Graco GM 1030 TexSpray Operation manual

INSTRUCTIONS-PARTS LIST
This manual contains IMPORTANT (3 308-269
Rev A
READ AND RETAIN FOR REFERENCE
WARNlNGSend INFORblAnON 0-
For use ONLY with the GM 1030 TexSpray Gun
GM 1030.. Texture Sprayer
GASOLINE-POWERED SPRAYER Patents Pending
WITH PNEUMATIC GUN CONTROL
IO00 psi (70 bar) MRYMUM WORIUNG PRESSURE
The OM1030 TexSpray Sprayer, Gun and Hose Set
are deslgned to work together. This unlque combhation
of components Is posslble because of the Unn’s
Easy Spray Control whfch ensures that no
flufd can
be trapped under pressure In the gun
or hose. When
used accordlng to the lnstructlons, the fluld pressure
wlll not exceed the worklng pressure rating of the components.
with one 50 foot (15 rn) air and fluid hose set
Model 231 -300, Series A
TABLE OF CONTENTS
Warnings ........................ 2
Component Description ........... 4
Setup
........................... 6
Startup .: ........................ 8
Helpful Hints 11
Flushing Guidelines
10
Fueling ......................... 11
Maintenance ..................... 12
Troubleshooting Guide ............ 13
Repair
.......................... 15
Parts. 1.. ........................ 28
Technical Data 35
Accessories 34
Graco
Phone Numbers.. 35
Dimensions 35
Waranty
......................... 36
..............
.....................
.....................
...................
......................
..........
GRACO INC. EO. BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1993, GRACO INC.

HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY OBSERWE ALL WARNINGS.
Read and understand all instruction manuals before operating the equipment.
PRESSURE RELIEF PROCEDURE
This procedure applies to the sprayer when used with of injuty, including injuty from moving parts, always
the
3 GPM pump and Easy Spray Control. If you are follow this procedure when not spraying and before
usino the
1.2 GPM IGM 3012) oaint oumo. follow the checkina or adjusting the system.
Pressure Relief Procedure in manuai
308-127.
Fluid oressure is relieved automatically when the gun
- -
1. Turn the Easy Spray Control to OFF.
trigger is released. However,
to further.reduce therisk 2. Turn the engine stop lever to OFF.
GASOLINE ENGINE HAZARD
NEVER operate the engine in a closed building unless NEVER fill the fuel tank while the engine is running or
the engine exhaust is piped outside. The exhaust con- hot. Fuel spilled on a hot surface can ignite and cause
tains carbon monoxide, a poisonous, odorless and
invisible gas which can &use serious illness and
a fire.
even death of inhaled. ALWAYS pour
fuel in slowly to avoid spilling. Also read
FIRE OR EXPLOSION HAZARD, below, and FUEL-
ING on page 11.
. ..
EQUIPMENT MISUSE HAZARD
General Safety Fluid and Solvent Compatibility
Misuse of the spray equipment or accessories, such
as overpressurizing, modifying parts, using incompat-
All chemicals used in the sprayer must be chemically
ible chemicals and fluids, or using worn or damaged
compatible with the welted parts shown in the TECH-
parts, can cause them
to rupture and result in fluid NEAL DATA on page
35. Consult your chemical
Suoolier
to ensure comDatibiliW.
*>.,.<
injection, splashing in the eyes or on the skin, or other
serious bodily injury, or fire, explosion or property
Do not use 1,1,1-trichloroethane, methylene chloride,
damaoe. other halogenated hydrocarbon solvents or fluids con-
,.
NEVER alter or modify any part of this equipment; taining such solvents
in this equipment, which con-
doing so could cause it to malfunction. tains aluminum and/or zinc parts. Such use could re-
sult in a serious chemical reaction, with the possibility
CHECK
all spray equipment regularly and repair or . of exolosion. which could cause death, serious bodily
I
replace worn or damaged parts immediately. injui and/or substantial property damage.
Always wear protective eyewear, gloves, clothing and
respirator as recommended by the fluid and solvent
manufacturer.
System Pressure
This sprayer can develop
1000 psi (70 bar) MAXIMUM
WORKING PRESSURE.
The GM1030 TexSpray Sprayer, Gun and Hose Set
are designed
to work together. This unique cornbina-
tion of components
is possible because of the unit's
Easy Spray Control which ensures that no fluid can
be trapped under pressure in the gun or hose. When
used according
to the instructions, the fluid pressure
will not exceed the working pressure rating of the
components.
2 308-269

