ou due
remplacement des ajutages du pulvérisateur . Si l’ajutage se
bouche pendent la pulvérisation, mettre immédiatement le ver -
rou
de sécurité du pistolet. T OUJOURS bien observe la Marche
à
Suivre Pour Détendre la Pression puis enlever l’ajutage du
pulvérisateur pour le nettoyer .
NE JAMAIS essuyer ce qui s’est accumulé autour de l’ajutage
du pulvérisateur avant que la pression ne soit complètement
tombée
et que le verrou de sécurité du pistolet ne soit engagé.
MARCHE
À
SUIVRE POUR D
É
TENDRE LA PRESSION
Pour réduire les risques de blessures graves, y compris les bles -
sures
par projection de fluide ou celles causées par de éclabous -
sures
dans les yeux ou sur la peau, par des pièces en mouve -
ment,
toujours bien observe cette marche à suivre chaque fois
que l’on arrête le pulvérisateur , à l’occasion de la vérification, du
ègale ou du nettoyage du système ou lors du changement des
ajutages.
1. Engager
le verrou de sécurité du pistolet.
2. Mettre le levier d’arrêt du moteur sur ARRET (OFF).
3. Basculer l’interrupteur de commande de pression sur ARRET
(OFF).
4. Désengager
le verrou de sécurité du pistolet. T out en mainte -
nant
une partie métallique du pistolet fermement appuyé con -
tre
le côte d’un seau en métal, actionner le pistolet pour libérer
la pression.
5. Engager le verrou de sécurité du pistolet.
6. Ouvrir la soupape de sécurité et la laisser ouverte jusqu’à ce
que l’on soit prêt à se servir de nouveau du pulvérisateur .
7.
Débrancher le fil de la bougie.
Si l’on soupconne que le tuyau ou l’ajutage est complètement bou -
ché
o u q u e l a p ressio n n ’ a p a s é t é c omplètemen t l ibéré e après
avoir procédé aux opérations ci–dessus, desserrer TRES LEN -
TEMENT
un raccord de bout de tuyau ou l’écrou de retenue de la
protection de l’ajutage et libérer progressivement la pression.
1,5 23
46

5
308–029
RISQUES EN CAS DE MAUV AISE UTILISA TION DU MATERIAL
Consignes générales de sécurité
toute utilisation anormale de l’appareil du pulvérisation ou des
accessoires comme, par exemple, la mise sous une pression
excessive, les modifications de pièces, l’utilisation de produits
chimiques
et de matières incompatibles et l’utilisation de pièces
usées ou abîmées peut causer des dégâts à l’appareil ou des
ruptures
de pièces et entraîner une injection de liquide ou d‘au -
tres
blessures sérieuses, un incendie, une explosion ou d’autres
dégâts.
Toujours
porter une protection pour les yeux, de gants, des vête -
ments
protecteur et un dispositif pour la respiration correspon -
dant
aux recommandations des fabricants de fluides et solvants.
Pression
Ce pulvérisateur peut produire une PRESSION MAXIMUM DE
TRAVAIL 210 bar (3000 lb/po. @ ) S’assurer que tous les éléments
du pulvérisateur et ses accessoires sont conçus pour résister à
la pression maximum de travail de ce pulvérisateur . NE P AS dé -
passer
la pression maximum de travail d’aucun des éléments ou
accessoires utilisés avec cet appareil.
Compatibilité chimique des corps
BIEN S’ASSURER que tous les corps des solvants utilisés sont
chimiquement compatibles avec les parties mouillées indiquées
dans les “Données techniques”, à page 39. T oujours lire soi-
gneusement les documents et brochures du fabricant des flui-
des et solvants utilisés avant de s’en servir dans ce pulvérisa-
teur.
Le
fluide à haute pression circulant dans les tuyaux peut être très
dangereux. En cas de fuite sur le tuyau, de fissure, déchirure ou
rupture à la suite de l’usure, de dégâts ou d’une mauvaise utilisa -
tion,
les projections de fluide haute pression qui en proviennent
peuvent entraîner des blessures graves par pénétration sous la
peau ou par contact, ainsi que des dégâts matériels.
TOUS LES TUY AUX FLEXIBLES DOIVENT A VOIR DES RES -
SORTS
SPIRALE DE PROTECTION AUX 2 BOUTS! Les spira -
les
de protection contribuent à éviter la formation de pliures, de
boucles ou de nœuds sur les tuyaux qui pourraient entraîner la
rupture du tuyau à l’endroit du raccord ou à son voisinage.
SERRER FERMEMENT tous les raccords avant chaque utilisa -
tion.
Le fluide sous pression peut faire sauter un raccord desser -
ré ou produire un jet à haute pression s’échappant par le rac-
cord.
NE
JAMAIS utiliser un tuyau endommagé. NE P AS essayer de
refaire le raccord d’un tuyau haute pression ni de réparer le
tuyau
avec du ruban adhésif ou par tout autre moyen. Un tuyau
réparé ne peut pas résister au fluide sous pression.
MANIPULER LES TUY AUX A VEC PRECAUTION ET CHOISIR
SOIGNEUSEMENT LEUR CHEMIN. Ne pas déplacer le fluide
en tirant sur le tuyau. Ne pas utiliser de fluides ou de solvants
que
ne sont pas compatibles avec l’enveloppe intérieur ou exté -
rieure
de tuyau. NE P AS exposer le tuyau à fluides des tempéra -
tures supérieures à 82 _C (180 _F) ou inférieures à –40_C
(–40_F).
Continuité de la mise à la terre des tuyaux
Une bonne continuité de la mise à la terre des tuyaux est essen -
tielle
pour maintenir la mise à la terre de l’ensemble de vaporisa -
tion.
Vérifiez la résistance électrique de vos tuyaux à fluides et
à air , au moines une fois par semaine. Si votre tuyau ne compor -
te
pas d’étiquette qui précise la résistance électrique maximum,
prenez contact avec le fournisseur de tuyaux ou la fabricant pour
avoir les limites de résistance maximum. Utilisez un mètre de ré -
sistance
de la gamme appropriée pour votre tuyau et vérifiez la
résistance. Si celle–ci dépasse les limites recommandées, rem -
placez
le tuyau immédiatement. Un tuyau sans mise à la terre ou
avec une mise à la terre incorrecte peut entraîner des risques
pour votre système. Lisez aussi LES RISQUES D’INCENDIE
OU D’EXPLOSION.
RISQUES D’INCENDIE OU D’EXPLOSION
De l’électricité statique est produite par le passage du fluide à
grande
vitesse dans la pompe et dans les tuyaux. Si toutes les
pièces de l’appareil de pulvérisation ne sont pas convenable-
ment
reliées ou à la masse ou à la terre, des étincelles peuvent
se produire et l’appareil risques d’être dangereux. Des étincelles
peuvent Également se produire à l’occasion du branchement ou
du débranchement du cordon d’alimentation ou de l’utilisation
d’un
moteur à essence. Les étincelles sont suf fisantes pour allu -
mer
les vapeurs de solvants et le fluide pulvérisé, les fines parti -
cules
de poussière ainsi que d’autres substances inflammables,
quand on pulvérisé à l’intérieur ou à l’extérieur , et elles peuvent
causer un incendie ou une explosion, ainsi que des blessures
graves
et des dégâts matériels.
S’il se produit des étincelles d’électricité statique, ou si vous res -
sentez
la moindre décharge, ARRETEZ IMMEDIA TEMENT LA
PULVERISATION. Vérifiez que le système avant que le problème
soit identifié et corrigé.
Mise à la terre ou à la masse
Pour réduire les risques de production d’étincelles d’électricité
statique, le pulvérisateur et tous les équipement utilisés ou se
trouvant
dans la zone de pulvérisation doivent être reliés à la ter -
re ou à la masse. Pour connaître le détail des instructions de
mise
à la terre dans la région et le type particulier d’équipement,
CONSULTER le code ou les réglementations électriques loca -
les.
S’ASSURER que tous le équipements de pulvérisation sui -
vants
sont bien reliés à la terre:
1. Pulvérisateur: Relier le file de masses et le collier (fourni) à
une
bonne terre.
2. Pistolet: Réaliser la mise à la terre en le raccordant à une
tuyau
flexible et à une pulvérisateur déjà convenablement re -
liés
à la terre.
3. Tuyaux flexibles: Afin d’assurer la continuité de la mise à la
terre,
n’utiliser que des tuyaux comportant une mise à la terre
et ayant une longueur maximum combinée de 150 m (1500
pieds). Se reporter également au paragraphe, “Continuité
du
circuit de mis à la terre des tuyaux”.
4. Récipient d’alimentation: observer le code ou les réglementa -
tions
locales.
5. Objets, matériel ou surfaces recevant la pulvérisation: obser -
ver
le code ou les réglementations locales.
6. Tous le seaux de solvant utilisés pour le rinçage: observer le
code ou les réglementations locales. N’utiliser que des seaux
métallique conducteurs de l’électricité. Ne pas mettre le seau
sur une surface non conductrice comme sur du papier ou du
carton car cela interromprait la continuité de la mise à la terre.
7. Pour conserver la continuité de la mise à la terre quand on rin -
cé le matériel ou quand on libère la pression, toujours mainte -
nir
une partie métallique du pistolet fermement appuyée con -
tre
le côté d’un seau en métal puis appuyer sur la détente du
pistolet.
Mesures de Sécurité concernant le Rinçage
Pour réduire les risques de blessures par pénétration de la peau
et les risques dûs aux étincelles d’électricité statique ou aux
éclaboussures,
observe la marche à suivre pour le rinçage don -
née
à la page 12 de ce manuel.
RISQUES DUS AUX MOTEURS A ESSENCE
NE JAMAIS remplir le réservoir de carburant quand le moteur
tourne
ou quand il est chaud. Le carburant renversé sur une sur -
face chaude peut s’enflammer et causer un incendie. T OU-
JOURS
verse le carburant lentement pour éviter d’en renverser .
Lire
RISQUES D’INCENDIE OU D’EXPLOSION.
NE JAMAIS faire tourner un moteur dans un bâtiment fermé à
moins
que les gaz d’échappement ne soient dirigés au dehors.
Les gaz d’échappement contiennent de l’oxyde de carbone, un
gaz toxique, inodore et invisible qui peut entraîner des malaises
graves ou même la mort se l’on le respiré.

