Graco GM 3500 User manual

INSTRUCTIONS-PARTS LIST
This manual contains IMPORTANT
WARNINGS and INFORMATION
READ AND RETAIN FOR REFERENCE
3.5 HORSEPOWER, GASOLINE-POWERED
GM 3500
AIRLESS PAINT SPR
3000 psi (210 bar) "MUM WORKING PRESSURE
LO-BOY CART
Model
222-028, Series F
Basic Sprayer
Model 231-077
Completesprayer,with hose andgun, RAC iV@
Dripless@Tip Guard, and 517 sizeSwitchTipo
UPRIGHT CART
Model
221-040, Series F
Basic Sprayer
Model 231-057
Completesprayer, with hose andgun, RAC iV@
Dripless@Tip Guard, and517 sizeSwitchTip@
Warnings
................... .2
setup ...................... .a
Fueling ..................... .9
Stanuo ..................... 10
TABLE OF CONTENTS
- ~-
Maintenance11
TroubleshootinoGuide
13
Flushing Guidelines.12
- ~~~~~ ~ ~
................
..........
........
-
Repair ...................... 14
Parts
....................... 30
Accessories ................ .38
Technical Data .............. .39
Dimensions ................ .39
Warranty .40
NOTE This is an example of the DANGER label onyour sprayer.
This label is available inother languages,
free of charge.
See page38 to order.
..
...................
307-863
Rev G
Supersedes F
Spray palntlng, flushing or cleaning equlpment with flammable liq-
uids In confined areas can result In fire or expioslon.
Use outdoors or In earemely well ventilated areas. Ground equip-
ment, hoses, containers and objects being sprayed.
Avoidall Ignition sources such as static electrlckyfrom plastic drop
cloths, open flames such as pilot lights, hot objects such as clga-
rems, arcs from connectlng
or dlsconnectlng power cords or turn-
Ing light swltches on and
on.
Failure to follow thls warning can resultIndeath or serlous Injury.
READ AND UNDERSTAND ALL LABELS
1
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. Dralnall pressure before removlng parts.Avoid accldentai
trig-
gering of gun by always setting safety latch when not spraying.
Never spray without atipguard.
In caseofaccldentalskinInjection.seeklmmedlate
"Surgical Treatmenr'.
Faliure
10 follow thls warnlng can result In amputation or serious
Injury.
IDINSTRUCTION MANUALS BEFORE USE
GRACOINC. P.O. BOX 1441 MINNEAPOLIS,MN 55440-1441
@COPYRIGHT 1988, GRACO INC.

General Safety
This equipment generates veryhigh fluidpressure. Sprayfrom
the gun, leaks or ruptured components can inject
fluid through
yourskinandintoyourbody,andcauseextremelyseriousbodily
injury, including the need for amputation. Also, fluid injected or
solashedintothe eyes or
on the skin can cause serious damage.
NEVERpoint the spray gun at any one or at any part
of the body.
NEVER put your handor fingers over the spraytip.NEVER tryto
"blow back" paint; thisis NOTan air spray system.
ALWAYShavethe tip guard
in place on the spray gun when
spraying.
ALWAYSfollowthe PRESSURE RELIEF PROCEDURE, below,
beforecieaningorremovingthespraytiporservicinganysystem
equipment.
NEVERtry to stop or deflect leaks with your hand or
My.
each use.
Be sure equipment safety devices are operating properly before
Medical Alert--Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE.
DO NOTTREATAS A SIMPLE
CUT. Tell the doctor exactly whatfluidwas injected.
Note
to Physlclan: Injection in the skin isa traumatic injury.
It
is importantto treat the injury surgicaliyas soon aspossible.
Donotdelaytreatmenttoresearch toxicity. Toxicityisacon-
cernwith some exotic coatings injected directlyinto theblood
stream. Consultation with aplasticsurgeon or reconstructive
hand surgeon maybeadvisable.
Spray Gun Safety Devlces
Besureallaunsafetvdevicesareooeratinaorooerlvbeforeeach
use. DO not;emovebr modify any part of ti% gun; this can cause
a malfunction and result
in serious Wilyinjury.
Safety Latch
Whenever you stop spraying, even for a moment. always set the
gunsafety latchinthe closed or "safe" position, making the gun
triggering of the gun.
inoperative. Failuretoset the safetylatch can result
in accidental
Diffuser
Thegundiffuser breaksupspray and reduces the rlsk of fluid in-
jection when the tip is not installed. Check diffuser operation
regularly. FollowthePRESSURE RELIEFPROCEDURE, below,
then remove the spraytip.Aim thegun into a metal pail, holding
thegunfirmlytothepail.Usingtheiowestpossiblepressure,trig-
ger the gun. If the fluid emittedis not diffused into an irregular
stream, replace the diffuser immediately.
ALWAYShavethe
tip guard In place on the spray gun while
Tip Guard
spraying. Thetip guard alerts you to the fluid Injection hazard
and helps reduce, but does not prevent, the risk of accidentally
tip.
placingyour fingers or any part
of your bcdycloseto the spray
Always havethetrigger guardinplaceon thegunwhen spraying
Trigger Guard
toreducetheriskofaccidentaiiytriggeringthegunifitisdropped
or bumped.
Sarav
Tia Safetv
-I-~ ~ I ~ .~ ~ ~
Useextremecautionwhencleaningorchangingspraytips.Ifthe
spray tipclogswhile spraying, engage thegunsafety latch im-
mediatelv.ALWAYSfollowthePRESSURERELIEFPROCE-
DURE, below, and then remove the spraytip
to clean it.
NEVER wipe
off build-up around the spraytip untilthe pressure
Is fully relieved and the gun safety is engaged.
To reduce the risk
of serious bodily Injury, including fluid injec- 5. Engage the gun safety latch.
tion, Splashingfluid orsolvent
in the eyesoronthe skin, or injury
from
movingpartsorelectricshock,alwaysfollowthisprocedure 6. Openthepressuredrainvalve,having a containerready to
whenevervoushut off the soraver. when checkina or servicina catch the drainage. Leave the valve own until YOU arereadv
any partofihespray system; wtkn.installing. cleaningorchan6 to spray again.
ingspray tips,andwhenever you stop spraying.
1. Engage thegunsafety latch.
~ ~ ~~ -
7. Disconnect the sparkplugcable.
2. Turn theON/OFFswitch to OFF. If yoususpectthatthespray tip orhose iscompletelyclogged,
3. Flipthe pressure control switch toOFF.
or that pressure has not been fully relieved after following the
4. Disengage the gun safety latch. Hold a metal partof the gun hose end couplingand VERY SLOWLY loosen the part lo relieve
stepsabove, wrap a rag around the
tip guard retaining nut or
firmly to the side
of a grounded metal pail, and trigger thegun pressure gradually. then loosen completely. Now clear thetipor
to relievepressure.hose.

parts. KEEP CLEARof moving parts
when starting or operating
Moving parts can pinch or amputate
your fingers or other
body
the sprayer. Follow the Pressure Rellef Procedureon page 2
before checking or servicingany part of the sprayer,to prevent
it
from starting accidentally.
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying
parts, using Incompatible chemi-
caisandfluids,orusingwomordarnagedparts,cancausethem
to rupture and resultinfluid injection, splashing in the eyesoron
the skin, or other seriousbodilyinjury, or fire, expiosion orprop
erty damage.
cause it to malfunction.
NEVERalterormodifyanypanofthisequipment;doingsocould
CHECKallsprayequipment regularly andrepairorreplaceworn
or damaged parts immediately.
Always wear protective eyewear, gloves.clothing and respirator
as recommended by the fluid and solvent manufacturer.
System Pressure
This sprayercandevelop 3000 psi (210 bar) MMiMUM WORK-
ING PRESSURE. Be sure allspray equipment and accessories
used are rated to withstand the this Dressure. DO NOT exceed
the maximum working pressure
of any component or accessory
usedinthe system.
Fluid and Solvent Compatibility
All chemicals used in the sprayer mustbechemically compat-
ible with the wetted parts shown
in the TECHNICAL DATA on
page39.Consultyourchemicalsuppliertoensurecompatibllity.
Donotuse1,1,l-trichioroethane,methyienechioride,otherhalo-
aenated hvdrocarbonsolventsorfiuidscontaininasuchsoivents
h this eauioment. which contains aluminum anslor zinc oarts. ~ ~~~
Suchusecould result in a-serious~chemical reaction, wiih the
possibilityofexplosion, whichcouldcausedeath, seriousbodiiy
_.~ ~ ~~
injury and/or substantial property damage.
Highpressurefluid inthe hosescan bevery dangerous.
If the
damage or misuse, thehighpressure spray emitted from
it can
hose develops a leak. split or rupture due to any kindof wear,
causeafiuidinjectioninjuryorotherseriousbodiiyinjuryorprop
erty damage.
ALL FLUID HOSES MUST HAVE STRAIN RELIEFS ON BOTH
at or closetothe coupling which
can result in hose rupture.
ENDSl~estrainreliefsheipprotectthehosefromkinksorbends
TIGHTEN ail fluidconnections securely before each use. High
pressurefluid candislodge alwsecoupllngorallow highpres-
sure spray
to beemitted from the coupling.
NEVER usea damaged hose. Before each
us, check the entire
hoseforcuts,leaks,abrasion, bulging cover,ordamageor
mwement ofthe hosecoupiings. if anyoftheseconditionsexist,
replace the hose immediately. DONOTtrytorecouple highpres-
sure hose or mend it with tape or any other device.
A repaired
hose cannot contain the high pressure fluid.
hosestomoveequipment. Keephosesclearof movingpartsand
HANDLEANDROUTEHOSESCAREFULLYDonot pull
on
hotsurfacesofthepumpandgasengine.Donotusefluidsorsoi-
vents whichare notMmDatible with the inner tube and cover of