HOSE SAFETY
Use only genuine Graco hoses and replacement Handle and route hoses carefully. Do not pull on
hoses as shown on page 30 and page
34. The hose hoses
to move equipment. Keep hoses clear of mov-
used at the sprayer
outlet must have a spring guard ing parts and hot surfaces of the pump and gas en-
at that end. gine.
Do not use fluids or solvents which are not com-
Tighten all fluid connections securely before each patible with the inner tube and cover of the hose.
DO
NOT exDose Graco hoses to temperatures above
use;
Do not use a damaged or repaired hose. Before each
use, check the entire hose for cuts, leaks, abrasion, If the hose develops a leak, split or rupture due to any
couplings.
If any of these conditions exist, replace the
bulging cover, or damage or movement of the hose kind of wear, damage or misuse, the spray coming
from it can cause splashing on the eyes or skin or
hose immediately. property damage.
FIRE OR EXPLOSION HAZARD
The GM 1030 TexSpray Sprayer are intended for use sory, GM 3012, you must provide complete system
outside and with texture materials at low application grounding, as explained in manual 308-127,
pressures.
If you are using the sprayer for any other supplied with the GM 3012.
application, including the high pressure pump acws-
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other
body parts. KEEP
CLEAR of moving parts when start-
lief Procedure above before checking or servicing
ing or operating the sprayer. Follow the Pressure Re-
any part of the sprayer, to prevent
it from starting acci-
dentally.
IMPORTANT
These standards - particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 -
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
should be consulted.
180- F (82. C) or below -40Q F (-40' C).
308-269 3

COMPONENT DESCRIPTION
Easy Spray Control
The Easy Spray Control (A) has a quick shut off and
pressure relief feature
so you get a soft start each
time you trigger the gun, instead of a blast of unato-
mized material.
See Fig 1. The control has three
modes:
e SPRAYIFILL HOSE Triggering the gun sends an
the Automatic Pressure Drain Valve and starts the
air signal
to the Easy Spray Control that closes
pump which fills the material hose. When the gun
trigger
is released, the Automatic Pressure Drain
Valve opens and relieves the system pressure into
the supply container. This automatic pressure
design eliminates blasts of material when the gun
relief and the special TexSpray hoses and pump
is triggered and eliminates "spray pulsing" to
ensure consistent atomization.
e OFF/RELIEVE PRESSURE Puts the sprayer in
the gun
will operate and there is no material pres-
neutralhelieve pressure
- neither the pump nor
sure in the pump, hose or gun.
PRIME PUMP The Automatic Pressure Drain
Valve remains open
so material circulates through
the pump and back to the drum through the drain
hose.
I .
I SPRAY I FILL HOSE^-
Automatic Pressure Drain Valve
The pressure drain valve (B) automatically relieves
system pressure when you release
the gun trigger
and also stops
the pump. See Fig 1.
TexSpray Gun, P/N 235-490
WARNING
This gun is for use ONLY with the GM 1030
TexSpray system, P/N 231 -300.
The operator controls the air flow at the gun. During
priming, turn the gun's Air Control Valve (C) in fully
to
prevent air from mixing with the fluid, which allows
you to check and adjust the fluid flow accurately.
(When this valve is closed the air exits the rear of the
gun.) During operation, open the Air Control Valve
to
introduce air at the correct volume for the desired
spray pattern. The gun also has a trigger bail (D) to
reduce operator fatigue when spraying large surfaces.
See Fig
2.
Fig 2
TexSpray Hoses
CAUTION
with this sprayer. Using other hoses will damage
Use only genuine Graco hoses designed for use
2 gpm Pump Kit, P/N 235-965
TexSpray 3 gpm pump. Use it when spraying smooth
This accessory
kt directly replaces the standard
and fine textures where lower volume
is important for
better control. (Not shown.)
4 308-269

COMPONENT DESCRIPTION
GM3012 High Pressure Paint Pump Kit,
PIN 224-524
Convert the GM1030 TexSpray sprayer to an airless
sprayer to spray primer, sealer, smooth elaStomericS
and paints at up to
1.25 gpm (4.75 Ipm) with 0.035
maximum size spray tip at 3000 psi (210 bar)
Maximum Working Pressure. This accessory includes
a
high pressure pump, fluid filter, optional filter
screen, drain valve and pressure control.
See Fig 3.
Switching pumps takes about 5 minutes. See the
ACCESSORIES section on page
34. Refer to the.
manual
308-127, supplied with @e kit, for specific
warnings, setup, operating and repair procedures.
Fig 3 0416
Compressor Requirements
NOTE This sprayer will not operate without an external air compressor.
Air compressor range:
5 scfm to 35 scfm, 30 to 100 psi (2 to 7.6 bar)
2 gpm Desired Fluid Flow
3 gpm Desired Fluid Flow
Material
Minimum Minimum
Air Requirements*
(0.7 m31min at 6.3 bar)
(textured)
30 scfm at 90 psi
15
HP
25 scfm at 90 psi Elastomerics
Compressor
Size Air Requirements* Compressor Size
18 HP
(0.64 rn31min at 6.3 bar)
Simulated
15 scfm at 40 psi
5 HP
Knockdown
10 scfm at 40 psi Splatter Coat and
(0.56 m31min at 4.2 bar)
(0.42 m3/min at 4.2 bar)
Accoustical
10 HP
20 scfm at 60 psi 8 HP
15 scfm at 60 psi
(0.42 m31min at 2.8 bar)
(0.28 m31min at 2.8 bar)
15 HP
I' I I I
Orange Peel 15 scfm at 60 psi
10 HP 8 HP 20 scfm at 60 psi
10~42 rn3lrnin at 4~2 bar1 (0.56 rn3Imin at 4.2 bar1
Material, temperature and volume affect the dm needed to properly atomize the material.
Fluid Nozzle and Spray Disc Selection
Three spray discs and nozzles are supplied with the Refer to Steps 7 and 8 on page 9 to fine tune the
sprayer. The nozzles are numbered
1,2 or 3 - the spray pattern.
larger the number the more scfm is required. These
parts can be interchanged to produce a pattem suit-
able for each job.
Spray
Discs (by aggregate size)
Material
114" I 114-318" I 318"
1 18"
#3 Elastomerics
Fluid
Nozzle
Fine
Extra Coarse
Coarse
Medium
Simulated
Accoustical
n/a nla nla
116 - 114"
#2
Orange Peel
n/a
nla nla
114 - 318" #1 Splatter Coat* and Knockdown
318"
1 14 - 318"
114"
1 16"
#2
When spraying interior splatter coat with heavy (unthinned or slightly thinned) drywall mud and the desired flow
rate is
1 gpm or less, we recommend using the accessory 2 gpm pump, P/N 235-965.
308-269 5

