Graco DutyMax EH 230DI User manual

3A4401A
EN
Operation, Parts, Repair
DutyMax EH™230DI
Hydraulic Sprayer
For professional use only.
Not approved for use in explosive atmosphere or hazardous locations.
For portable airless spraying of architectural paints and coatings.
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual and in related manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.
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23A4401A
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding of Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Switch Tip™ and Guard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clear Tip Clogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clean Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DutyMax EH230DI ProContractor Series Parts . . . . . . . . . . . . . . . . . . . . 22
Spray Gun Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Number Sprayer Model Description
2AZ582 EH230 240VAC, 50Hz, 13.4A

Warnings
3A4401A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this
equipment. The exclamation point symbol alerts you to a general warning and the hazard
symbols refer to procedure-specific risks. When these symbols appear in the body of this
manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols
and warnings not covered in this section may appear throughout the body of this manual where
applicable.
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding
reduces the risk of electric shock by providing an escape wire for the electric current.
This product is equipped with a cord having a grounding wire with an appropriate
grounding plug. The plug must be plugged into an outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
•Improper installation of the grounding plug is able to result in a risk of electric
shock.
•When repair or replacement of the cord or plug is required, do not connect the
grounding wire to either flat blade terminal.
•The wire with insulation having an outer surface that is green with or without
yellow stripes is the grounding wire.
•Check with a qualified electrician or serviceman when the grounding instructions
are not completely understood, or when in doubt as to whether the product is
properly grounded.
•Do not modify the plug provided; if it does not fit the outlet, have the proper outlet
installed by a qualified electrician.
•This product is for use on a nominal 230V circuit and has a grounding plug similar
to the plugs illustrated in the figure below.
•Only connect the product to an outlet having the same configuration as the plug.
•Do not use an adapter with this product.
Extension Cords:
•Use only a 3-wire extension cord that has a grounding plug and a grounding
receptacle that accepts the plug on the product.
•Make sure your extension cord is not damaged. If an extension cord is
necessary, use 12 AWG (2.5 mm2) minimum to carry the current that the product
draws.
•An undersized cord results in a drop in line voltage and loss of power and
overheating.
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Warnings
43A4401A
I
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or
explode. To help prevent fire and explosion:
•Do not spray flammable or combustible materials near an open flame or sources
of ignition such as cigarettes, motors, and electrical equipment.
•Paint or solvent flowing through the equipment is able to result in static
electricity. Static electricity creates a risk of fire or explosion in the presence of
paint or solvent fumes. All parts of the spray system, including the pump, hose
assembly, spray gun, and objects in and around the spray area shall be properly
grounded to protect against static discharge and sparks. Use Graco conductive
or grounded high-pressure airless paint sprayer hoses.
•Verify that all containers and collection systems are grounded to prevent static
discharge. Do not use pail liners unless they are anti static or conductive.
•Connect to a grounded outlet and use grounded extensions cords. Do not use
a 3-to-2 adapter.
•Do not use a paint or a solvent containing halogenated hydrocarbons.
•Do not spray flammable or combustible liquids in a confined area.
•Keep spray area well-ventilated. Keep a good supply of fresh air moving through
the area.
•Sprayer generates sparks. Keep pump assembly in a well ventilated area at
least 20 feet (6.1 m) from the spray area when spraying, flushing, cleaning, or
servicing. Do not spray pump assembly.
•Do not smoke in the spray area or spray where sparks or flame is present.
•Do not operate light switches, engines, or similar spark producing products in the
spray area.
•Keep area clean and free of paint or solvent containers, rags, and other
flammable materials.
•Know the contents of the paints and solvents being sprayed. Read all Safety
Data Sheets (SDS) and container labels provided with the paints and solvents.
Follow the paint and solvents manufacturer’s safety instructions.
•Fire extinguisher equipment shall be present and working.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation.
To avoid severe burns:
•Do not touch hot fluid or equipment.

Warnings
3A4401A 5
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily
injury. In the event that injection occurs, get immediate surgical treatment.
•Do not aim the gun at, or spray any person or animal.
•Keep hands and other body parts away from the discharge. For example, do not
try to stop leaks with any part of the body.
•Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
•Use Graco nozzle tips.
•Use caution when cleaning and changing nozzle tips. In the case where the
nozzle tip clogs while spraying, follow the Pressure Relief Procedure for
turning off the unit and relieving the pressure before removing the nozzle tip to
clean.
•Equipment maintains pressure after power is shut off. Do not leave the
equipment energized or under pressure while unattended. Follow the Pressure
Relief Procedure when the equipment is unattended or not in use, and before
servicing, cleaning, or removing parts.
•Check hoses and parts for signs of damage. Replace any damaged hoses or
parts.
•This system is capable of producing 3300 psi (22.8 MPa, 228 bar). Use Graco
replacement parts or accessories that are rated a minimum of 3300 psi (22.8
MPa, 228 bar).
•Always engage the trigger lock when not spraying. Verify the trigger lock is
functioning properly.
•Verify that all connections are secure before operating the unit.
•Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar
with the controls.
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the
system can cause electric shock.
•Turn off and disconnect power cord before servicing equipment.
•Connect only to grounded electrical outlets.
•Use only 3-wire extension cords.
•Ensure ground prongs are intact on power and extension cords.
•Do not expose to rain. Store indoors.
•Wait five minutes after disconnecting power cord before servicing large
capacitor units.