the hose. DO NOT expose Graco hoses to temperatures above
180' F (82" C) or below -40' F (-40° C).
HoseGrounding Continuity
grounded spray system. Check the electrical resistanceofyour
Proper hosa grounding continuity is essential to maintaining a
fluidhoses at ieast once a week.
If your hose does not have a tag
on it which specifies the maximum electrical resistance, contact
the hose supplier or manufacturer for the maximum resistance
limits. Use a resistance meterinthe appropriate range for your
hose
to check the resistance. If the resistance exceeds the rec-
ommendedlimits.replaceitimmediately,Anungroundedor
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 thissprayer.
Static electricityiscreated by the flow of
fluid through the pump
and
hose. If every part of the spray equipment is not properly
grounded,sparkingmayoccur,andthesystemmaybecomehaz-
ardous.Sparkingmayalsooccurwhenplugginginorunplugging
a~werSUDDlvCOrdOruSinaaaasolineenaine.Soarkscanionite
6mes from'sdlvents and tk fruid being sprayed, dust partbs
and other flammable substances, whether you are spraying in-
- ~ ---
doorsoroutdoors,andcancauseafireorexpiosionandserious
Wilyinjury and property damage.
ifyouexperienceanystaticsparkingorevenaslightshockwhile
usingthisequipment.ST0PSPRAYlNGiMMEDIATELY.Check
the entire system for proper grounding. Do not use the system
again until
the problem has been identified and corrected.
To reduce the risk of static sparking, ground the sprayer and ail
Grounding
otherspray equipmentusedorlocatedinthesprayarea. CHECK
your local electrical code for detailed grounding instructions for
your area and type of equipment. BE SUREto ground all of this
spray equipment:
1. Sprayer:connectagroundwireandclamp(supplied)toatrue
earth ground.
spilledona hot surface can ignite and cause a fire.
NEVERfillthe fuel tank while the engine is running or hot. Fuel
ALWAYSpourfuel
in slowiy to avoidspiliing.Also read FIRE OR
EXPLOSION HAZARD, above, and FUELINGonpage 9.
gineexhaustis piped outside.Theexhaustcontainscarbon
NEVER operatethe engine
in a closed buildingunless the en-
cause serious Illness and even death of inhaled.
monoxide,
a poisonous, odorless and invisible gas which can
2. Fiuidhoses: useonly grounded hoses with a maximum of 500
~(150m)combinedhoselengthtoensuregroundingcontinu-
itv. See Hose Groundlna Contlnultvabove.
-
3. Spraygun:obtalngroundingthroughconnectiontoaproperly
grounded fluid hose and sprayer.
4. Object beingsprayed: according to local code.
5. Fluid supply container: according to local code.
6. Allsolventpails used whenllushing, according to local code.
pail on a non-conductive surface. such as paper or card-
Use only metal pails, which are conductive. Do notplacethe
7. To maintain grounding continuity when llushing of felieving
board, which interrupts the grounding continuity.
pressure, alwayshold
a metal part of the gun firmly to the side
of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce theriskof fluid injection injury, staticsparking.orsplash-
ingby following the flushing procedure given
on page 12 of this
2, and remove the spraytipbefore flushing. Hold a metal partof
manua1,FollowthePRESSURE RELIEF PROCEDUREonpage
the gun firmly
to the side of a grounded metal pail and use the
lowest possible fluid pressure during flushing.
United States Government safety standards have been adopted
under the Occupational Safety and Health Act.
These standards
- particularly the General Standards, Part 1910, andtheCon-
struction Standards, Part
1926 - should be consulted.

La puiverisation A haute pression peut causer de blessures tres graves.
Reserve exclusivement a I'usage professionnei. Observer toutes les consignes de SeCUrite.
Bien
lire et bien comprendre tous les manueis d'instructions avant d'utiliser le materiel.
RlSQUES D'INJECTION ~~~~~~~~~~~~~~~~~~~~~~~~~~~~,~~~~~~~~~,~~~~-~~~~~,~~~~~~~~~,~~~~~~,~~~,~~~~~~~~~~~~~~
Consignes generales de securite
Verrou de s6curit6
veriseparlepiaoletou iefiuidesouspressionprovenantdefuites
duncourt instant, toujours mettre ie verrou de securite du pisto-
Cet appareiiproduitunfiuideatres hautepression.Lefiuidepu1-
A chaque fois que I'on s'arrete de puiveriser, mhe s'ii s'agit
ou deruptures peutpenetrersou la peauou al'interieurducorps
let sur la position, "fermee" ou 'Skurite" ('safe'). pour em+
etentrainerdesbiessurestresgraves,voirmemeuneamputation.
cher le pistolet de fonctionner. si le verrou de &Curitetest pas
Meme sans &re sous Dression, iefluideeciaboussantouentrent mis. ie pistoietput
se declencher accidentellement.
dans ies yeux peut aussi entrainer des blessures graves.
NE JAMAIS pointer
le pistoietversquelqu'un ouvers une partie
queiconqueducorps. NE JAMAIS menre
le main ou Ies doigts
sur I'ajutagedupuiverisateur. NE JAMAIS essayerde "refouler"
la peinture.
Cet 'appareil N'est PAS uncnmpresseur
TOUJOURS garder ia protection de I'ajutage
en piace sure ie
pneumatique.
TOUJOURSobserver la Marche
a Suivre Pour Detendre la
pistoiet pendant
la puiverisation.
Pressiondonneepius loin, avant de nettoyer ou d'eniever i'aju-
tage
du puiveris&teur,oud'effectuer un travail quelconque sur
une partie de I'appareii.
NE JAMAIS essayer d'arreteroude davier ie fuites avecia main
ouie corps.
Avantchaqueutiiisation. biens'assurerque lesdispositifsdesg-
curite fonctionnent correctement.
Sains medicaux
En cas de penetration defiuide
=,US iapeau: DEMANDERIM-
MEDIATEMENTDESSOINSMEDICAUXDURGENCE.NE
PASSOIGNERCETTEBLESSURECOMMEUNESIMPLE
- - ... - ... - -. . - -. .
~~~
COUPURE.
~~
Avls au medecln: La penetration des fluides sous lapeau est
un traumatisme. II est Important de tralter chlrurglcaiernent
mentpoureffectuerdesrecherchessurlatoxicit~. Cettainsre-
cette blessure Irnrnediaternent.
Ne pas retarder le traite-
Sontinjectes directement dans
le sang. I1 est souhaitable de
v.4tementsexotiquessontdangereusementtoxiques quandils
consulterun chirurgienesthetiques
ou un chirurgien speciali-
Dispositifs
de securite du pistolet
se danslareconstruction des mains.
Avantchaqueutiiisation,biens'assurequetouslesdispositifsde
securite du pistoiet fonctionnent correctement. Ne pas eniever
ni modifier une partie quelconquedu pistolet; ceci risquerait
dentrainerunmauvaiSfonCtionnementet des biessuresgraves.
Diffuseor
Le diffuseur du pistolet sert A diviser le jet et a reduire Ies risques
dinjectionaccidenteile quand i'ajutage n'est pas
en place. Veri-
fieriefonctionnementdudiffuseurregulierement.Pourcettev8ri-
fication, detendre ia pression en Observantla Marche it Sulvre
Pour Detendre la Pression donnee plus loin enlever i'ajutage
dupuiverisateur. Pointer
ie pistolet dans un seau en metal, en ie
maintenant fermement contre
le seau. puis, en utilisant la pres-
sion la plus faibie possible, appuyer sur ia gachettedupistolet.
Si
le fiuideprojete n'est pas diffusesous formede jet irregulier,
rempiacer immediatement
le diffuseur.
Protection
de I'ajutage
TOUJOURS maintenir ia protection de I'ajutage en place sur le
pistoietdupuiverisateur pendant ia puiverisation. La protection
dei'ajutage attire I'attention sur ies risques d'injection let Contri-
bueareduire.main'eviteoasierisaue.clueiesdoiatsouuneDar-
tiequelconqueducorps ne passentacdidentelienFent a prodmi-
te immediatedeI'ajutage dupulverisateur.
Consignes de securite concernant I'ajutage
du pulverisateur
Faire extrhementattention i'occasion du nettoyageoudue
remplacementdesajutagesdupuiverisateur. Sii'ajutagesebou-
chependent iapuiverisation, menre immediatement
le verroude
securitgduDistolet. TOUJOURSbien observe la Marche
a Sul-
~~
vre Pour DhtendreiaPresslon puiseniever i'ajutagedupulve
risateur pourlenettoyer.
NEJAMAiSessuyercequis'estaccumuleautourdei'ajutagedu
pulverisateur avant que la pression ne soit completement tom-
bee et que ie verroude&curite du pistoiet ne soit engage.
Pourrauire
les risques de biessures graves, y compris 18s bies- 5. Engager le verrou de securitedupistoiet.
sures
parprojectiondefiuideouceiiescauseespardetjciabous- 6, ouvrir la soupap de securite et la iaisser ouverte iusqu~g ce
suresdansiesyeuxousurlapeau,pardespiecesenmouvement,
tOUjOurS bienObserve cette marche asuivre chaquefois que i'on
dunettoyagedusystemeou
lors duchangementdesajutages. Sil'onsoupconnequeletuyauoul'ajutageestcompletementbou-
arrete le puiverisateur,i'occasion delaverification,duegaieou 7. Debrancher fil dela bougie.
2. Menre ie levier d'arrdtdumoteur sur ARRET (OFF).
1. Engagerieverroudesecurite dupistoiet.che ou quelapressionn'apasefecomplbtementlibereeapres
3. Basculeri'interrupteurdecommandedepressionsurARRET MENTunraccorddeboutdetuyauoui'ecrouderetenuedeiaPro-
avoirprocedeauxoperationsci-dessus,desserrerTRESLENTE-
(OFF).
4. Desengager le verroudesecuritedu pistoiet. Tout en mainte- tection de I'ajutage
et liberer progressivement la pression.
ire
le c6ted'unseau en metal. actionner le pistolet pour iiberer
nant une partie metailiquedupistoiet fermement appuye con-
la pression.
que
l*on soit pret a se servir de nouveaudupulverisateur.