SETUP
Fig 4 01780
I 1
1. .&ad and follow the WARNINGS on pages 2 and
These procedures are only for this sprayer when 3 to help you to operate the system safely.
used with the
3 GPM texture wmD. If usina the
GM 3012 high pressure pain; pump, refer io the
manual supplied with
it for specific information.
2. .&ad the COMPONENT DESCRIPTION on pages
4 and 5 to familiarize yourself with the features
of this sprayer and to select a spray disc and
NOTE Refer to Fig 4 unless otherwise indicated. nozzle combination.
6 308-269

SETUP
3. Connect the spring guard end of the 50 R
(15 m) material hose (85b) to the outlet of the
automatic pressure drain valve
(2).
WARNING
A spring guarded material hose (85b) must be
drain valve. The spring guard helps protect the
Installed at the outlet of the automatic pressure
hose from stress and strain.
4. Connect the gun air hose (85a) to the Easy SPMY
Control
(75).
5. Connect additional material and air hoses up to
150 ft (45 m). See page 38 to order.
6. Connect the air and material hoses to the gun
and tighten securely.
7. Connect a 1/2" ID compressor air hose (customer
supplied) to the air regulator inlet (C).
Do not use
quick disconnect couplers.
8. Tighten the pump's lug nut (214) very tight using
a hammer. This helps prevent air leaks which
prevent priming.
9. Clamp the siphon hose to the pump. Be sure the
gasket is in place in the quick disconnect elbow
(le)
- air leaks will prevent priming.
IO. Connect the drain hose (86) to the rear outlet of
the automatic pressure drain valve (2).
11.
Install the hose clips (83) on the siphon hose and
drain hose
as shown.
'C
01811
Fig 5
12. See page 9 for disc and nozzle recommenda-
tions. Install the disc (A) and nozzle
(B) on the
gun. as shown in Fig
5. Tighten the retaining rings
(C and
D) snugly, but do not use a wrench.
13. Add Throat Seal Liquid, supplied, to the Pump
wet cup
(B) until it is visible at the top of the cup.
14. Check the engine oil level. Refer to the Honda
engine manual, supplied. In summary: remove
one oil
fill plug (E) - the oil should be almost
overflowing. Add oil as necessary. Also read the
MAINTENANCE section on page
12.
Recommended engine oil: Use a high-quality,
detergent
oil, SAE IOW-40, classified "FOR
SERVICE SE or SF".
start, if it is
low on oil. If you try to start it again without
NOTE: The engine stops automatically, or will not
adding more oil,
a red light near the engine on/off
switch
glows as you pull the starter rope.
15. Fill the gas tank. See FUELING, page 11.
16. Agitate or mix the material thoroughly1 Make sure
the heavier material on the bottom of the contain-
er is completely mixed in.
17. Start the sprayer. See page
8.
308-269 7

START UP
Fig 6
01181
WARNING
These procedures are only for this sprayer when
used with the 3 GPM texture pump. If using the
GM3012 high pressure paint pump, refer to the
manual supplied with it for specific information.
Always start the sprayer using water or a com-
patible solvent and circulate the solvent for at
fore priming with the texture material.
This helps
least one minute
to wet the pump and hoses be-
prevent material from packing out the hoses.
2.
3.
4.
Prime the Pump
NOTE Before vou start tboraver the first time, flush
out the lightweight oil left in for storage. See
FLUSHING GUIDELINES on page
10.
1. Route the siphon hose (1 a) and drain hose over
the cart’s hose rack and into the water or solvent
container.
8 308-269
Set the Easy Spray Control (75) to PRIME.
Turn the gun’s Air Control Valve (G) fully in.
Start the engine:
a.
b.
C.
d.
e.
Turn ON the engine switch (B).
Open the black fuel shutoff lever (C) by push-
ing
it in the direction of the arrow.
Slide the throttle lever
(E) fully left to the maxi-
mum position.
If the engine is cold, close the choke (D) (fully
left)
.
If the engine is warm, close the choke half
way or not at all.
continued on
page 9