6308–029
ADVERTENCIA
EL ROCIADO A AL T A PRESION PUEDE CAUSAR GRA VES LESIONES.
SOLO P ARA USO PROFESIONAL. RESPECTE LOS A VISOS DE ADVERTENCIA.
Lea y entienda todo el manual de instrucciones antes de manejar el equipo.
PELIGRO DE INYECCION DE FLUIDO
Seguridad general
Este equipo general un fluido a una presión muy alta. El rociado
de la pistola, los escapes de fluido o roturas de los componentes
pueden inyectar fluido en la piel y el cuerpo y causar lesiones
extremadamente graves, incluyendo a veces la necesidad de
amputación.
T ambién, el fluido inyectado o salpicado en los ojos
puede causar graves daños.
NUNCA
apuntar la pistola hacia alguien o alguna parte del cuer -
po.
NUNCA colocar la mano o los dedos encima de la boquilla.
NUNCA tratar de “hacer retornar la pintura”; este NO es un siste -
ma
de rociado de aire.
SIEMPRE tener colocado el protector de la boquilla en la pistola
mientras se está pulverizando.
SIEMPRE seguir el procedimiento de descarga de presión,
dado
más abajo, antes de limpiar o sacar la boquilla o de dar ser -
vicio
a cualquier del sistema.
NUNCA tratar de parar o desviar los escapes con la mano o el
cuerpo.
Asegurar
que todos los aparatos de seguridad del equipo están
funcionando bien antes de cada uso.
Tratamiento médico
Si pareciera que un poco de fluido penetró la piel, conseguir
TRATAMIENTO
MEDICO DE URGENCIA DE INMEDIA T O. NO
TRAT AR LA HERIDA COMO UN SIMPLE CORTE. Decir al mé -
dico
exactamente cua fluido fue.
Aviso al médico: Si se llega a inyectar este fluido en la piel se
causa una lesión traumática. Es importante tratar quirúrgi -
camente
la lesión a la brevedad posible. No demorar el tra -
tamiento
para investigar la toxicidad. La toxicidad es algo de
sumar importancia en algunas pinturas exóticas cuando se in -
yectan
directamente al torrente sanguíneo. Sirá conveniente
consultar a un especialista en cirugía plástica o reconstructiva
de las manos.
Aparatos de seguridad de la pistola pulverizadora
Asegurar que todos los aparatos protectores de la pistola están
funcionando bien antes de cada uso. No sacar ni modificar nin -
guna
pieza de la pistola pues podría causar el malfuncionamien -
to
de la misma con las consiguientes lesiones personales.
Pestillo de seguridad
Cada vez que se deje de pulverizar, aunque sea por un breve
momento, siempre colocar el pestillo de seguridad en la posi-
ción “cerrada”, lo que deja la pistola inoperante. El no hacerlo
puede
llevar al disparo imprevisto de la pistola.
Difusor
El difusor de la pistola dispersa el chorro pulverizado y reduce
el riesgo de inyección cuando no está instalada la boquilla. Revi -
sar
con regularidad el funcionamiento del difusor . Seguir el pro-
cedimiento
de descarga de presión, dado más abajo, y des -
pués sacar la boquilla. Apuntar la pistola a un balde metálico,
sosteniéndola
bien firme contra él. Utilizando la presión más ba -
jo
posible, disparar la pistola. Si el fluido emitido no sale disperso
en un chorro irregular , reemplazar de inmediato el difusor .
Protector de la boquilla
SIEMPRE tener el protector de la boquilla colocado en la pistola
mientras se está pulverizando. Este protector llama la atención
contra el peligro de inyección y ayuda a reducir, pero no evita,
la
colocación accidental de los dedos o cualquier otra parte del
cuerpo cerca de la boquilla.
Seguridad de la boquilla pulverizadora
Tener mucho cuidado al limpiar o cambiar las boquillas. Si llega -
ra
a obstruirse mientras está pulverizando, enganchar el pestillo
de la pistola de inmediato. SIEMPRE seguir el procedimiento
de descarga de presión y después sacar la boquilla para
limpiarla
NUNCA
limpiar la acumulación de pintura alrededor de la boqui -
lla
antes de que se haya descargado por completo la presión y
el pestillo esté enganchado.
PROCEDIMIENTO DE DESCARGA DE PRESION
Para reducir el riesgo de sufrir graves lesiones corporales, inclu -
yendo
la inyección de fluidos, salpicaduras en los ojos o la piel,
o lesiones causadas por piezas en movimiento, siempre seguir
este procedimiento al apagar la máquina pulverizadora, al revi -
sar,
ajustar o limpiar el sistema, o al cambiar las boquillas.
1. Enganchar el pestillo de seguridad de la pistola.
2. Mover el interruptor de parada del motor a OFF .
3.
Mover el interruptor de control de presión a OFF .
4. Desenganchar el pestillo de seguridad de la pistola. Mante-
ner
una parte metálica de la pistola firmemente contra el lado
de un balde de metal y activar la pistola para descargar la
presión.
5. Volver a enganchar el pestillo de seguridad de la pistola.
6. Abrir la válvula de alivio de presión y dejarla abierta hasta que
se esté nuevamente listo para pulverizar .
7.
Desconectar el cable de la bujía.
Si se sospecha que la boquilla o la manguera esté completamente
obstruida, o que no se ha descargado por completo la presión des -
pués
d e h abe r s eguid o e l p rocedimient o a nterior , a floja r MUY
LENTAMENTE
un adaptador de extremo de la manguera o la tuer -
ca
de renención del protector de lay punta y descargar gradual -
mente la presión.
1,5 23
46