SOLO PARA US0
PROFESIONAL. RESPECTE LOSAVISOS DEADVERTENCIA.
EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES.
Lea y entienda todo el manual de lnstrucciones antes de manejar el equipo.
PELlGRO DE INYECClONDE FLUID0 ~~~~~~~~~~~~~~~~~~~~;~~~~~~~~~~~~~~~,~~~,~~,~~~~~~~~~~~~~~,~~~;~~~~,~~~~~~~~~~~~~~,~~~,~~,~~
Seguridad general
Aparatos de segurldad de la pistola pulverlzadora
delapistoia. 10s escapesdefiuidoo roturasde loscomponentes funcionando bienantes de cada uso.Nosacar ni modificar nin-
Esteequipo general
un fiuido a una presion muy alta. Eirociado Asegurar que todos
10s aparatos protectoresde lapistola est6n
puedeninyectarfluidoenla pieiye1cuerpoycausarIesionesex- guna piezade lapistolapues podriacausarelmalfuncionamien-
tremadamente graves, inciuyendo a veceslanecesldad de am-
. to de la mismacon las consiguientes lesiones personaies.
putacion. Tambien.ei fluido inyectado
o salpicado en 10s ojos
puedecausargraves daiios. Pestilode seguridad
NUNCA apuntar lapistola haciaaiguien oalgunaparte del cuer- mento, siempre colocar el pestill0 de seguridad en la posicion
Cadavezquesedejedepulverizar,aunqueseaporunbrevemo-
Po. NUNCA coiocar la manOO1oS dedos encimadelabquilia. "cerrada",
lo quedeja la pistolainoperante. Elnohacerlo puede
NUNCAtratarde "hacer retornarlapintura";esteNOesunsiste-
ilevaral &par0 imprevisto de la pistola,
ma derociado de aire.
- ..
SiEMPRE tenercolocado el protector de ia boquilla en la pistola
mientras se esta pulverizando.
SIEMPREseguir elprocedimiento de descarga de presion,
dadomasabajo,antesdelimpiarosacarlaboquiilaodedarser-
vicio a cualquier del sistema.
cuerpo.
NUNCA tratarde parar
o desviar ios escapescon lamano o el
Asegurar que todos
10s aparatosdeseguridad delequip esth
funcionando bien antes de cada uso.
Tratamiento
medico
.~
Si pareciera que un poco de fluidopenetro la piel. conseguir
TRATAMIENTOMEDICODEURGENCIADEINMEDIATO.
NOTRATAR
Lp. HERIDA COMO UN SIMPLE CORTE. Deciral
medico exactamentecua fluidofue.
~~
Avlso almedico: Sise llega a inyectareste fluldo en lapiel
se causa unalesi6ntraumatica.
Es lmportante tratarquirk-
gicamente la lesion a labrevedadposible.
No demorarel
tratamiento para investigar la toxicidad. La toxicidad es
algo
de sumarimportancia enalgunaspinturasex6ticas cuandose
inyectan directamentea1torrente sanouineo. Sird convenien-
teconsuitara
un especialista en cirug7apldstica o reconstruc-
tiva de /as
manos.
DifuSOr
el riesgode inyeccion cuando no esta instaiada la boquiila. Revi-
El difusor de la pistola dispersa el chorro pulverizado
y reduce
sarcon reguiaridad
e1 funcionamien!o del difusor.Seguirelpro-
cedirniento de descargade presion, dado
mas abajo, y des-
sosteniendolabienfirmecontrael.Utilizandolapresion masba-
pues sacarla boquiila. Apuntar la pistola aunbalde metalico,
io posible, disparar la pistola. Si si fiuido emitido no sale disper-
so en un chorro irregular, reemplazarde inmediato el difusor.
Protector de /a boquilla
SIEMPREtenerelprotectordelaboquillacoiocadoenlapistola
contrael Deliaro de inveccion v avuda a reducir. Der0noevita.
mientras
se est& pulverizando. Este protector llamalaatencion
la coiocacibnaccideniaide losdebos
o cuaiquieiotraparte dei
cuerpo cerca
de la bcquilla.
Segurldad
de la boquilla pulverlzadora
Tenermuchocuidadoaliimpiarocambiariasboquillas.SiIlega-
ra a ObstNirse mientrasesta pulverizando, enganchar el pestillo
de la pistola de inmediato. SIEMPRE seguir elprocedlmlento
dedescargade preslon
y despues scar ia boquiila para
limpiarla
NUNCAlimpiar laacumulacl6ndepintura alrededorde la boqul-
el pestillo este enganchado.
Iia antes de que se haya descargado por compieto la presion
y
2. Mover el interruptor de paradadelmotor a OFF.
Slsesospechaquelaboquiliaolamangueraest~completamente
3. Mover el interruptor de controlde presion a OFF.
obstruida.oquenosehadescargadoporcompletolapresi6ndes-
4. Desengancharelpestillodeseguridaddelaplstola. Mantener pu6s de haberseguidoelprocedimientoanterior, aflojarMUY
una parte metalica dela pistolafirmemente contraelladode
LENTAMENTEunadaptadordeextremodelamangueraolatuer-
un baldedemetal y activar ia pistolaparadescargar ia ca de renencion del protector de lay punta
y descargar Qradual-
presion. mente la oresion.