START UP
WARNING
Hold the engine starter rope as it recoils to
prevent
lt hitting someone and causing injury, or
f. Hold the frame of the sprayer with one hand
and pull the starter rope rapidly and firmly.
Continue holding the rope as it returns.
Repeat 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.
5.
Prime with texture material
suction strainer.
NOTE If the pump does not prime easily, remove the
a.
b.
C.
d.
Reduce the engine speed.
Put the siphon hose (la) in the prepared
texture material.
Set the Easy Spray Control to
PRIME to load
the pump. Set the control to
SPRAY when
material appears at the drain hose.
Trigger the gun and direct the solvent into the
solvent container, then when the texture mate-
rial appears, direct the flow into a material
drum.
If you are ready to adjust the spray
pattern, do not release the trigger.
.,
6. Fill the pump:
a.
b.
C.
d.
Start the air compressor and adjust the pres-
sure according to the chart on page
9, or to at
least
30 psi (2.8 bar)
Set the Easy Spray Control
(75) to SPRAY
Trigger the gun for about one minute,
directing the fluid back into the solvent
container. (Air will exit the rear
of the gun.)
Thls starts the pump and wets the hoses.
Release the trigger. The system pressure will
be relieved automatically.
7. To adjust the spray pattern:
a.
b.
While triggering the gun, adjust the engine
good starting point is to adjust the fluid flow
RPM to determine fluid flow and pressure. A
until you have an 8 in (20 cm) stream.
Holding the gun 18 to 30 in (0.5 to 1.0 m)
from a test surface, test the spray pattern
while backing out the gun's Air Control Valve
(G) which allows the air to atomize the fluid.
Adjust the Air Control Valve to obtain.the
desired spray pattern.
TIP More fluid flow = more air,
and less fluid flow
= less air.
c. If you cannot get a good spray pattern, try
adjusting the air compressor pressure or try
another spray disc and nozzle combination.
8. To prevent material surge at the beginning of a
spray pattern
a. Always trigger the gun fuilF
If triggered partially, which only triggers the air
portion of the system, the pump will start and
complete the triggering action you will get a
pressurize the hoses. Then when you
blast of unatomized material.
b.
When you release the gun trigger, allow the
materlal
to completely depressurize before
trlggerlng the gun agaln.
Failure to do this will result in spraying some
to back up into the gun air passages and
unatomized material, and may cause material
block air flow. Longer hoses and heavier
material may take several seconds longer to
depressurize.
As you test the spray pattern, also time how
long
it determine to depressurize the system
and keep that
in mind as you are working.
/G
Fig 7
OIBOB
Use the lowest fluid pressure and the lowest
throttle setting needed. Higher settings cause
excessive drain time from the dump valve and
premature seal wear.
9. When you stop spraying release the gun trigger
to relieve pressure. Shut
off the sprayer.
308-269 9
~~~

FLUSHING GUIDELINES
NOTE Several flushes are often required to thor-
fluid to be sprayed, or to store the sprayer. Use this
oughly clean
the system and prepare it for the next
chart to determine the required flushes for the fluids
you are using, and then follow the procedure below
for flushing.
*Use this categoty for flushing a brand new sprayer
and flushing after storage.
System has
sprayed.
this fluid in It:
Flushing order: Next fluid to be Before you spray or store
sprayer:
Flush
1 I Flush 2 I Flush 3
I I I I I
'Oil-base fluid Prime with oil-base fluid none none Mineral spirits
Oil-base fluid
-
new color
Oil-base
Leave drain valve oDen
water*
storage Relieve pressure,
Mineral spirits
Clean water Warm soapy
base fluid
Prepare for
Water or water-
water*
base fluid
Prime with oil
Mineral spirits
Clean water Warm soapy Oil-base fluid Water or water-
Prime with water
water*
- new color
base fluid
none
Clean water
Warm soapy
Water-base fluid Water or water-
Leave drain valve open
Relieve pressure,
storage
solvent or fluid
none
none Mineral spirits Prepare for Oil-base
Prime with water-base
Clean water
Warm soapy Mineral spirits Water-base fluid
water fluid
*We recommend using Graco Gold Soap, P/N 162-805.
NOTE Refer to Figs 6 and 7. 4. Release the trigger - pressure will be relieved
1. Setup - prepare a pail of warm, soapy water or
way In.
Start the sprayer in the OFF mode.
solvent. Turn the gun's Air Control Valve all the
automatically.
.. 5. Set the Easy Spray control to PRIME.
2. Set the Easy Spray control to SPRAY
3. Trigger the gun. Direct the spray material into a 6. Circulate the flushing fluid through the pump,
waste container until the flushing fluid appears. siphon hose and drain hose until well flushed.
Now direct the flushing fluid into the flushing pail,
secure the trigger bail to keep the gun triggered
thoroughly flushed.
and circulate the fluid until the gun and hose are
7. If you are are going to prime the system to spray,
see page 8.
10 308-269

HELPFUL HINTS
A spraying distance of 18 to 30 in (0.5 to 0
1 .O mm) is recommended for most applications.
Keep the
gun triggered and moving as much as
possible.
0
Set the gun's trigger ball to hold the trigger
open and reduce operator fatigue on large area
surfaces.
0
When releasing the trigger wait until the system
pressure is fully relieved before triggering the gun
again to eliminate a blast of unatomized material.
0
texture compresses easily so the system pressure
Simulated acoustic material with polystyrene
builds up more slowly.
. ..
When spraying elastomerlcs, maintain a wet
edge, spray vertical passes followed by horizontal
passes. Then hold the gun further away and
"dust" the area to blend in the pattern.
To spray ceilings
as high as 9 to 12 ft (3 to 4 m)
without using stilts or scaffolding, use a higher
Valve more to project the material onto the ceiling,
englne RPM and open the gun's Air Adjustment
and increase the regualtor air pressure.
To spray a small, confined area, you may be
able to restrict the spray pattern sufficiently by
restricting the gun's air. For further adjustment,
reduce the engine RPM.
The material may thicken as it sits which slows
Check the material consistency periodically.
down production. Check and thin the material
as
needed to maintain proper consistency.
FUELING
WARNING
Gasoline
is extremely flammable and explosive
under certain conditions. To reduce the risk of a
fire or explosion follow the Refueling Procedure
Fuel Specifications
1. Use automotive gasoline with a pump octane
number of
86 or higher. If the engine knocks or
pings, use a higher octane fuel.
2. Unleaded fuel minimizes combustion chamber
deposits.
3. If using gasohol, it may contain no more than 5%
and corrosion inhibitors.
methanol,
dit must have methanol cosolvents
damage resulting from the use of gasolines contain-
NO= The HONDA engine warranty does not cover
ing alcohol.
4. Do not use oil and gasoline mixtures or contami-
nated gasoline.
Refueling Procedure
1. Shut off the engine before refueling.
2. Refuel in a well-ventilated area. Do not smoke or
allow flames or sparks in the area where the en-
gine
is refueled or where the gasoline is stored.
3. The tank capacity is 0.95 gal (3.6 I). Leave 1/2 in
(13 mm) at the top of the tank for gas expansion.
4. Fuel vapor or spilled fuel can ignite. If any fuel is
spilled, make sure the area is dry before starting
the engine.
5. Tighten the fuel tank cap firmly.
CAUTION
Close the black fuel shutoff lever whenever you
flooding the engine.
are transporting the sprayer to prevent fuel from
ing it and when transporting it. This prevents
Keep the sprayer upright and level when operat-
crankcase oil from leaking into the combustion
chamber, which makes start up very difficult.
308-269 11

MAINTENANCE
WARNING
Pressure
Relief Procedure
Thls procedure only applies to the sprayer when
used with the
3 GPM pump and Easy Spray
Control.
If you are using the GM3012 high pres-
sure paint pump, follow the Pressure Relief
Procedure in manual 308-127.
Fluid pressure
is relieved automatically when the
gun trigger is released. However, to further re-
duce the risk of serious bodily injury, including
injury from moving parts, always follow the
Pressure
Relief Procedure Warning on page 2
before checking, adjusting, cleaning or shutting
down the sprayer.
1. Set the Easy Spray Control to OFF.
2. Turn the engine stop lever to OFF.
CAUTION
For detailed engine maintenance and specifica-
tions, refer to the separate HONDA engine
CAUTION
are transporting the sprayer to prevent fuel from
Close the black fuel shutoff lever whenever you
flooding
the engine.
Keep the sprayer upright and level when operat-
ing
it and when transporting it. This prevents
crankcase oil from leaking into the combustion
chamber, which makes startup very difficult
DAILk Check the engine oil level and fill
as needed.
DAILk 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 fiiter
daily. Replace the element as needed. Replacement
elements can be purchased from your local HONDA
dealer.
SPARK PLUG: Use only a (NGK) BPGES or BPRGES
plug. Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8
mm). Always use a spark plug wrench.
12 308-269

TROUBLESHOOTING GUIDE
WARNING
Pressure Relief Procedure gun trigger is released. However, to further reduce
This procedure only applies to the sprayer when the risk of injury, including injury from moving
used with the
3 GPM pump and Easy Spray
Control.
If you are using the 1.2 GPM pump kit, spraying and before checking or adjusting the
parts, always follow this procedure when not
Model
224-524, follow the Pressure Relief Proce system.
dure in manual
308-127.
Fluid pressure is relieved automatically when the 2. Turn the engine stop lever to OFF.
1. Turn the Easy Spray Control to OFF.
I
Check everything in the chart before disassembling the sprayer.
'ROBLEM
Engine won't start Engine switch not on
Out of gas
Try starting engine.
If light on rear of en-
gine glows, replenish oil.
I
Connect cable on top of engine or re-
place spark plug.
4 times. Clean and replace plug. Try to
Remove spark plug. Pull starter rope
3 or
start. Keep sprayer upright to avoid
oil
seepage.
Spark plug cable disconnected
or
spark plug damaged
Oil seepage into combustion
chamber
Engine won't "fire" or
'pull over"
I ECISY Spray Control set wrong
Engine operates, but
displacement pump doesn't
4lso see manual 308- 127.
I
Air supply to Easy Spray Control or
gun is not connected
Start compressor.
I
Air compressor not on
Enaine RPM too low
~~~~~
I
Increase.
Be sure foot valve is tightened each day.
Be sure seal in elbow is in place and
is
not worn or damaged.
Clean tin
Air leak at pump foot valve or
siphon tube elbow
I
Insufficient compressor air Increase SCFM
or compressor size.
System requires a minimum of
30 psi
(2.8 bar) to run. I
I
Displacement pump rod seized by
dry coating Service pump. See page
19.
I
Connecting rod wom or damaged
Drive housing worn or damaged
Replace connecting rod. See page
22.
Replace drive housing. See page 23.
Clutch worn or damaged
Pinion assembly wom or damaged
Service clutch. See page
26.
Setvice pinion assembly. See page 24.
3gine starts but dies I Oil level drops below oil sensor
Sudden pressure
loss System has overpressurized, which
opened the Pressure Drain Valve
Air to sprayer or gun stopped
308-269 13