7
308–029
PELIGRO POR MAL USO DEL EQUIPO
Seguridad general
Cualquier mal uso del equipo pulverizador o los accesorios, tal
como sobre presurización, modificación de piezas, uso de ma -
teriales
y productos químicos incompatibles, o utilización de pie -
zas dañadas o desgastadas, puede hacen que se rompan y
causen
la inyección de fluido u otras lesiones corporales graves,
incendio, explosión o daños a la propiedad.
Siempre usar gafas, guantes, vestimentas protectoras y un res -
piradero, tal como recomiendan los fabricantes del fluido y del
solvente.
Presión del sistema
Esta pulverizadora puede desarrollar 210 barías (3000 psi) de
PRESION DE TRABAJO MAXIMA. Asegurar que todo el equipo
pulverizador y sus accesorios tienen la capacidad para aguan -
tar
la presión máxima de trabajo de ningún componente o acce -
sorio
de este sistema.
Compatibilidad de fluido
Siempre leer las instrucciones del fabricante del fluido y solven -
te
antes de usarlos en esta pulverizadora.
SEGURIDAD EN EL USO DE LAS MANGUERAS
El fluido que escapa a alta presión por las mangueras puede ser
muy peligroso. Si en la manguera se desarrola un escape, una
rotura o rajadura debido a cualquier tipo de desgaste, daño o
maltrato, el chorro a alta presión emitido por allí puede causar
una lesión por inyección u otras lesiones corporales graves o
daños
a la propiedad.
¡TODAS LAS MANGUERAS PARA FLUIDOS TIENEN QUE
TENER GUARDAS DE RESORTE EN AMBOS EXTREMOS!
Estas
protegen las mangueras contra dobleces o retorceduras
en los acoplamientos o cerca de ellos, los que podrían traducir -
se
en roturas de la manguera.
Antes de usarlas, APRET AR bien firmes todas las conexiones.
El fluido a lata presión puede desalojar un acoplamiento suelto
o dejar que pro él escape un chorro a alta presión.
NUNCA usar una manguera que está dañada. Siempre revisarla
en busca de cortaduras, escapes, abrasión, cubierta abultada, o
acoplamientos sueltos o dañados. Si llegara a encontrarse cual -
quiera
de estas condiciones, reemplazar de inmediato la mangue -
ra.
NO intentar reacoplar una manguera de alta presión o enmen -
darla
con cinta adhesiva u otro material similar . Una manguera que
ha sido remendada no aguante el fluido al alta presión.
MANEJAR Y P ASAR CUIDADOSAMENTE LAS MANGUE-
RAS.
No tirar de las mangueras para mover el equipo. No usar
fluidos o solventes que sean incompatibles con el tubo interno
y la cubierta de la manguera. NO exponer las mangueras a tem -
peraturas
sobre 82 ) C (180 _ F) o bajo -40 _C (-40_ F).
Continuidad del circuito de puesta a tierra
de la manguera
La continuidad del circuito de puesta a tierra apropiado es esen -
cial para mantener conectado a tierra el sistema pulverizador.
Es
indispensable revisar la resistencia eléctrica máxima de las
mangueras de aire y de fluido por lo menos una vez a la semana.
Si la manguera no tiene una etiqueta en la cual se especifica la
resistencia eléctrica máximum, ponerse en contacto con el pro -
veedor o fabricante de la manguera para la información sobre
los
límites de resistencia. Usar un metro de resistencia en la ga -
ma
apropiada para comprobar la resistencia; si excede los lites
recomendados, reemplazarla de inmediato. Es muy arriesgado
tener una manguera sin puesta a tierra o con la puesta a tierra
en malas condiciones. Leer también la información sobre RIES-
GO DE INCENDIO O EXPLOSION
, más arriba.
PELIGRO DE INCENDIO O EXPLOSION
El flujo a alta velocidad del fluido al pasar por la bomba y mangue -
ra
crea electricidad estática. Si todas las partes del equipo pulve -
rizador
no tienen buena tierra, pueden ocurrir chispas, convirtién -
do al sistema en algo peligroso. T ambién, pueden producirse
chispas
al enchufar o desenchufar el cordón eléctrico o al usar
un motor de gasolina. Estas chispas pueden inflamar los vapores
de los solventes y el chorro de fluido pulverizado, partículas de
polvo y otras sustancias inflamables, sea al aire libre o bajo techo,
lo que podría causar una explosión o incendio y graves lesiones
corporales y daños a la propiedad.
Si ocurre una chispa de electricidad estática o incluso un ligero
choque eléctrico mientras se usa el equipo, DEJAR DE PUL VE-
RIZAR
DE INMEDIA T O. Revisar todo el sistema en busca de una
tierra apropiado. No usar de nuevo el sistema hasta haber identifi -
cado
y solucionado el problema.
Puesta a tierra
Para reducir el riesgo de chispas estáticas, conectar a tierra la
pulverizadora y todo el otro equipo de pulverizar que se use o
se
encuentre en el lugar que se va a rociar . CONSUL T AR el códi -
go
eléctrico de la localidad para las instrucciones sobre las co -
nexiones
a tierra exigidas para la zona y tipo de equipo. ASEGU -
RAR
de conectar a tierra todo este equipo pulverizador:
1. Pulverizadora: Conectar el alambre de tierra y la abrazadera
(suministrada) a una buena conexión a tierra.
2. Mangueras para fluidos: usar solamente mangueras con
puesta a tierra de una longitud combinada de 150 m (500
pies), para asegurar buena continuidad a tierra. Referirse
también
al párrafo sobre continuidad a tierra de la mangue -
ra.
3.
Pistola: hacer la puesta a tierra conectándola a una mangue -
ra
de fluido y pulverizadora bien conectadas a tierra.
4. Suministrar un recipiente: de acuerdo al código local. Usar
solamente baldes de metal, que sean conductivos. No colo -
car el balde en una superficie no conductiva, como papel o
cartón,
que interrumpe la continuidad a tierra.
5. Objeto que se está rociando: de conformidad con el código
local.
6.
Todos los baldes de solvente usados durante el lavado, de
conformidad
con el código local.
7. Para mantener la continuidad a tierra durante el lavado o des -
carga de presión,
siempre apoyar una parte metálica de la
pistola bien firme contra el costado de
balde de metal , des-
pués
apretar el gatillo.
Seguridad durante el lavado
Para reducir el riesgo de que se inyecte o salpique fluido en la
piel, o que ocurra una descarga de electricidad estática, siempre
seguir las INSTRUCCIONES PARA EL LAVADO, dadas en la
página
12. Seguir el procedimiento de descarga de presión
en la página 6, y quitar la boquilla de metal y usar le presión más
baja posible de fluido durante el lavado.
PRECAUCIONES P ARA LOS MOT ORES DE GASOLINA
NUNCA llenar el tanque de combustible mientras el motor está
funcionando o caliente. El combustible derramado en una su-
perficie caliente puede encenderse y provocar un incendio.
SIEMPRE verter el combustible lentamente para evitar derra-
mes.
Leer PELIGRO DE INCENDIO O EXPLOSION.
NUNCA
hacer funcionar el motor en un edificio cerrado sin en–
caminar los gases de escape hacia el aire libre. Los gases de
escape
contienen monóxido de carbono, un gas venenoso, sin
olor e invisible que podría causar enfermedades graves, incluso
la muerte, al inhalarse.