Segurldad general Preslhdel Sisterna
comosobre presurizacih, rnodificacion de piezas. us0 de ma- PRESION DE
TRABAJO MAXIMA. Asegurar que todoel equipo
Cuaiquier mal us0 del equipopulverizadoro
10s accesorios.tal Esta pulverizadora puede desarrollar 210 barias (3000 psi) de
teriales y productosquimicosIncompatibles, o utiiizaciondepulverizadory susaccesoriostienanlacapacidadparaaguantar
piezas daiiadas 0 desgastadas, puede hacen que se rompan y ia presion mhxirna de trabajo de ningljn componente 0 acceso-
causenla inyeccion de fluido
u otras Iesiones corporales graves, riode este sistema.
incendio, explosion
o dafios a la propiedad.
Siempreusargafas,guantes,vestimentasprotectorasy unrespi- Cornpatibilldaddefluido
radero, tal como recomiendan 10s fabricantes del fluido y del Siempreleer iasinstruccionesdelfabricantedelfluido y solvente
solvente. ante?, deusarlosenestapulverizadwa.
S EG U R I DAD EN EL US0 DE US MANG U ERAS ~,~,~~~,~~,~~.~,,~~~~:~~,~,~~,~~~~~~~~~~~,~,~~,~~~~~,~,~~~.~~~,~,~~~~~~~~!?!~
El fiuido que escapa a alta presion por ias mangueras puede ser
muy peligroso.
SI en lamanguera se desarrola un escape, una
rotura
0 rajadura debido a cualquier tipo de desgaste, daAo 0
maltrato. e1 chorro a alta Dresi6n emitido cor alii ouede causar
unalesidnporinyeccionuotraslesionescorporalesgravesoda-
60s a la propiedad.
TENERGUARDASDERESORT€ENAMBOSEXTREMOSl
iTODAS
LAS MANGUERAS PARA FLUIDOSTIENENQUE
Estas Droteaen las manaueras contra dobleces o retorceduras
enlosacop~mientosocercadeellos,losquepodriantraducirse
enroturas de iamanguera.
Antesdeusarlas, APRETARbienfirmes todas las conexiones. El
fluido a lata presion puede desalojar
un acoplamiento suelto 0
dejar quepro e1 escape un chorro a alta presion.
en buscadecortaduras, escapes,abrasih,cubierta abultada, o
NUNCAusar una mangueraque estadafiada. Siempre revisarla
acoplamientossueltosodaiiados. Si Ilegaraaencontrarsecual-
quieradeestascondiciones,reemplazardeinmediatolamangue-
ra.NOintentarreacopiarunamangueradealtapresionoenmen-
darlaconcintaadhesivauotromaterialsimiiar.Unamangueraque
hasidoremendadanoaguanteelfluidoalaltapresion.
MANEJAR Y PASAR CUiDADOSAMENTE US MANGUERAS.
Notirar de
las mangueras para mover el equipo. No usarfluidos
o solventes que Sean incompatiblescon e1 tub0interno y la cu-
biem
de lamanguera. NO exponer ias manguerasa temperatu-
rassobre
820 C (180°F) o bajo -40°C (-40' F).
Continuidad del clrcuito de puesta a tierra
de larnanguera
cia1 para mantenerconectado a tlerra e1 sistema pulverizador. Es
Lacontinuidaddelcircuitodepuestaatierraapropiadoesesen-
indispensablerevisar ia resistenciaelectricamhxima de las
Si lamanguera
no tiene una etiquetaen la cualse especifica la
manguerasdeaireydefluidoporlomenosunavezalasemana.
resistencia elactrica maximum, ponerseen contact0 can si pro-
veedorofabricantedelamangueraparalainformacionsobrelos
limites de resistencia. Usarunmetrode resistencia en la gama
apropiada para comprobar la resistencia; si excede ios litesre
comendados, reemplazariade inmediato.
Es muy arriesgado te
ner una manguera sin puesta a tierra o con la puesta a tierra en
malascondiciones.Leer tambienlainformacion sobre RIESGO
DE INCENDIO
0 EXPLOSION, mas arriba.
Elflujoaaltavelocidaddeifluidoalpasarporlabombaymangue
racreaelectrlcidadesthtica.Sltodaslaspartesdelequipopulve
do alsistema en algo peiigroso.Tambien. pueden producirse
rizadornotienenbuenatierra,puedenocurrirchispas,convirtien-
chispas al enchufar o desenchufarel cordon electric0 o al usar
unmotordegasolina.
Estaschispaspuedeninflamarlosvapores
de 10s solventes y el chorrode fiuidopulverizado, particuias de
polvoyotrassustanciasinfiamables,seaalairelibreobajotecho.
lo que podria causar una explosion o incendio y graves iesiones
corporales
y daiios ala propiedad:
SI murreuna chlspa de eiectricidad estbtica 0 incluso un ligero
choqueelectricomientrasseusaelequipo,DEJARDEPULVERI-
tierraapropiado.Nousardenuev0elsistemahastahaberidentiA-
ZAR DE INMEDIATO. Revisar todo el sistema en buscade una
cad0
y soiucionado el problema.
Puesta
a tierra
Para reducir ei riesgo de chispas esthticas, conectar a tierraia
puiverizadora
y tcdoel otro equipo de puiverizarque se use o se
encuentreen el lugar que se va armiar.CONSULTAR el c6digo
electric0 de la localidad para Ias instrucciones sobre lascone
xiones a tierra exigidas para la zona
y tip0 deequipo. ASEGU-
RAR deconectar a tierra todo este equipo pulverizador:
1. Pulverizadora: Conectar el alambre de tierra y laabrazadera
(suministrada) a una buena conexion a tierra.
2. Manguerasparafluidos:usarsolamentemanguerascon
pussta a tierra de una longltud combinada
de 150 rn (500
pies),paraasegurarbuenacontinuidadatierra. Referirsetam-
bien al pArrafo sobrecontinuidad a tlerrade
la manguera.
3. Pistoia: hacerlapuesta atierra conectandola a una manguera
de fluido
y pulverizadora bien conectadas a tierra.
4. Sumlnistral un reclpiente: de acuerdo al codigo local. Usar
solamente baldes
de metal, que Sean conduclivos. Nocob
car ei balde
en una superficie no conductiva, como papel o
carton, que interrumpe la continuidad a tierra.
5. Objeto que se esta rociando: de conformidadcon e1 codigo
local.
6. Todos 10s baldes de solvente usados durante el iavado. de
conformidad con el codigo local.
7. Paramantenerla continuidada tierradurante ellavado 0 des-
carga de presion, siempre apoyaruna parte metalicade ia
Pistola bien firms contra
el costado de balde de metal. des-
pub apretar sigatillo.
Segurldad duranteel lavado
piei,oqueocurraunadescargadeelectricidadestatica,siempre
Para reducir el riesgo de que se inyecte o saipique fluido en la
seguirlaslNSTRUCClONESPARAELIAVAD0,dadasenlapa-
gina 12. Seguirel procedlmlentode descarga depreslon en
ia pkgina
6, y quitar la boquilla de metal y usar le presion mas
baja posible de fiuido duranteellavado.
PRECAUClONESPARA LOS MOTORES DE GASOLlNA ~~~~~::-i''"~~~~~~,~~~~~~~~~~~~~~~~.~j~~~~,~~~~~~~~~~~~'~ *. :.;;.:.:.:.:.:,: ,$:$?:$2...:.: _..,.,.,... ,.._x ,,,,
funcionando 0 caliente. El combustible derramado en una su- caminar 10s gases de escape hacia el aire libre.
Los gases de
NUNCA llenar
e1 tanque de combustible mientras el motor esta
NUNCA hacer funcionar ei motor en unedificiocerrado sin en-
perficie calientepuedeencenderse
y provocar un incendio. escape contienen monoxida de carbono,
un gas venenoso, sin
SIEMPRE verter el combustible lentamente para evitar derra- olor
e invisible que podria causar enfermedades graves, inciuso
mas. Laar PELlGRn nE INCFNnln n EYDl nClnhl I^ -,,"A- ^I :*b."n""