Warnings
63A4401A
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Always wear appropriate gloves, eye protection, and a respirator or mask when
painting.
•Do not operate or spray near children. Keep children away from equipment at
all times.
•Do not overreach or stand on an unstable support. Keep effective footing and
balance at all times.
•Stay alert and watch what you are doing.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not kink or over-bend the hose.
•Do not expose the hose to temperatures or to pressures in excess of those
specified by Graco.
•Do not use the hose as a strength member to pull or lift the equipment.
•Do not spray with a hose shorter than 25 feet.
•Do not alter or modify equipment. Alterations or modifications may void agency
approvals and create safety hazards.
•Make sure all equipment is rated and approved for the environment in which you
are using it.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can
cause serious chemical reaction and equipment rupture. Failure to follow this
warning can result in death, serious injury, or property damage.
•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated
hydrocarbon solvents or fluids containing such solvents.
•Do not use chlorine bleach.
•Many other fluids may contain chemicals that can react with aluminum. Contact
your material supplier for compatibility.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or
servicing equipment, follow the Pressure Relief Procedure and disconnect all
power sources.

Warnings
3A4401A 7
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Do not wear loose clothing, jewelry or long hair while operating equipment.
•Equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power
sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or
on skin, inhaled, or swallowed.
•Read SDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to
applicable guidelines.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and
be seriously injured.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent
serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and
burns. Protective equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and
solvent manufacturer.

Component Identification
83A4401A
Component Identification
3.
13.
2.
12.
on
off
bar/MPa
PSI
4.
1.
11.
9.
10.
5.
6.
14. 15. 16. 17. 18.
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1 Pressure Gauge
2 Pressure Control
3 Hydraulic Pump Valve
4 ProConnect
5 Displacement Pump
6 Inlet Strainer
9 Electric Motor On/Off Switch
10 Gun Trigger Lock
11 Grounding Clamp
12 Serial Number Tag
13 Prime/Drain Valve
14 Hydraulic Oil Cap / Dipstick
15 Hose Reel Lock
16 Hose Reel Handle
17 Hydraulic Oil Filter
18 Paint Filter

Grounding
3A4401A 9
Grounding
The sprayer cord includes a grounding wire
with an appropriate grounding contact.
The plug must be plugged into an outlet that
is properly installed and grounded in
accordance with all local codes and
ordinances.
Do not modify the plug provided; if it does not
fit the outlet, have the proper outlet installed
by a qualified electrician.
Air and fluid hoses: Use only electrically
conductive hoses with a maximum of 500ft.
(150 m) combined hose length to ensure
grounding continuity. Check electrical
resistance of hoses. If total resistance to
ground exceeds 29 megaohms, replace hose
immediately.
Spray gun: Ground through connection to a
properly grounded fluid hose and pump.
Power Requirements
230V units require 230 VAC, 50/60 Hz, 16A,
1 phase
Extension Cords
Use an extension cord with an undamaged
ground contact. If an extension cord is
necessary, use a 3-wire, 12 AWG (2.5 mm²)
minimum.
NOTE: Smaller gauge or longer extension
cords may reduce sprayer performance.
Grounding of Pails
Solvent pails used when flushing: Follow
local code. Use only conductive metal pails,
placed on a grounded surface. Do not place
the pail on a non-conductive surface, such as
paper or cardboard, which interrupts
grounding continuity.
Always ground a metal pail: connect a
ground wire to the pail. Clamp one end to the
pail and the other end to a true earth ground
such as a water pipe.
To maintain ground continuity when
sprayer is flushed or pressure is relieved:
hold metal part of spray gun firmly to the side
of a grounded metal pail then trigger the gun.
Circuit Protection
Connect sprayers only to circuits which have
the properly sized circuit breaker and/or
fuses (for unit power requirements see
Technical Specifications, page 49.
The equipment must be grounded to
reduce the risk of static sparking. Static
sparking can cause fumes to ignite or
explode. Grounding provides an escape
wire for the electric current.
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Setup
10 3A4401A
Setup
1. Install hose to spray gun and tighten
securely.
2. Engage trigger lock.
3. Remove Tip Guard.
4. Screw inlet strainer to bottom of suction
hose and hand tighten securely.
5. When spraying texture, remove inlet
strainer and filter bowl screen.
6. Fill throat packing nut with TSL to
prevent premature packing wear. Do this
each time you spray.
7. Check hydraulic oil level. Add only Graco
Hydraulic Oil, ISO Grade 46, 169236 (5
gallon/18.9 liter) or 207428 (1 gallon/3.8
liter). Hydraulic tank capacity is 1.25
gallon (4.75 liters).
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Trigger lock engaged
Trigger lock disengaged
1
2
1
2
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Setup
3A4401A 11
8. Attach sprayer grounding clamp to earth
ground.
Pressure Relief Procedure
Follow the Pressure Relief
Procedure whenever you see this
symbol.
.
1. Engage trigger lock.
2. Turn sprayer OFF. Unplug power cord to
electric motor.
3. Move pump valve to OFF and turn
pressure control knob fully
counterclockwise to lowest setting.
4. Disengage trigger lock. Hold metal part
of gun firmly to side of grounded metal
pail, and trigger gun to relieve pressure.
5. Engage trigger lock.
6. Turn prime valve down to DRAIN
position. Leave prime valve down until
ready to spray again.
7. If you suspect the spray tip or hose is
clogged or that pressure has not been
fully relieved:
a. VERY SLOWLY loosen tip guard
retaining nut or hose end coupling to
relieve pressure gradually.
b. Loosen nut or coupling completely.
c. Clear hose or tip obstruction.
Safe Range (cold)
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This equipment stays pressurized until
pressure is manually relieved. To help
prevent serious injury from pressurized
fluid, such as skin injection, splashing fluid
and moving parts, follow the Pressure
Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
the equipment.