8308–029
SETUP
To reduce the risk of serious bodily injury
caused by static sparking, fluid injection or
over-pressurization and rupture of the hose
or gun, be sure:
1. Connect the sprayer’s ground wire to a
true earth ground. Also read FIRE OR
EXPLOSION HAZARD , on page 3.
2. The spray hoses are electrically
conductive. See additional hose require-
ments in the following CAUTION.
3. The spray gun has a tip guard.
4. All parts added to the sprayer are rated
for at least
3000 psi (210 bar) Maximum
Working Pressure
.
WARNING To avoid damaging the pressure control,
follow these precautions.
1. Always use grounded, flexible spray hose
at least 50 feet (15.2 m) long.
2. Never use a wire braid hose; it is too rigid
to act as a pulsation dampener.
3. Never install a ball valve or shutoff device
between the filter and the first 50 feet
(15 m) of hose.
CAUTION
Fig 1
OUTLET NIPPLE
1/4 npsm(m)
PRESSURE DRAIN V ALVE
PUMP
ON/OFF
SWITCH
PRESSURE
ADJUSTING
KNOB
SECONDAR Y HOSE OUTLET
1/4 npsm(m)
FILL P ACKING NUT/
WET–CUP
1/3 FULL WITH TSL
KEEP P ACKING NUT
JUST TIGHT ENOUGH
T O ST OP LEAKAGE
ENGINE
ON/OFF
SWITCH
GROUND WIRE
AND CLAMP
OIL FILL CAP