WARNING
If yousupply your own hoses and
spray gun, besurethe hosesareelec-
trically conductive, that thegun has a
tipguard,andthateachpart is ratedfor
at least
3000 psi (210 bar) Maximum
the risk of seriousbodily injury
caused~
Working Pressure. This is to reduce
bystatic sparking,fluid injection
or ov-
er-pressurization and rupture
of the
hoseor gun.
1.
ConnectHose and Gun. Removethe
plastic cap plug from the outlet nipple.
Assemblethe
50 fl. (15m) hose, 3 fl(.9
m) whiphoseand gun, and connect
them to the outlet nipple.
DO NOT use thread sealant onthe
hose and
gun connections. DO NOT in-
stallthe spray tip until the'system is
primed.
2.
TWO GunHookup. Unscrew the cap
from the secondary hose outlet. Con-
nect an accessoryhose andguntothe
1/4npsm(m) nipple.
CAUTION
To avoid damaging thepressurecon-
trol, follow these precautions.
1. Always use nylon spray hose at
least 50
ft. (15.2 m) long.
2. Never use a wlre braid hose; It Is
toorigidto act asapulsation
dampener.
3. Never install a ballvalve
or shut-
off device between the filter and
the 50
ft. (15 m) hose.
4. Always usethemain filter outlet
for onegunoperation.Neverplug
this outlet.
3.
Fill the Packlng Nutwet-Cup 1/3 full
with Graco Throat Seal Liquid (TSL),
tend the pump life.
supplied, and keep it filled, to helpex-
SECONDARY
OUTLET
HOSE
1/4 npsm(m)
PRESSURE
VALVE
DRAIN
' OUTLET
NIPPLE
1/4 npsm(m)
I WHIP
HOSE
3 n (0.9 m)
Flg 8-1

4. Checkthe.englne oil level. Referto
the Honda engine manual, supplied.
This is a summary of the information:
Remove oneof the oil fillplugs; theoil
shouldbealmost overflowing.
See Fig
9-1. Add
oil as necessaty.
high-quality, detergent oil, SAE
Recommended lubrication oil:
Use a
SEor
SF", for regular use and for
1OW-40, classified
"FOR SERViCE
breaking-in a new engine.
5. Besureyoursystem Is properly
and follow
the warning section,FIRE
grounded before operatlng
It. Read
OR EXPLOSION HAZARD, page 3.
6. Fillthegastank. See the FUELING
section, below.
7. Flushthe pump to remove the light-
weight oil whichwas left
in the pump
to protect it from rust.Refer to the
FLUSHING GUIDELINES, page 12.
8. Preparethepalntaccording to the
manufacturer's recommendations.
formed. Stirthe paint
to mix pigments.
Remove any skin that may have
9. Straln the paint through a fine nylon
meshbag (available at mostpaint
dealers)toremove partlclesthatcould
clogthe filter or spraytip.This isprob-
ably the most important step toward
trouble-free spraying.
10. Keep the sprayer uprlght and level
duringoperation and whenever it is
being moved.ReadthelastCAUTION
on page10.
' OIL FILL PLUG
Flg 9-1
Gasoline is extremelyflarnmableand explosiveun-
WARNING
dercertain conditions.To reducetheriskof afireor
explosion:
0 Always shut off the enginebefore refueling.
0 Refuel in awell-ventilated area.
0 Do not smoke or allow flames or sparks in the
areawhere the engine is refueledor wherethe
gasoline
Is stored.
0 Do notoverfill thetank. Make sure thefillercap
Is securely closedafter refueling.
0 Becarefulnottospilifueiwhenfueling.Fuelva-
por or spilledfuelcanignite. If any fuelis
spilled, makesure the area isdry beforestart-
ingthe engine.
1. Fuel specifications.Use automotive gasolinewith a
pump octane number of
86 orhigher. If the engine
knocks or pings,
use a higher octaine gasoline. Un-
leadedfuel minimizes combustionchamberdeposits.
2. Gasollnes contalnlng alcohol (gasohol). Do not use
gasohol which containsmethanol,ifthe gasohol does
notcontaincosoivents and corrosioninhibitors for
methanol.Evenif
itdoescontainsuchadditives, donot'
use thegasoholifitcontainsmorethan 5% methanol.
NOTE
The HONDA engine warranty doesnot cover
taining alcohol. See the HONDA engine manual
damage resultingfrom the
use of gasolines con-
for more information.
3. General. Do not use oiland gasoiinemixturesorcon-
taminated gasoline. Avoid gettingdirt, dust
or water
in the fuel tank.
4. Tank Capacity.
0.66 gallons (2.5 liter). Always leave
at least 1/2in. at the top of the tank for expansion.
5. Shut off the englne before refuellng.
6. After refueling, tlghten the fuel tank capfirmly.