I PROBLEM
at gun
Loss
of air control or volume Loss of air control or volume
at gun
Displacement pump output
low on downstroke or both
strokes
Material leaks into wet-cup
Low fluid delivery
No fluid delivery
Spitting from gun
I material when oun is first tria-
Heavy or poorly atomized
CAUSE
Air passages clogged with material
Piston ball
(220) not seating
SOLUTION
After releasing the gun trigger, make sure
the system
is fully depressurized before
triggering the gun again. This helps
prevent material backing into gun
passages.
Clean piston area. See page
20.
Piston packings wom or damaged
worn or missing.
Siphon hose coupling gasket
(le)
or missino
Pump cylinder O-ring
(205) worn
Replace packings. See page
20.
Replace or install gasket.
Check and replace.
Siphon hose strainer
is clogged Clean strainer.
Piston packings worn or damaged Replace packings. See page
20.
Intake valve ball (21 6) not seating Clean and service intake valve. See page
properly
19.
Clutch (9) worn or damaged Replace clutch. See page 26.
Loose wet-cup (202) Tighten wet-cup just enough to stop
Throat packings worn or damaged Replace packings. See page
20.
Displacement rod (201) worn or
damaged
Replace displacement rod. See page
20.
Siphon hose strainer is clogged. Clean or remove strainer.
leakage.
Engine RPM
too low
SPRAY mode
Easy Spray Control not set to
Compressor is not on and/or air
hoses are not properly connected
Gun is not fully triggered
Fluid supply is low or empty
Increase throttle setting. See Startup,
Steps
4, page 13.
Reset.
Check and correct.
Squeeze trigger firmly and completely.
page 13. Check fluid supply often to pre-
Refill and prime the-pump. Seestartup,
vent running the pump dry.
Fluid pressure was not allowed to Wait a little longer between releasing gun
fully self relieve after releasing gun trigger and pulling it again.
trigger
I
Gun was not fully triggered Always squeeze the trigger fully to
immediately when squeezed, prevent just the air from turning on,
causing gun air passages to clog which
starts the pump and pressurizes
with material. the hoses. Disassemble and clean gun.
Gun’s Air Control Valve is turned Turn valve
out for desired atomization.
fully in
Insufficient compressor air Increase SCFM or compressor size.
Sun nozzle too small for applica- Increase nozzle size.
:ion
14 308-269