9
308–029
SETUP
5. Connect Hose and Gun to the 1/4 npsm(m)
fluid outlet. Be sure to remove the plastic cap
plug from the outlet nipple. For more flexible
gun movement, install a 3 feet, 3/16 inch
diameter hose between the gun and main
spray hose.
DO NOT use thread sealant on the hose and
gun connections. DO NOT install the spray tip
until the system is primed.
6. Fill the Packing Nut/Wet–Cup 1/3 full
with Throat Seal Liquid (TSL), supplied, and
keep it filled, to help extend the pump life.
7. Check the engine oil level. Remove one of
the oil fill plugs; the oil should be almost
overflowing. See Fig 1. Add oil as needed.
Refer also to the engine manual, supplied.
Recommended lubrication oil: Use a high–
quality, detergent oil, SAE 10W–40, classified
“FOR SER VICE SE or SF”, for regular use
and for breaking–in a new engine.
8. Be sure your system is properly grounded
before operating it.
See FIRE OR EXPLO -
SION HAZARD , page 3.
9. Fill the gas tank.
See FUELING, below.
10. Flush the pump to remove the oil which was
left in the pump after factory testing. See
FLUSHING GUIDELINES , page 12.
11. Prepare the paint according to the recom-
mendations on the paint can.
12. Strain the paint through a fine nylon mesh
bag to remove particles that could clog the
filter or spray tip. This is probably the most
important step toward trouble–free spraying.
13. Keep the sprayer upright and level during
operation and whenever it is being moved.
Read the last CAUTION on page 10.
FUELING
Gasoline is extremely flammable and
explosive under certain conditions. To reduce
the risk of a fire or explosion:
DShut off the engine before refueling.
D Refuel in a well–ventilated area.
D Do not smoke or allow flames or sparks in
the area where the engine is refueled or
where the gasoline is stored.
D Do not overfill the tank. Close the filler
cap is securely after refueling.
D Do not spill fuel. Fuel vapor or spilled fuel
can ignite. If any fuel is spilled, make sure
the area is dry before starting the engine.
WARNING
1. Fuel specifications. Use automotive gasoline
with a pump octane number of 86 or higher. If
the engine knocks or pings, use a higher
octane gasoline. Unleaded fuel minimizes
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 damage resulting from the use of
gasolines containing alcohol. See the
engine manual for more information.
3. General. Do not use oil and gasoline mixtures
or contaminated gasoline. Avoid getting dirt,
dust or water in the fuel tank.
4. Tank Capacity: 0.66 gallons (2.5 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.

10 308–029
START UP
NOTE: Refer to Fig 2 as you start the sprayer.
NOTE: When starting a sprayer that IS NOT
PRIMED, remove the spray tip.
1. Open the fuel shutoff valve.
2. Check the engine oil level.
NOTE: The engine stops automatically if it is low
on oil. If you try to restart it without adding
more oil, a red light on the rear of the en-
gine glows as you pull the starter rope.
3. Place the suction tube in the paint.
4. Turn the pressure control switch to OFF.
5. Open the fuel shutoff lever by pushing it in
the direction of the arrow.
6. Be sure the spark plug cable is firmly
pushed onto the spark plug.
Be sure fluid pressure is relieved and the
pressure control is turned OFF before starting
the engine. Attempting to start the engine
when the sprayer is pressurized will damage
the recoil system.
CAUTION
7. To start the engine:
a. Turn
the pressure control adjusting knob
fully counterclockwise to the lowest setting.
b. Pull the throttle lever away from the fuel
tank to the maximum position (fully left).
c. If the engine is cold, close the gray choke
lever, located beneath the air cleaner.
If
the engine is warm, close the choke only
half way or not at all.
d. Turn the engine switch to ON.
WARNING
A rope which recoils too quickly may hit
someone and cause serious bodily injury.
The rope could also jam in the recoil system.
e. Pull the starter rope rapidly and firmly
while holding the frame of the sprayer with
one hand. Hold the rope as it recoils. Pull
and return the rope until the engine starts.
f. Open
the choke. In cold weather , leave the
choke closed for 10 to 30 seconds before
opening it. Otherwise, open the choke as
soon as the engine starts.
8. Disengage the gun safety latch.
9. To start the pump:
a. Open the pressure drain valve.
b. Turn the pressure control switch to ON.
c. Slowly increase the pressure setting until
the pump is cycling slowly. Cycle the pump
until fluid flows smoothly from the pressure
drain valve, indicating the pump is fully
primed.
d. Close the pressure drain valve.
e. Hold
a metal part of the gun firmly against a
grounded metal pail and squeeze the trigger
until fluid is flowing smoothly from the gun.
f. Release the trigger and engage the gun
safety latch.
WARNING
To reduce the risk of serious bodily injury
from fluid injection, NEVER operate the spray
gun with the tip guard removed.
10. Install the spray tip. Refer to the instruction
manual supplied with the tip.
11. Adjust the engine speed and pump
pressure. Set the throttle lever to the
maximum RPM setting (fully left). Trigger the
gun on to 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.
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 and
premature tip wear and pump wear.
CAUTION
Close the fuel valve whenever you are
transporting the sprayer to prevent fuel from
flooding the engine. The fuel can also leak
into the oil and seriously damage the motor.
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 start up
very difficult.
CAUTION

11
308–029
START UP
Fig 2
CLUTCH
HOUSING
FUEL
SHUTOFF
LEVER
CHOKE
THROTTLE
ENGINE
OIL LIGHT
SPARK PLUG CABLE
GAS FILL CAP
ST ARTER ROPE
SUCTION TUBE
PRESSURE DRAIN V ALVE
PUMP
ON/OFF
SWITCH
PRESSURE
ADJUSTING
KNOB
ENGINE ON/OFF SWITCH
PACKING NUT/
WET–CUP
KEEP 1/3 FULL
WITH TSL
AIR FIL TER
MUFFLER
MAINTENANCE
To reduce the risk of serious bodily injury
always follow the Pressure Relief Proce-
dure Warning on page 2 before checking,
adjusting, cleaning or shutting off the sprayer.
WARNING
CAUTION
For detailed engine maintenance and specifi-
cations, refer to the separate engine manual.
Daily: Check and fill the engine oil level as
needed.
Daily: Check and fill the gas tank.
After the first 20 hours of operation and each
100 hours thereafter: Change the oil.
Weekly: Remove the air filter cover and clean
the element. In very dusty environments, check
the filter daily. Replace the element as needed.
Purchase replacement elements from a local
HONDA dealer.
Weekly: Check the level of the TSL in the
displacement pump packing nut. Fill the nut as
needed. TSL helps lubricate the pump packings.
SPARK PLUG:
Use only a (NGK) BP6ES or
BPR6ES plug. Gap the plug to 0.025 to 0.030 in.
(0.7 to 0.8 mm).