NOTE: Refer to Fig 11 -1 as youstart the sprayer.
NOTE: When starting a sprayer that IS NOT PRIMED, re-
1. Be surethe gas tank Is full. Open the blackfuel shut-
2. Checktheenglne 011 level.
NOTE:
The engine stops automaticallyif it is low on oil.
If youtry to start it againwithout adding more oil,
a red light
on the rear ofthe engine glows as you
pull thestarter rope.
move the spray tip.
off lever.
3. Place the suction tube Into the paint container.
4.
Turn the pressure control switch to OFF.
5. Openthe black fuel shutoff lever by pushingit in the
6. Be sure the spark plug cable Is flrmly pushed onto
directionof the arrow.
the spark plug.
CAUTION
Never attempt to startthe engineunless fluid pres-
OFF. Attemptingto start the enginewhen
it ispres-
sure is relieved andthe pressurecontrol isturned
surizedwill damagethe recoil system.
7. To start the englne:
a. Turn the pressure acljustlng knob all the way
counterclockwise tothe lowest pressuresetting.
b. Pull the metalthrottle lever awayfromthe fuel
tank
to the maximum position(fully left).
c. If the englne Is cold,close the gray chokelever,
located beneaththe air cleaner.
way or not at all.
If the englne Is warm, close the chokeonly half
d.
Turn theenglneswltch to ON.
WARNING
A rope which recoils too quickly mayhit someone
andcause serious bodily injury.
The ropecould
also jam in the recoil assembly.
e. Graspthe starter rope. Holdingthe frame of the
sprayer with
one hand, pull the rope rapidly and
firmly. Continue holdingthe rope as youlet it re-
turn.
Pull and return the ropeuntiltheengine
starts.
f. Open thechoke. In cold weather, leave the
choke closedfor
10 to 30 seconds beforeopen-
ingitto keepthe enginetunning.Otherwise,open
the choke as
soon as the engine starts.
8.Dlsengagethegunsafetylatch.
9. To startthepump:
a. Openthe pressure drain valve.
b. Turn the pressure control switchto ON.
c. Slowly increase the pressuresettinguntil the
pumpstartsto cycleslowly. Cyclethepumpslow-
drainvalve, indicatingthe pump is fully primed.
ly until fluid is flowing smoothlyfromthe pressure
d. Close the pressuredrainvalve.
e. Hold a metal part of the gun firmly against a
til fluid is flowing smoothly from thegun.
groundedmetalcontainer,squeezethetrigger
un-
f. Release the trigger andengagethegunsafety
latch.
10. Install the spray tip. Refer to the Instructionmanual
suppliedwiththetip
(307-848 if you are usinga
RAC
IV).
11. Adjust the englne speed and pump pressure. Trig-
ger the gun onto a test paperto check thespray pat-
ternandatomization.Turn the pressure adjusting knob
throttle setting asfar as you canwithout changingthe
until you get a good pattern.
Then slowly lower the
spray pattern.
CAUTION
Always use the lowest needed fluid pressure and
the lowest neededthrottle setting, to increase the
lifeof the sprayer. Highersettings cause excessive
cluich cycling, premature tip wear and premature
pumpwear.
CAUTION
thesprayertopreventfuelfrom flooding theengine.
Closethe fuel valve wheneveryou are transporting
Keepthe sprayer upright and level when operating
Itandwhentransporting
it. Thispreventscrankcase
which makesstart up very difficult.
oilfromleaking into the combustion chamber,

low the Pressure Relief Proceduie Warniig on
page 2 beforechecking,adjusting,cleaning or
WEEKLY: Removethe air filtercover andclean theele-
shutting
down the sprayer.
ment.Inverydustyenvironments,checkthefilterdaily.Re-
placetheelementasneeded. Replacementelementscan
be purchasedfrom your local HONDA dealer.
CAUTION WEEKLY: Checkthelevel oftheTSLin thedisplacement
For detailedengine maintenance and specifica-
tions, refer
to the separate engine manual. pump packing
nut. Fillthe nut, if necessary. Keep TSL in
the
nut to help lubricatethe pump packings.

To reducethe risk ofserious bodilyinjury, including
fluid injecfon, always follow the Pressure Relief
Procedure Warningon page 13 before checking,
adjusting, cleaningor shutting downthe sprayer.
When To Flush
CAUTION
chance it couldfreeze.Push thewater
out with min-
NEVER leavewater in the sprayerIfthere istheany
era1spirits.Waterfrozen
in thepressurecontrol tube
prevents the sprayer from being started, and
causes serious damageto the pressure control.
1. NewSprayer.Thissprayerwasfactorytested
in light- ' 5, Storage..
weight oi1,which was tell in toprotect
the pump parts. Wafer basepaint: flush withwater, then mineral spirits
Before using wafer-basepaint, flush with mineral spir- andleavethe pump, hose andgunfilled withmineral
soirit. Relieveoressure.
its, then soapywater, andthen cleanwater.
Before
using oil-basepainr, flush with mineralspirits.
Oil basepaint: flush withmineral spiritsandleave the
pump, hoseand gunfilled with mineralspirit. Relieve
2. ChangingColors. Flushwithacompatible solvent pressure.
suchasmineralspirits orwater. 6. Startup after storage.
__ ..". ~~~~
r~- ~~~~~
3. Changlngtromwater-basetooil-basepalnt. Flush
with warm, soapy water, and then mineral spirits. Before usingwafer-base paint, flush
out the mineral
snirits with soaovwater. and then with cleanwater.
4. Changlng from oil-base to water-base palnt.Flush
-8 ~~~~ ~I I
with mineral spirits,thenwarm, soapywater, andthen Whenusingoil-basedpainf, flush
out themineralspir-
clean water. its with the paint to besprayed.
How To Flush \A
1. Relieve pressure.
2.Remove the filter bowl and screen:
see manual
307-273. Clean the screen separatelyand install the
bowl, without the screen,toflush it.
See Fig12-1.
FILTER BOWL
SCREEN
FILTER
SUPPORT
Fig 12-1
3.Close the pressure drain valve.
4. PLlt the suction tube in a grounded pail of solvent.
5. Removethe spray tip from the gun.
PRESSURE DRAIN VALVE'
WARNING
6. Disengage thegun safety latch. Startthe sprayer,trig-
ger the gun makingmetal-to-metal contact between
the gunanda grounded metal pail,andslowly turnthe
pressure adjustingknob just until the pump starts.
the nozzle.
See Fig 12-2.Releasethe trigger anden-
Keep the guntriggered until cleansolventcomesfrom
gage the gun safety latch.
._
MAINTAIN FIRM METAL-TO-
FLUSHING
TO REDUCETHE
METAL CONTACTWHEN
CHANCEOF STATIC
SPARKING AND SPLASHING.
Flg 12-2
7. Check allfluidconnections for leaks.Relievepres-
sure beforetightening any connections. Start the
sprayer. Recheckthe connections for leaks.
8. Removethe suction tubefromthe pail. Disengagethe
thehose.
Do notletthe pumprun dryfor morethan 30
gun safety latch.Trigger the gunto forcesolventfrom
seconds, to avoid damaging the pump packings!
Re-
lievepressure.
9. Remove the strainer and suctiontube (if used) and
cleanseparatelyto be sure allpaint sediment is
removed.
10. Leavethe pressure drain valveopen during non-use.
Installthe cleanscreen. Install the bowl, handtight.
11. If you flushed with mineral spiritsand aregoing to use
a water-base paint, flush withsoapy water followed
by a cleanwater flush. Relievepressure.

TROUBLESHOOTING GUIDE
WARNING
Pressure Relief Procedure 5. Engagethe gun safety latch.
Tored~cetheriskOfSeriOUsbodl~yinjury, lncludlngfluld 8. Openthefluid pressure drainvalve and leave it
Injection,splashing
in the eyesor onthe skin, of injury openuntil you s:art the sprayer again.
from movingparts,alwaysfollowthis procedurewhen
7, the spa& plug,
you shut off the sprayer, when checking, adjustingor
dogged of fhar presufe is not My relieved after fob
1. Engagethe gun safety latch. /owing
the sreps above, wrap a rag aroundthe tip re-
2. Turn the engine stop leverto OFF. taining nut or hose end coupling and VERY SLOWLY
3. Flipthe pressure control switchto OFF. loosen the part to relieve pressure gradually. Now
4. Disengagethe gun safety latch. Holda metal part clear thetip
or hose.
cleaningthesystem,andwhenchanging spray tips.
You rhe hose Or Is comP'efe&
of the gun firmly to tne side of a grounded metal
pail, andtrigger thegun.
2
Check everything in the chart before disassembling the sprayer. (Confinued on page i4)
:ngine won't 'pull over"
:ngineoperates, butdisplacement
sumpdoesn't
CAUSE
SOLUTION
Engine switch not on
I Turn on.
Out ofgas I Replenish I
Engine oil level low
Plug.
spark plugdamaged Connect cable on top of engine or replace spark
Spark plug cable disconnected or
Try startingengine.Iflightonrearofengine
glows, replenish oil.
Water frozen inpressure control Retumpressurecontrol
to authorized Gram
I dealer for repair. I
I
Oil seepageintocombustion I Rernoves~ark~lu~.Pullsta~erro~3or4times.
chambir
I
Cleanandreplace~lug.Trytostari.Keepsprayer
uprlght to avoidoilseepage. I
I
Pressuremntroiswitchtumed OFF Turnon.
I
Pressuresetting too low I Increasepressure. I
Displacementpumpoutlet filter difly I Cleanfilter. I
Tip or tip filterclogged I Cleantip or tip filter. I
7
Displacement pump rod seized by Service pump. See page
18.
dry pint
Connecting rod worn or damaged Replace. See page 20.
Drive housing worn or damaged
Check wiring connections.
See page 16. El&rical power not energizingfield
Replace.
See page 21.
With pressure control switch ON andpressure
turned
to MAXIMUM, use a test light to check
continuityacrossblackandwhitewiresfrom
pressure control.
Havepressurecontrolcheckedbyauthorized
Graco dealer.
Clutch worn or damaged
Service. See page
22. Pinion assembly worn or damaged
%Nice. See page
24.
"" "" "