REMOVING & INSTALLING A DISPLACEMENT PUMP
Removal 5. Lift the pump to align the mounting holes and in-
stall the mounting screws. IMPORTANT
- torque
the screws to
20 ft-lb (27 N.m). See Fig 9.
shut off the engine and disconnect the spark
plug before performing any checks or seivice.
6. Connect all cables (D) to the pressure drain valve.
See Fig
11. Plug in the power cord so the notch
1. Flush the sprayer. Remove the suction hose.
Remove the outlet hose. align. Screw on
the collar. See Fig
IO.
(6) in
the collar
(C) and the tab
(A)
in the socket
WARNING
228
23
61
22
2.
Siart the engine. Jog the Easy Spray Control
between PRIME and OFF until the connecting link
stops near the bottom of the stroke and is fully
exposed. See Fig
9. Shut off the engine. 60A,
3. Unscrew the collar (C) and disconnect the power
supply cord from the control
(75). See Fig 10.
A Torque to 20 fl-ib (27 N.m)
4. Loosen the two mounting screws (60). See Fig 9.
A Back of pump
5. Use a screwdriver to push in the connecting link
A Cutaway view shows how pin (228) goes
pin (228) just until you Can gently pry the retaining Fig
9 Dun
ring up (61) from the back of the connecting link
(22). Then push the pin in so it falls out the back.
6. Remove the two mounting screws (60) while sup-
porting the weight
of the pump with your free
hand.
See Fig 9.
through connecting rod
7. Disconnect the cables (D) from the pressure drain
8. Unscrew the gauge, using a 1 .OW wrench.
valve. See Fig 11.
the the pump.
Unscrew the pressure drain valve assembly from
Installation
1. Screw the pressure drain valve into the pump.
Install the gauge.
2. Push the pin (228) slightly into the connecting link
(a), but not into the mating hole of the pump.
3. Pull the piston rod (201) out of the pump 2 to 3 in
(50 to
75 mm).
4. Align the flats of the pump piston rod and the
pump outlet.
Lift the pump into position and gent-
ly push on the pin while moving the pump slightly
until the pin slips into the hole. Be sure the retain-
ing ring
(61) snaps down over the end of the pin.
the parts are installed
properly.
Check the back
of the bearing housing to be sure
1- WARNING -I
To reduce the risk of serious injury or property
damage, be sure the retaining spring
is firmly
and completely in the groove of the connecting
link to prevent
it from working loose due to vi-
bration. See Fig
9.
C
A
Fig 10 w "
Fig 11
'I
308-269 15