Startup
12 3A4401A
Startup
1. Place displacement pump in grounded
metal pail partially filled with flushing
fluid. Attach ground wire to pail and to
earth ground.
2. Turn prime valve down. Turn pressure
control counterclockwise to lowest
pressure.
3. Set hydraulic pump valve OFF.
4. Plug cord into outlet.
5. Turn motor ON.
6. Set hydraulic pump valve ON (hydraulic
motor is now active).
7. Increase pressure enough to start
hydraulic motor stroking and allow fluid
to circulate for 15 seconds; turn pressure
down, turn prime valve horizontal.
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Startup
3A4401A 13
8. Disengage trigger lock.
9. Hold gun against grounded metal
flushing pail. Trigger gun and increase
fluid pressure slowly until pump runs
smoothly.
10. Inspect fittings for leaks. If leaks occur,
turn sprayer OFF immediately. Perform
Pressure Relief Procedure, page 11.
Tighten leaky fittings. Repeat Startup
procedure steps 2-8. If no leaks,
continue to trigger gun until system is
thoroughly flushed.
11. Place displacement pump in paint pail.
12. Trigger gun again into flushing fluid pail
until paint appears.
13. Assemble Tip and Guard, page 14.
High-pressure spray is able to inject toxins
into the body and cause serious bodily
injury. Do not stop leaks with hand or rag.
Trigger lock engaged
Trigger lock disengaged
1
2
1
2
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How to Spray
14 3A4401A
How to Spray
Switch Tip™and Guard
Assembly
1. Perform Pressure Relief Procedure,
page 11.
2. Engage trigger lock. Insert Switch Tip.
Insert seat and OneSeal™.
3. Insert Switch Tip and face forward.
4. Screw assembly onto gun. Tighten.
How to Adjust the Spray
Pattern
1. To adjust the spray pattern direction,
relieve pressure. Loosen the tip guard
retaining nut (B). Turn the tip guard/tip
groove horizontally (C) for a horizontal
pattern and vertically (A) for a vertical
pattern. Tighten the nut.
2. The spray tip orifice and spray angle
determines the coverage and size of
pattern. When more coverage is
needed, use a larger spray tip rather
than increasing fluid pressure.
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NOTICE
Openings in the tip guard reduce paint
buildup on the guard while spraying.
Damage to the sharp edges of the
openings causes paint to collect at that
area. Never hang the gun by the tip guard.
A
B
C
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How to Spray
3A4401A 15
Spray
1. Spray test pattern. Increase pressure to
eliminate heavy edges. Use smaller tip
size if pressure adjustment can not
eliminate heavy edges.
2. Hold gun perpendicular, 10-12 in. (25-30
cm) from surface. Spray back and forth.
Overlap by 50%. Trigger gun after
moving and release before stopping.
Clear Tip Clogs
1. Release trigger, engage trigger lock.
Rotate Switch Tip. Disengage trigger
lock. Trigger gun to clear clog.
2. Engage trigger lock. Return Switch Tip to
original position. Disengage trigger lock
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How to Spray
16 3A4401A
Hose Reel
1. Make sure hose is routed through hose
guide.
2. Lift and turn pivot lock 90° to unlock hose
reel. Pull on hose to remove it from hose
reel.
3. Pull reel handle up and turn clockwise to
reel in hose.
4. NOTE: The hose reel can be locked into
two positions: Usage and Storage.
To avoid injury, keep your head clear of
hose reel while winding up hose.
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Clean Up
3A4401A 17
Clean Up
1. Perform Pressure Relief Procedure,
page 11.
2. Remove Guard and SwitchTip.
3. Remove displacement pump from paint
and place in flushing fluid. Use water for
water-based paint and mineral spirits for
oil based paint.
4. Turn motor switch ON. Turn hydraulic
pump valve ON. Turn prime valve
forward to SPRAY position.
5. Hold gun against pail. Disengage trigger
lock. Turn pressure control up until motor
begins to drive pump. Trigger gun until
flushing fluid appears.
6. Move gun to waste pail, hold gun against
pail, trigger gun to thoroughly flush
system. Release trigger and engage
trigger lock.
7. While continuing to trigger gun, turn
prime valve down. Then release gun
trigger. Allow flushing fluid to circulate
until fluid comes out of drain tube clear.
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Clean Up
18 3A4401A
8. Raise displacement pump above
flushing fluid and run sprayer for 15 to 30
seconds to drain fluid. Turn hydraulic
valve OFF. Turn engine OFF or turn
electric motor OFF and unplug.
9. Engage trigger lock.
10. Unscrew and remove inlet strainer.
Clean and replace strainer if necessary.
11. If flushing with water, flush again with
mineral spirits, or Pump Armor, to leave
a protective coating to prevent freezing
or corrosion.
12. Wipe sprayer, hose and gun with a rag
soaked in water or mineral spirits.
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Maintenance
3A4401A 19
Maintenance
DAILY: Check hydraulic oil level and fill as
necessary.
DAILY: Check hose for wear and damage.
DAILY: Check trigger lock for proper
operation.
DAILY: Check prime/drain valve for proper
operation.
DAILY: Check that displacement pump is
tight.
DAILY: Check level of Throat Seal Liquid
(TSL) in displacement pump packing nut. Fill
nut, if necessary. Keep TSL in nut to help
prevent fluid buildup on piston rod and
premature wear of packings and pump
corrosion.
WEEKLY/DAILY: Remove any debris or
SEMI-ANNUALLY: Check belt wear.
Replace if necessary.
AFTER EACH 500 HOURS OR 3 MONTHS
OF OPERATION: Replace hydraulic oil and
filter with Graco hydraulic oil 169236 (5
gallon/20 liter) or 207428 (1 gallon/3.8 liter)
and filter 246173. Oil change interval
dependent on environmental conditions.
YEARLY OR 2000 HOURS: Replace belt.