12 308–029
FLUSHING GUIDELINES
To reduce the risk of serious bodily injury,
including fluid injection, follow the Pressure
Relief Procedure Warning on page 13 be-
fore flushing the sprayer.
WARNING
When To Flush
1.
New Sprayer . Flush out the factory test oil.
Before using water–base paint, flush with min-
eral spirits, then soapy water, and then clean
water.
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, and then
mineral spirits.
4. Changing from oil–base to water–base
paint. Flush with mineral spirits, then warm,
soapy water, and then clean water.
NEVER leave water in the sprayer if there is
any chance it could freeze. Push the water
out with mineral spirits. Water frozen in the
pressure control tube prevents the sprayer
from being started, and causes serious dam-
age to the pressure control.
CAUTION
5. Storage.
Water base paint: flush with water, then miner-
al spirits and leave the pump, hose and gun
filled with mineral spirits. Relieve pressure.
Oil base paint: flush with mineral spirits and
leave the pump, hose and gun filled with min-
eral spirits. Relieve pressure.
6. Startup after storage.
Before using water–base paint , flush out the
mineral spirits with soapy water, and then with
clean water.
When using oil–based paint, flush out the min-
eral spirits with the paint to be sprayed.
How To Flush
1. Relieve pressure.
2. Remove the filter bowl and screen; see manu-
al 307–273. Clean the screen separately. In-
stall the bowl, without the screen, to flush it.
See Fig 3.
Fig 3
PRESSURE DRAIN V ALVE
FIL
TER BOWL
SCREEN
FILTER
SUPPORT
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.
To reduce the risk of static sparking and
splashing when flushing, remove the spray
tip, and hold a metal part of the gun firmly to
the side of a grounded metal pail .
WARNING
6. Disengage the gun safety latch. Start the
sprayer, trigger the gun and slowly turn the
pressure adjusting knob just until the pump
starts. Keep the gun triggered until clean sol-
vent appears. See Fig 4. Release the trigger
and engage the gun safety latch.
MAINTAIN FIRM MET AL-TO-
MET AL CONT ACT WHEN
FLUSHING T O REDUCE THE
CHANCE OF ST A TIC
SP ARKING AND SPLASHING.
Fig 4
7. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
Start the sprayer. Recheck for leaks.
8. Remove the suction tube from the pail. Disen-
gage the gun safety latch. Trigger the gun to
force solvent from the hose. Do not let the
pump run dry for more than 30 seconds, to
avoid damaging the pump packings! Relieve
pressure.
9. Leave the pressure drain valve open during
non-use. Install the clean screen. Install the
bowl, hand tight.
10. If you flushed with mineral spirits and are
going to use a water–base paint, flush with
soapy water followed by a clean water flush.
Relieve pressure.

13
308–029
TROUBLESHOOTING GUIDE
Pressure Relief Procedure
To reduce the risk of serious bodily injury,
including fluid injection, splashing in the eyes
or on the skin, or injury from moving parts,
always follow this procedure when you shut off
the sprayer, checking, adjusting or cleaning the
system, and when changing spray tips.
1. Engage the gun safety latch.
2. Turn the engine stop lever to OFF.
3. Flip the pressure control switch to OFF.
4. Disengage the gun safety latch. Hold a
metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun.
5. Engage the gun safety latch.
6. Open the fluid pressure drain valve and
leave it open until you start the sprayer
again.
7. Disconnect the spark plug.
If you suspect the hose or spray tip is com-
pletely clogged or that pressure is not fully
relieved after following the steps above,
and
VERY SLOWLY loosen the tip guard retaining
nut or hose coupling to relieve pressure
gradually. Now clear the tip or hose.
WARNING
1,5 2 3
46
Check everything in the chart before disassembling the sprayer. (Continued on page 14)
PROBLEM CAUSE SOLUTION
Engine/sprayer won’t start Engine switch not on T urn on.
Out of gas Replenish
Engine oil level low Try starting engine. If light on rear of engine
glows,
replenish oil.
Spark plug cable disconnected or
spark plug damaged
Connect cable on top of engine or replace spark
plug.
Water frozen in pressure control Return pressure control to authorized Graco
dealer
for repair .
Engine won’t fire Oil seepage into combustion
chamber Remove
and clean spark plug. Slowly pull starter
rope several times. Install plug. T ry to start. Keep
sprayer upright to avoid oil seepage.
Engine operates, but displacement
pump doesn’t
Pressure control switch turned OFF T urn on.
Pressure setting too low Increase pressure.
Displacement pump outlet filter dirty Clean filter .
T ip or tip filter clogged Clean tip or tip filter .
Displacement pump rod seized by
dry paint
Service pump. See page 18.
Connecting rod worn or damaged Replace. See page 20.
Drive housing worn or damaged Replace. See page 21.
Electrical power not energizing field Check wiring connections. See page 16.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check
continuity across black and white wires from
pressure
control.
Have pressure control checked by authorized
dealer.

14 308–029
PROBLEM CAUSE SOLUTION
Engine operates, but displacement
pump doesn’t (continued)
Clutch worn or damaged Service. See page 24.
Pinion assembly worn or damaged Service. See page 22.
Engine starts, but quits when gun is
triggered Oil level low, but not low enough for “Oil
Alert”
light to come on
Add oil.
Displacement pump output low on
upstroke
Pump inlet screen clogged Clean.
Piston ball check not seating Service piston ball check. See page 27 – 29.
Piston packings worn or damaged Replace packings. See page 27 – 29.
Sleeve gasket in displacement pump
worn or damaged
Replace. See page 27 – 29.
Displacement pump output low on
downstroke or both strokes
Pump inlet screen clogged Clean.
Piston packings worn or damaged Replace packings. See page 27–29.
Intake valve ball check not seating
properly
Clean and service. See page 27–29.
Engine RPM too low Increase throttle setting. See Startup,
Step 1 1, page 10.
Clutch worn or damaged Replace. See page 21.
Paint leaks into wet–cup Loose wet–cup T ighten just enough to stop leakage.
Throat packings worn or damaged Replace packings. See page 27–29.
Displacement rod worn or damaged Replace rod. See page 27–29.
Low fluid delivery Pump inlet screen clogged. Clean.
Pressure setting too low Increase pressure. See Startup,
Step 1 1, page 10.
Engine RPM too low Increase throttle setting. See Startup,
Step 1 1, page 10.
Dirty outlet filter , tip filter or tip Clean.
Large pressure drop in hose Use larger diameter hose.
Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake and
tighten. Them prime the pump.
See Startup , page 10.
T ip partially clogged Clear.
Fluid supply is low or empty Refill and prime the pump. See Startup , page 10.
Check fluid supply often to prevent running the
pump dry.