DISPLACEMENT PUMP REPAIR
WARMING 4. Install the ball (220*) in the piston housing (206).
To reduce the risk of serious bodily injury, always
shut
off the engine and disconnect the spark
plug before performing any checks or service.
5. Apply blue Loctite (supplied in kit) to the piston
the rod, hand tight.
seat
(213) threads and screw the assembly onto
TIP Use a felt tip marker to draw a line across the
..
Disassemble the pump male gland, nut and piston housing to use as a visual
1.
2.
3.
See page 15 for how to remove the pump.
Use a hammer on the tabs of the lug nut
(214) to 6. Place the piston seat (213) in a vise. Hold the
loosen the foot valve housing. packing nut
(208) steady with one wrench and
Disassemble the pump, but do not disassemble use a torque wrench to tighten the rod assembly
the piston rod
(201) from the piston housing (206)
to 90-125 ft-lb (122-170 Nm). Make surethe
unless one of those parts needs to be replaced. line you made in step
5 is still aligned.
Due to the high-strength (red) Loctites used at the
7. Grease the throat of the intake housing (227).
joint of these two parts, the joint must be heated
before disassembly. Refer to Fig
13.
Assemble into the throat: male gland (204*), flat
side first: alternate white Dackinas
(225*) and
reference when tightening the piston and nut.
-
Clean and inspect all parts
I. Use a compatible solvent to thoroughly clean all
2. Inspect the parts, including the seats, for nicks
parts and remove all traces of sealant.
and scratches. Replace worn or damaged park
as they cause the packings to wear more quickly
and may result in poor pump performance.
Repair Kit
A Packing Repair Kt, Part No. 235-186, is available.
the pressure drain valve u-cup packing (included in
Use
all the parts in the kt for the best results. Change
kit) when you repack the pump.
the text and drawings. For example,
208'.
Parts included in the kit are marked with an asterisk in
Reassemble the pump
NOTE Refer to Fig 13.
1.
2.
3.
If you disassembled the piston rod (201) and pis-
ton housing
(206), clean the threads thoroughly.
Apply Loctite primer and then red Loctite
to the
threads and torque to
80 to 100 fl-lb (110 to
135 Nm). Allow to dry at least one hour.
Assemble onto the piston seat
(213): washer
female gland (21 1 *) and then alternate the white
(212); u-cup seal (218*) with lips toward ring;
facing up: male gland
(209*).
(210*) and purple packings (219*). all with lips
Install the nut
(208*) on the piston seat (213).
md tiohten the nut very firmly.
purple packings
(203*) and then the female
gland, all with lips facing down. Install the packing
nut
(202) and tighten firmly by hand.
8. Grease the piston packings and inside the throat
9. Grease the new O-rings (205*) and install on the
cylinder
(221). Slide the cylinder into the bottom
of the intake housing
(227) until you hear it snap.
packings.
IO. Guide the piston rod assembly into the cylinder
so the piston rod flats are aligned with the
opening in the front of the pump. Push down until
you hear another snap. Turn the pump over and
push the assembly the rest of the way In.
11. If the rod hole is not aligned with the front of the
pump, use a screw driver through the rod hole to
turn it into place.
12. Grease the O-ring (223*), install on the plug .
(224), install the plug and the screws (222)
loosely. Torque the screws to 50-70 in-lb
(5.6-8 N.m) in a crosswise pattern.
13. Install the ball (216') and ball guide (217) into the
foot valve. Place the pump assembly on the foot
valve and push into place.
14. Screw on the lug nut (214). Use a hammer to
tighten the lug nut securely.
TIP The lug nut must be very tight or the pump will
not prime. Use a felt tip marker to draw a line
between the intake housing and the lug nut to use
as
a visual alignment reference during operation.
16 308-269

DISPLACEMENT PUMP
whenever you repack the pump. The packings is
NOTE Replace the u-cup packing (G-p/nllI -829)
supplied with the pump repair kit. A
15. Remove the three screws (E). Pull off the cap (F).
Remove the packing (G). Install the new packing
so the lips face into the cap. See Fig 12.
the pump.
(E) to 40-50 in-lb (45-55 N.m) and screw it onto
Torque to
(45-55 N.m)
40-50 in-ib
16. Reassemble the drain valve. Torque the screws
17. Install the pump and prime
it. Check the packing
nut
(202) and tighten it just enough to prevent
Fig 12
leakage.
Grease inside of throat
before installing packings
A throat must face down
Ups
of v-packings in
4 after inaling
Grease inside
of packings
A Torque 50-70 in-ib
(5.6-8 N.m)
in crosswisi pattern
Torque piston housing
A to piston seat (213) to
(122-170 N.m)
without changing
alignment
of packing
nut
Uns ofv-packings on
SO-lZ55-ib
A after indiing
Grease outside
of packings
A piston must faca down
Ups
of U-cup sa on
If piston seat and rod were
Primer, then red
Locute.
and torque to 80-100
fl-ib (110-135 N.m)
Fig 13
01785
308-269 17