Troubleshooting
20 3A4401A
Troubleshooting
Problem Cause Solution
Motor operates, but
displacement pump does not
operate
Hydraulic pump valve is OFF Set hydraulic pump valve ON
Pressure setting too low Increase pressure, page 13
Displacement pump outlet filter
(if used) is dirty or clogged
Clean the filter
Tip or tip filter (if used) is
clogged
Remove tip and/or filter and
clean
Hydraulic fluid too low Shut off sprayer. Add fluid*. See
page 10
Belt worn or broken or off Replace belt
Hydraulic pump worn or
damaged
Bring sprayer to Graco
distributor for repair
Dried paint seized paint pump
rod
Service pump. See Pump, page
41
Hydraulic motor not shifting Set pump valve OFF. Turn
pressure down. Turn engine
OFF. Pry rod up or down until
hydraulic motor shifts.
Displacement pump operates,
but output is low on upstroke
Piston ball check not seating
properly
Service piston ball check. See
Pump, page 41
Piston packings worn or
damaged
Replace packings. See Pump,
page 41
Displacement pump operates,
but output is low on down stroke
and/or on both strokes
Piston packings worn or
damaged
Tighten packing nut or replace
packings. See Pump, page 41
Intake valve ball check not
seating properly
Service intake valve ball check.
See Pump, page 41
Suction tube air leak
Hydraulic oil filter is dirty Replace filter.
Paint leaks and runs over side of
wet cup
Loose wet cup Tighten wet cup enough to stop
leakage
Throat packings worn or
damaged
Replace packings. See Pump,
page 41
Excessive leakage around
hydraulic motor piston rod wiper
Piston rod seal worn or
damaged
Replace these parts. See
Pump, page 41