15
308–029
PRESSURE CONTROL REPLACEMENT
To reduce the risk of serious bodily injury, fol-
low the Pressure Relief Procedure Warning
on page 13 before repairing the sprayer.
WARNING
1. Disconnect both hoses at the pressure control
(63), while holding the elbows firmly. Note the
original location of each hose. See Fig 5.
DO NOT allow the elbow (322) to turn when
removing or connecting the hoses, to avoid
damaging the sensitive bourdon tube.
CAUTION
2. Working under the engine mounting plate,
disconnect the three wires. Pull the wires
through the clamp (32) one at a time. Remove
the pressure control screws (62) and pull the
control away from the frame. See Fig 6.
3. Remove the pressure control cover (76) and
the plate (67). See Fig 5.
4. Unscrew the connector (315) from the control
box, pulling the wires out with it.
5. Hold the hex of the adapters (A) with a wrench
while removing the elbows (322).
6. Reinstall the control.
7. Perform the Pressure Control Adjustment
on page 16.
Fig 5
TO
FILTER
TO
PUMP
64
63
76
322
65
67
Fig 6 VIEW
FROM UNDER CART
66
32
66
BLACK
T
O FIELD
TO ENGINE
RED
WHITE
62,9
Fig 7
BLACK
RED
WHITE
308
RED 322
314,305,306
307
308
RED
310,305
RED
~–
+~
RECTIFIER (307) CONNECTIONS
GROUND (308)
BLACKRED
WHITE
TOP VIEW
315
A

16 308–029
PRESSURE CONTROL CALIBRA TION
USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRA TION PROCEDURE to reduce
the risk of a fluid injection injury or other serious bodily injury, which can result from component
rupture, electric shock, fire, explosion or moving parts.
This procedure sets the sprayer to
2600–3000
psi (182–210 bar)
Maximum Working Pressure.
Perform this procedure whenever the pressure
control assembly is reinstalled or replaced, to
be sure the sprayer is properly calibrated.
Improper calibration can cause the sprayer to
over–pressurize and result in component rup-
ture, fire or explosion. It may also prevent the
sprayer from obtaining the maximum working
pressure, resulting in poor performance.
NEVER attempt to increase the fluid outlet
pressure by performing these calibrations in
any other way
. NEVER EXCEED 3000 psi (210
bar)
Maximum Working Pressure. Normal oper-
ation of the sprayer at higher pressures could
result in component rupture, fire or explosion.
ALWA
YS use a new 50 foot (15.2 m) spray
hose, rated for at least
3000 psi (210 bar) Maxi-
mum Working Pressure, when performing this
procedure. A used, under–rated hose could
develop a high pressure leak or rupture.
WARNING
Service Tools Needed:
DNEW 50 foot (15.2 m), 3000 psi (210 bar), flex-
ible nylon airless spray hose, p/n 223–541
D0–5000 psi (0–350 bar) fluid–filled pressure
gauge, p/n 102–814
DNEW spray tip, size 0.025 to 0.029
D3/8 in. ignition wrench
D5 gallon pail and water
DMineral spirits
1. Follow the Pressure Relief Procedure
Warning on page 13. Engage the gun safety
latch.
2. Remove the plug from the top of the fluid filter
and install the fluid-filled gauge. Install the
new test hose in place of the old hose.
3. Remove the pressure control cover.
4. Put the suction tube in a pail of clean water.
5. Start the engine (only).
6. Use the ignition wrench to turn the pressure
adjusting nut (E)
clockwise two full turns.
Turn the pressure control knob (D) to the
minimum setting. Turn the pressure control
switch ON.
7. THE PUMP SHOULD NOT CYCLE. If it does
cycle,
turn the pressure control OFF, relieve
pressure. Engage the gun safety latch. Turn
the adjusting nut (E)
clockwise 1/8 turn. Turn
the pressure control on again to be sure THE
PUMP DOES NOT CYCLE. Repeat this step if
necessary.
8. Increase the throttle setting and then increase
the pressure control setting to the maximum
while triggering the gun. Keep the gun
triggered while observing the pressure at
which the pump stalls, which should be
approximately 3000 psi (210 bar).
NOTE: When the gun trigger is released, it is
normal for the stall pressure to be 3100 to
3400 psi (217 to 238 bar).
9.
If the pressure is not 3000 psi (210 bar), turn
the adjusting nut (E)
clockwise to reduce
pressure and counterclockwise to increase
it, to obtain exactly 3000 psi (210 bar)
pressure.
10. Then, note the pressure to which the gauge
drops when the clutch engages and the
pressure begins to rise again.
11.
If the pressure drops to below 2600 psi (182
bar),
turn the differential wheel (A) clockwise
to raise the pressure to 2600 psi (182 bar).
12.
If the clutch engages and the pressure rises
before 2600 psi (182 bar), turn the differential
wheel (A) counterclockwise to decrease the
pressure.
13. Relieve pressure. Install the pressure control
cover. Flush the water out with mineral spirits,
relieve pressure again, and then remove all
the test equipment.
Fig 8
AD
E
CCW
CW

17
308–029
BEARING HOUSING & CONNECTING ROD
To reduce the risk of serious bodily injury, fol-
low the Pressure Relief Procedure Warning
on page 13 before repairing the sprayer.
WARNING
NOTE: Refer to Fig 9.
1. Remove the pump. See page 27.
2. Remove the front cover (23). Remove the
screws (73) and lockwashers (74) from the
bearing housing (21).
3. While pulling on the connecting rod (22),
lightly tap the lower rear of the bearing
housing (21) with a plastic mallet to loosen it
from the drive housing (20). Pull the bearing
housing (21) and the connecting rod assembly
(22) off the drive housing.
4. If the crank (A) is worn, replace the drive
housing (20).
5. Evenly lubricate the inside of the bronze
bearing (B), and the inside of the connecting
rod link (C), with high–quality motor oil.
Liberally pack the roller bearing (D) with
bearing grease.
6. Assemble the connecting rod (22) and bearing
housing (21).
7. Clean the mating surfaces of the bearing and
drive housings.
8. Align the connecting rod with the crank (A)
and align the locating pins (E) with the the
bearing housing (21). Push the bearing
housing onto the drive housing.
DO NOT use the screws (73) to align or seat
the bearing housing with the drive housing.
Use the locating pins (E), to help avoid pre-
mature bearing wear.
CAUTION
9. Install the screws (73) and lockwashers (74)
on the bearing housing. Tighten the screws
evenly to 175 in–lb (20 N.m).
10. Install the pump. See page 29.
Fig 9
73
Torque to
175 in–lb
(20 N.m)
E
B
59
26
57
27
28
A
21
74
D
C
22
25
68
46
23
20