BEARING HOUSING & CONNECTING ROD
WARNING
I. Refer to Removing the pump on page 15.
2. Remove the screws (48) and lockwashen (49)
from the bearing housing (23).
3. While pulling the connecting rod assembly (22)
with one hand, llghtly tap the lower rear
of the
bearing housing (23) with a plastic maiiet to
loos-
en it from the drive housing (20). Pull the bearing
drive housing.
houslng and
the connecting rod assembly off the
4. Inspect the crank (A) for excessive wear and re-
place the drive housing. See page
19.
5. Evenly lubricate the inside of the bronze bearing
(E) in the bearing housing (23), and the inside of
the connecting rod link (C), with high-quality mo-
tor oil (do not
use grease). Liberally pack the roll-
er bearing
(E) in the connecting rod assembly
(22) with bearing grease
(20d), supplied.
6. Assemble the connecting rod (22) and bearing
housing (23).
7. Clean the mating surfaces of the bearing (23) and
drive (20) housings.
8. Align the connecting rod with the crank (A) and
carefully align the locating pins
(13) in the drive
housing
(20) with the holes in the bearing housing
(23). Push the bearing housing onto the drive
housing or tap it into place with a plastic mallet.
DO NOT use the bearing housing screws (48) to
align or seat
it with the drive housing. These
Parts must
be aligned using the locating pins
(Dl, to help avoid Drernature bearina wear.
9. install the screws (48) and lockwashen (49) on
the bearing housing. Tighten the screws evenly to
25 ft-lb (34 N.m).
10. Refer to installing the pump on page 15.
01788
Fig 14
18 308-269

DRIVE HOUSING
Y
21
A TORQUETO
25 fl-lb
(34 N.m)
WARNING
To reduce the risk of serious bodily injury, always
I. Disconnect the siphon hose elbow (If), drain
hose
(86) and material hose (not shown). Discon-
nect the pump outlet hose. Disconnect the pres-
sure control cord
(62). Remove ihe front cover
(21).
2. Remove the four screws
(48) and lockwashers
(49) from the bearing housing (23).
3. Ughtly tap the back of the bearing housing (23)
with a plastic mallet. Pull the pump, bearing hous-
ing and connecting rod away
from the drive hous-
ing (20) as one assembly.
4. Remove the bearing housing screws (41). and the
pinion housing screws
(3).
\ \73 ‘19k
20c
70,71
CAUTION
ing the drive housing (20). The gear cluster is
DO NOT drop the gear cluster (1) when remov-
easily damaged. The gear may stay engaged in
either the drive housing or the pinion housing.
DO NOT lose the thrust balls (20c and 19k) lo-
~ cated at each end of the gear cluster. The balls,
~ I which are heavily covered with grease, usually
stay in the shaft recesses, but they could be
dislodged.
If they are caught between the gears
and not removed, the balls will seriously dam-
age the drive housing.
If the balls are not in
place, the bearings
will wear prematurely.
5. Lightly tap around the drive housing (20) with a
plastic mallet to loosen it from the pinion housing
(19P).
6. Liberally apply bearing grease (20d, supplied) to
the gear cluster (73). Be sure the thrust balls (20c
and 19k) are in place.
7. Place the bronze colored washer (2Oa) and then
the silver-colored washer (20b) on the shaft pro-
truding from the big bearing of the drive housing
(20). Align the gears and push the new drive
housing straight onto the pinion housing and
lo-
cating pins (A).
8. Reassemble the sprayer. Or, go to the next sec-
tion in this manual if further service is needed.
308-269 19

PINION, CLUTCH, CLAMP, FIELD & ENGINE
Disassembling these parts can start from the pinion nstartlng
from the plnlon housing, first follow Steps
housing or from the clutch,
if no pinion service is
1 to 5 of DRIVE HOUSING, on page 19, and then
needed.. continue with the procedure below.
If startlng from the clutch, see page 22.
PlNlOM HOUSING
Removing the Pinion Housing
WARNING
To reduce the risk of serious bodily injury, always
shut
off the engine and disconnect the spark
plug before performing any checks or service.
1. Remove the two bottom screws (3) first, and then
remove the top three screws
(3).
2. Puli the pinion housing (19p) away from the clutch
housing
(17). The armature (9b) wiii come with it.
3. Pull the armature (9b) off the hub (19j - see Fig
78) of the pinion housing.
CAUTION
CAUTION on page 19 for
more information.
Do not lose the thrust bail
(19k). Refer to the
A see page 26 for pinion
A
NOTE To disassemble the pinion, go to Repairing ‘A
the Pinion, page 21. To disassemble more of the
from this point, go to Reassembly, page 27, Step 7.
sprayer, go to page 23. To reassemble the sprayer Fig
16 0171
Repairing the Pinion 19m
1.
2.
3.
20
NOTE: Refer to Fig 17.
NOTE: A hydraulic press is required if you purchase
the pinion parts individually. Otherwise, use Repair
Kit
No. 221 -032, which includes the shaft and bearings
pre-assembled and lubricated.
below.
If
using Repair Kit 227 -032, follow Steps 7 to 5,
Remove the small ring (19e**) from the hub (19f)
and the large ring (19m) from the bearing recess
of the pinion housing (19p).
Push on the front of the shaft (19b**) to force the
bearing and hub assembly
out of the housing
Install the new shaft assembly into the pinion
4. Install the rings (19m and 19e**).
housing, pushing
it to the shoulder of the housing
Fig
17
01 w
(I9P).
(19P).
5. Go to Reassembly, page 27, Step 7, or continue
308-269
on page 22.