1 PROBLEM I CAUSE I SOLUTION I
Displacementpump outpuilow on
upstroke Clean. Pump Inlet screenclogged
Piston
ball check not seating
Replace packings.
%a page 18.
Piston packings worn or damaged
Service piston
ball chack. Sae page 18.
I
Sleeve gasketIndisplacement pump Replace.
See page 18.
worn or damaged
I I
Displacementpumpoutput low on
downstroke or bothstrokes Pump iniet screen Clogged Clean.
Piston packings worn or damaged
Intake valve
ball check not seating Replace paCklngS.
Sae page 18.
Clean and sewica. %e page 18.
Increase throttle setting. See Startup,
proprly
Engine RPM
tco low
Clutch worn or damaged Replace.
Sea page 24.
step 11, Page 10.
I I
Paintleaks intowet-cup I Loose wet-cup I Tighten just enough to stopleakage. 1
1-
Throat packings worn or damaged. Replace paCkingS.
%a page 18.
DisDlacamantrodworn or damaaed I Replace rod. Sea Pam 18.
-
Low fluid delivery Claan. Pump inlet screen Clogged.
.-
Pressuresetting too low lncraase pressure. See Startup,
Step 11, page 10.
Step 11, page 10.
Incraase throttle salting. See Startup,
I
I
Dirlvoutletfiller. tiD filter or ti0 I Clean.
.-
I
I large pressure drop in hose I Use larger diameterhosa. I
I
Spitting fromgun
I
Air influid pumpor hose I Check for looseconnactions at Dum0 intake and I
Them prime the pump.
~ ~ ~~
.,
I
I
Tip parlially clcg~ed I claar. I
..
I
Fluid supplyislow or empty
~ ..
Refillandprimethepump.SaeStartup,pagelO.
Check fluid supply often to prevent running the
mlmn drv

WARNING
To reducetherisk ofseriousbodilyinjury, always fol-
page
13 before repairingthe sprayer.
lowthePressureReliefProcedureWarning on
1. Disconnectbothhoses (59) at the pressure control
TlON below. Notethe original locationof each hose
(63), while holding the elbowsfirmly. See the CAU-
to besure you reassemble themcorrectly at the end
of this procedure. See Fig 15-1.
2. Workingunder the engine mounting plateof the cart,
riaht cart, removethe three nuts
(61) and lockwashers
disconnectthe red, black andwhite wires. Forthe
UD-
move the two screws (62) and washers (9). See Fig
(9) fromthe capscrews (62). For the Lo-bov cart, re-
3. Remove the wire clamp (32). Remove the pressure
4. Remove the pressure control cover (76) and the
15-2.
control. See Fig 15-2.
mountingbracket (67). See Fig 15-1.
/ 76
64
page 19)
Fig 15-1
MOUNTING FOR UPRIGHT CART SHOWN MOUNTING FOR LO-BOY CART SHOWN
TO ENGINE
Flg 15-2
VIEW FROM UNDER ENGINE MOUNTING
PLATE ON UPRIGHT CART
VIEW FROM UNDER ENGINE MOUNTING
PLATE ON LO-BOY CART

5. Disconnectthered,blackand white wires fromthe 8.
rectifier (307) which are sheathed withthe conductor
(309). Unscrew the connector (313
or 105) from the
control box, pulling the conductor and wires
out with
it.
6. For the uDriaht soraver,remove the nipple(31 2) from
the elbow (314).
7. Use a wrench to holdthe hex of the adapters (A) while
removing the elbows(314 or 322).
9.
Reassemble inthe reverse order.
Forthe Uoriaht carts, guidethe new pressurecontrol
wires through the wire clamps (32). Fasten the wire
clamps
to the cart with the same screws, lockwash-
ers, andnuts(62,9, 61) which holdthebracket (67) to
the cart. See Fig 15-2.
throuqh the single wire clamp (32), andinstall
the
For the Lo-bov carts,guide thepressure control wires
screws
(62) and-washers (9) to hold thebracket (67)
to the cart. See Fig 15-2.
Performthe
Pressure Control Adjustment on page
17 beforeregular operation of the sprayer.
FOR UPRIGHTCART SPRAYERS
A
RECTIFIER (307) CONNECTIONS
I I
RED
flK
I WHITE GROUND I
FOR LO-BOY CART SPRAYERS
309 ,
TOP VIEW

USEEXTREMECAUTION WHEN PERFORMINGTHIS CALIBRATIONPROCEDURE to reducetheriskOf afluid
WARNING
injection injuryor otherserious bodily injury, which canresultfrom componentrupture, electric shock,fire, eXpl0-
sion or moving parts.
I
This proceduresetsthe sprayer to 2600-3000 psi NEVER attempt to increasethefluidOutletpressureby
(182-210bar)
MAXIMUM WORKiNG PRESSURE. . performingthesecalibrationsinanyother.way. NEVER
EXCEED 3000 PSI(210BAR\MAXIMUMWORKING
Performthis procedurewheneverthe pressurecontrol
PRESSURE. Normaloperatioi ofthesprayer at higher
assembly isremoved andreinstalled, or replaced,
to
pressures could result in component rupture, fire or
besure the sprayer is properlycalibrated. explosion.
Improper calibration can cause thesprayer
to over- ALWAYS use a new
50 foot (1 5.2 m) sprayhose,rated
pressurize and result in componentrupture,fire or
ex-
for at least 3000 PSI (210 BAR) MAXIMUM WORKING
plosion.
It may alsopreventthesprayer fromobtaining PRESSURE,when performingthis procedure.
A used,
themaximumworking pressure, resultinginpoor under-rated hose could develop a highpressureleak
sprayer performance. or rupture.
"~~
~ I- ~
Service Tools Needed:
NEW 50foot (15.2 m), 3000 psi (210 bar),
0-5000 psi (0-350 bar) fluid-filledpressure gauge,
flexible nylon airlessspray
hose, Part No. 223-541
0 NEW spraytip, size 0.025 to 0.029
Part NO. 102-814
318 in. ignition wrench or nut driver
5 gallonpail of water or mineral spirits
Swivel. 156-823
Nipple,162-453
Tee, 104-984
Set Up
1. Follow the PressureReliefProcedureWarnlngon
2.
Set up the system as shown in Fig17-1.
Set the Dead Band(Pressure Differential)
NOTE Donotalterthis adjustment if thewheel isalready
set as shown in Fig17-2.
page 13.
1. Removethepressurecontrol cover.
2. Setthewhitedifferentialwheel (A) on themicroswitch.
switch andthe letter A isthe first letter seen.
Turn the wheel
so the letter F is concealed behindthe
Pressure Up
1. Start the sprayer and prime it.
2. Adjust the pressure to 2600 psi (180 bar).
3. Shut
off the engine.If the pressuredrops, replacethe
pump packings before proceeding.See page 18.
AdjustthePressure See
Fig 17-3
1. Removethe plug(320) inthe bottomof the pressure
control.
2. Turn and holdthepressurecontrolknob(B) atthemax-
imum pressuresetting.
3. Engage the nut
(C): insert the nutdriver through the
pressure control holeor
use the ignitionwrench from
the front of the presure control.
a. Loosen the
nut just until you hear a click. Stop.
b. Slowlytighten the nutjust until another clickis
4. Replacetheplug(320)andthepressurecontrolcover.
heard. Stop.
162-453
NIPPLE
223-541 HOSE
Fig 17-1
INSIDE PRESSURECONTROL LOOKING UP
AT BOTTOM OF DIFFERENTIAL WHEEL
Fig 17-2
c'/
Fig 17-3 320