18 308–029
DRIVE HOUSING
To reduce the risk of serious bodily injury, fol-
low the Pressure Relief Procedure Warning
on page 13 before repairing the sprayer.
WARNING
NOTE: Refer to Fig 10.
1. Remove the front cover (23).
2. Disconnect the pump outlet hose (59).
3. Remove the screws and lockwashers from the
bearing housing (21).
4. Lightly tap the back of the bearing housing
with a plastic mallet. Pull the pump, bearing
housing and connecting rod away from the
drive housing as one assembly.
5. Remove the two screws (24) and lockwashers
(11). Remove the four screws (10) and
lockwashers (11).
6. Lightly tap around the drive housing (20) with
a plastic mallet to loosen it from the pinion
housing (19).
DO NOT drop the gear cluster (18) when re-
moving the drive housing. The gear cluster is
easily damaged. The gear may stay engaged
in the drive housing or the pinion housing.
DO NOT lose the thrust balls (20c or 19m)
located at each end of the gear cluster. The
balls, which are heavily covered with grease,
usually stay in the shaft recesses, but they
could be dislodged. If they are caught be-
tween the gears and not removed, the balls
will seriously damage the drive housing. If the
balls are not in place, the bearings will wear
prematurely.
CAUTION
7. Liberally apply bearing grease (20d, supplied)
to the gear cluster (18). Be sure the thrust
balls (20c and 19m) are in place.
8. Place the bronze colored washer (20a) and
then the silver–colored washer (20b) on the
shaft protruding from the big bearing of the
drive housing (20). Align the gears and push
the new drive housing straight onto the pinion
housing and locating pins (B).
9. Reassemble the sprayer if no further service is
needed.
Fig 10
10
11
19m
18
20c
11
24
68
23
22
20
20a 20b
19
11
10
B
74
73
TORQUE T O
175 IN–LB (20 N.M)
57

19
308–029
PINION, CLUTCH, CLAMP, FIELD & ENGINE
If starting from the pinion housing , first follow
Steps 1 to 6 of
DRIVE HOUSING , on page 18.
If starting from the clutch , see page 21.
PINION HOUSING
Removing the Pinion Housing
To reduce the risk of serious bodily injury, fol-
low the Pressure Relief Procedure Warning
on page 13 before repairing the sprayer.
WARNING
NOTE: Refer to Fig 10.
1. Remove the two bottom screws (10) first, and
then remove the three top screws (10).
2. Pull the pinion housing and armature (4a)
away from the clutch housing (2). Remove the
armature (4a) from the pinion.
Do not lose the thrust ball (19j). Refer to the
CAUTION on page 21 for more information.
CAUTION
NOTE: If you are not repairing pinion go to page
21. To reassemble the sprayer go to Reas-
sembly, page 28, Step 7. Fig
10
19j
4a
11
10
2
11
10
19
SEE P AGE 22
Repairing the Pinion
NOTE: A hydraulic press is required for this proce-
dure if you purchase the pinion parts indi-
vidually. Otherwise, use Repair Kit No.
221–043, which includes the shaft and
bearings pre–assembled and lubricated.
NOTE: Refer to Fig 11 except where noted.
If you are using Repair Kit 221–043, follow Steps
1 to 6, below.
1. Remove the small ring (19e) from the hub and
the large ring (19k) from the bearing recess.
2. Push on the front of the shaft (19b) to force
out the bearing and hub assembly.
3. Press the small bearing (19f) out of the pinion
housing (19n). Remove the new bearing from
the shaft of the kit and press it into the hous-
ing. See DET
AIL A.
4. Install the shaft assembly (19a), pushing it to
the shoulder of the housing (19n).
5. Install the rings (19e and 19k).
6. Skip ahead to Reassembly, page 26, Step 7,
or continue on page 23.
If you purchased parts separately, use the follow-
ing instructions. Disassemble only as far as need-
ed for the parts being replaced.
NOTE: The old bearing (19d) will be damaged
when it is removed for any reason. Always
have an extra one on hand.
1. To replace the small bearing (19c), press the
old one out of the pinion housing (19n).
2. Remove the small ring (19e) from the hub. Re-
move the snap ring (19k) from the bearing
recess.
3. Push on the clutch (19p) to force the bearing
and hub assembly out of the housing.
4.
Using a hydraulic press, place pieces of
steel bar stock on the inner race of the large
bearing (19d) and press the shaft through the
hub and bearing. See Fig 12.
5. Apply lubricant to the parts as shown in Fig
11.

20 308–029
PINION HOUSING
6. Press fit the following parts:
DSmall bearing (19c) into the rear of the
housing (19n). See DETAIL A in Fig 11.
DLarge bearing (19d) to shoulder of the
shaft (19b).
DHub (19f) onto the shaft (19b) all the way
to the large bearing (19d).
7. Install the shaft assembly (19a), pushing it to
the shoulder of the housing (19n).
8. Install the rings (19e and 19k).
9. Skip ahead to Reassembly, page 26, Step 7,
or continue on page 21.
Fig 1 1
Fig 12
PLACEMENT OF STEEL BLOCKS AND BAR
ST OCK WHEN PRESSING OFF LARGE BEARING
19g
Lubricate
exterior
DETAIL A
CUTAWAY VIEW OF PINION HOUSING
SHOWING PLACEMENT OF SMALL
BEARING (19C)
19k
19a
19m
19e
19f
19d
19b
19c
Lubricate inner and
outer diameters
Lubricate teeth
Lubricate inner and
outer diameters
Lubricate exterior
19h
19j
BACK OF
PINION
HOUSING
(19N)
PRESS FIT
SMALL
BEARING
(19C) HERE
HUB (19f)
STEEL BAR
STOCK
TWO STEEL
BLOCKS
ROUND STEEL
BAR T O PUSH
ON SHAFT (19b)
LARGE BEARING
(19d)
PRESS PLA TFORM
HYDRAULIC
PRESS