~~;~~,~~~,~~~~~~~~~~~~~~~~~~~~~~~~~~ D I S PUC E
WARNING
To reducetheriskof seriousbodilyinjury,alwaysfol-
lowthePressureReliefProcedureWarningon
page 13 before repairingthe sprayer.
Removing the pump.See
F/g 18-1.
1. Flush the pump. Relieve pressure.
2. Holdthe intakevalve (223)with awrench and
unscrew the suction tube
(30). Remove the
hose
(59). ForuDriahtcarts,removethespring
clips (101,103) and drain hose (102).
3. Pushtheretainingspring (26) up.Pushthepin
(25
) out the rear.
4. Loosenthe locknut (27). Unscrewthe pump.
See Disassembling the pump,below.
Dlsassembllng the pump.
1. Unscrewtheintakevalve(223)andremoveall
parts.
See F;g 18-1.
2. Removethe plug (205).Unscrewthepacking
nut (216).
See Ffg 18-2.
3. Tap the piston rod(224) down andthen pull it
out the bottom of the cylinder(219). See
F;g
18-2.
4. Removethe throat packings.See Fig 18-2.
5. Clamp thefiats of the piston rod(224) in avise. Loos-
ton. Removethe piston packings.
en the piston(222).Unscrewthenut (21 1) fromthe pis-
Fig
18-2
-

~~~~~~~~~~~~~~~~~~~~ &&..,*ns;.+.&/d ~~~~,sk.sA&,~~~~~~~,~~;~ D I S p LAC EM E NT p U M p ~~~~~~~~~~~~~~~~~~~~~~~~~~ ,X&*., " .w %d,>*> .,,~~~.,~~,~~~~~~~~,~:~~~~,
WARNING 5. Tighten the nut (211) onto the rod (224) to 19 ff-lb
(25Nm).Use
two wrenches to maintainthealignment
as mentioned
in Step3.
sleeve.
If the sleeve isstuck, send the cylinder to
yourGraco distributor for removal. 6. Stack the throat packings into thetop of the cylinder
(219). Installthe packing nut (216) loosely.
6. Removethe sleevewhenever
your servicethepump.Use
special
tool, Part No.
222-586 only. Screw the
nut
(H) Into thecylinder (219).
Screw
down the rod (J) to
push the sleeve
out. See Fig
19-1.
Flg
19-1
Assembling the pump.
NOTE Userepairkit222-588, and use allthekitparts,
forthebestresults.Partsincluded
in thekitare
marked with anasterisk, (201
*), in the text and
drawings.
NOTE: Soakthe packings in oil, and coatthe rodand
inside of the cylinderwith oil toprevent dam-
age during assembly..
NOTE:Alternateleather andplasticpackings as
shown in Fig1.8-3.
Be sure the lipsof the v-
packings face the direction shown. incorrect
installation damagesthe packings andresuits
in pump leakage.
1. Checkthe piston rod(224) andthe insideof thesleeve
. (218) forscoringor scratches. Ifthese parts are dam-
2.Stack the pistonpackings
onto the piston (222) as
aged, new packings will
not seal properly.
shown in Fig18-3 and Fig19-2.
3. Tighten thepiston
nut(211)
onto the
piston
to 10.5 in-lb
packings,and then
(1.2 N.m.)
to seatthe
tighten.
back
off and finger
211
APPLY ONE DROP
OF SEALANT TO
THESETHREADS
Flg 19-2
Note the alignmentof the piston (222) to the piston
5 and 6.
nut (211)and maintain this alignmentthroughSteps4,
4. Apply ONE dropof adhesive, suppliedwith the repair
kit,
to the pistonthreads. Placethe ball (225') on the
piston. Hand tightenthe piston into the rod(224) just
untilthe
nut (211) contacts the rod. Place the flats of
~ ~~
7. Insert the pistonrod
assemblyintothetop
CYLINDER
of the sleeve. Install
thegasket (202)
on
the sleeve. Slide the
sleeve assembly
Into
the bottomofthe
cylinder.Note that
thetapered endofthe
sleeve isthe bottom&y;;
See Fig 19-3. TAPERED
SLEEVE
Fig 19-3
END
8. Assemble and installthe intake valve. Use anew
gasket (202'). Tighten the valve
to 67 ff-lb (90
Nm). See Fig 18-1.
installing thepump. See
Fig 18-1 and19-4
1. Screwthe pump 3/4of theway intothe bearinghous-
ing(21). Holdthe pin(25) up tothepin hole inthe con-
necting rod (22) and continue screwing
in the pump
untilthe pin slides easilyInto the hole.
2. Align the top threads of the pump cylinder flush with
the faceof the bearing housing and
so the outlet nip-
ple
(57) is straight back.
3. Push the retaining
spring (26) into the
grooveof theconnect-
ing rod, all the way
around.Tighten the
locknut (27) very tight
prevent itloosening
anddamaging the
threads of the bearing
housing.
- 70 ft-lb (95 Nm), to
Fig 19-4
WARNING
Be sure the retaining spring (26) is firmly in the
groove, all the way around,
to prevent the pin (25)
from working
loose due to vibration.
Ifthe pin works
loose, it or other parts could break
off due to theforce of the pump action. These parts
could be projectedthroughthe air andresult inseri-
ous bodily injury or property damage,including
damage to the pump connecting rod and bearing
housing.
4. Tighten thepackingnut(21
6) just enough to stop leak-
ing, but
not tighter. Fillthe nut 1/2full with GraocTSL.
~~~~

ways followthe Pressure Relief Proce-
the sprayer.
dure Warning on page 13 beforerepairing
NOTE: Steps 1 to 13 referto Fig 20-1.
1. Refer to Removing the Pump on page 18.
2.
Removethefour screws (73) and lockwash-
ers
(74) from the bearing housing (21).
3. Whilepullingtheconnecting rod assembly
(22) with one hand,lightly tap thelower rear
ofthebearing housing
(21) withaplasticmal-
let
to loosen it’fromthe drive housing (20).
Pullthe bearing housing and the connecting
rod assembly
off the drive housing.
4. Inspectthe crank (A) for excessivewear and
replaceparts asneeded.
. ’
5. Evenly lubricate the inside of the bronze
the insideof the connecting rodlink
(D). with
bearing(C) in the bearing housing
(21), and
high-qualitymotoroil. Liberallypacktheroll-
er bearing
(E) in the connecting rodassem-
bly
(22) with bearinggrease.
6. Assemblethe connecting rod (22) andbear-
ing housing
(21).
7.
Cleanthemating surfacesof thebearing and
drive housings.
8. Align the connectingrod with the crank (A)
andcarefully alignthe locating pins
(F) inthe
drive housing
(20) withthe holes inthe bear-
ing housing
(21). Pushthe bearing housing
ontothe drivehousing ortapitintoplacewith
a plastic mallet.
CAUTION
DO NOT use the bearinghousing screw
(73) to align or seat the bearing housing
withthe drivehousing.Thesepartsmust be
aligned usingthe locating pins
(F), to help
avoid premature bearingwear.
9. Installthe screws (73) and lockwashers (74)
on the bearing housing. Tighten the screws
evenly
to 175 in-lb (20 Nm).
10. Refer to Installing the Pump on page 19.
Fig 20-1