Graco WONDER WETTER Jr. 222-684 Operation manual

INSTRUCTIONS-P ARTS LIST 307–959
Rev A
ABATEMENT TECHNOLOGIES
WONDER WETTER Jr . SPRAY SYSTEM
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
Model 222–684, Series A
120 V olt AC, 1 Phase, 1 Amp
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1989, GRACO INC.
This manual contains IMPORTANT
INSTRUCTIONS and WARNINGS.
READ AND RETAIN FOR REFERENCE.

307–959
TABLE OF CONTENTS
Terms 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray System Description 4. . . . . . . . . . . . . . . . . . . . .
Setup 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Guidelines 6. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 7. . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Repair
Fuse 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
ON/OFF
Switch 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 9. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outlet V alve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet V alve 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming V alve & T ube 11. . . . . . . . . . . . . . . . . . . . . .
Suction Tube 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod & Bearing 12. . . . . . . . . . . . . . . . . .
Motor 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray V alve Repair 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List and Drawing 15. . . . . . . . . . . . . . . . . . . . . . .
Accessories 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMS
Be sure you read and understand each of these terms be -
fore
reading the rest of the manual.
WARNING: Alerts user to avoid or correct conditions
which
could cause bodily injury .
CAUTION: Alerts user to avoid or correct conditions
which
could cause damage to or destruction of the equip -
ment.
NOTE: Gives additional explanation of a procedure or
helpful
hints.
WARNING
Be sure all operators of this equipment read, understand,
and follow the warnings and instructions in this manual!
ELECTRICAL GROUNDING
Electrical grounding is essential to reduce the risk of an
electric shock or other serious bodily injury from static
sparking.
Read and follow the grounding instructions on
page 4 of this manual.
EQUIPMENT MISUSE HAZARD
This system is designed to be used at 250 psi (17.5 bar)
MAXIMUM WORKING PRESSURE. Use only compo-
nents
or accessories which are designed for use with the
WONDER WETTER Jr . spray system.
Any misuse of this equipment, such as modifying parts,
using incompatible material or solvent, or using worn or
damaged parts, can cause the equipment to rupture and
result in serious bodily injury , fire, explosion and property
damage.
Never
alter or modify any part of this equipment; doing so
could cause it to overpressurize or malfunction.
Check all parts of the system regularly and repair or re-
place
any worn or damaged parts immediately .
GENERAL SAFETY
Use extreme care not to splash material, contaminated
flushing
water or solvent into your eyes. W ear protective
eyewear.
Be sure the area in which you are working is well venti-
lated,
to avoid a buildup of harmful material fumes.
To reduce the risk of electric shock, do not expose the
system
to rain . Always store the system indoors. Do not
operate the pump with the pump base cover removed.
HAZARD OF USING FLUIDS CONT AINING
HALOGENATED HYDROCARBONS
Never use 1,1,1–trichloroethane, methylene chloride,
other halogenated hydrocarbon solvents or fluids con-
taining
such solvents in this equipment. Such use could
result in a serious chemical reaction, with the possibility
of explosion, which could cause death, serious bodily in -
jury
and/or substantial property damage.
Consult your material suppliers to ensure that the fluids
being
used are compatible with aluminum and zinc parts.

3
307–959
ADVERTISEMENT
Assurez-vous que tous les utilisateurs de cet équipment lisent, comprenent et observent
les avertissements et les instructions de ce manuel!
MIS A LA TERRE
Il est essential d’ef fectuer la mise à la terre pour réduire
le risque de décharge électrique et de blessures
sérieuses résultant des étincelles d’électricité statique.
Lisez
et observez les instructions de mise à la terre, à la
page 4 de ce manuel.
SECURITE GENERAL
Faites extrêmement attention de ne pas éclabousser de
peinture, d’eau de rinçage sale ni de solvant dans les
yeux.
Portez des lunettes de protection.
Assurez-vous que l’endroit où vous travaillez est bien
aéré
afin d’éviter l’accumulation des vapeurs toxiques de
peinture.
Pour réduire le risque de décharge électrique, n’exposez
pas
le système à la pluie . Ranger toujours le système à
l’intérieur.
DANGERS POUR V ANT RESUL TER DU
MAUVAIS USAGE DE L’EQUIPMENT
Ce système est conçu pour être utilisé à une PRESSION
MAXIMUM DE FONCTIONNEMENTDE 17.5 BARS
(250 PSI).
N’utilisez que des pièces ou accessoires qui
sont
conçus pour être utilisés avec cet système.
L’utilisations incorrecte de cet équipment, la modifica-
tions
des pièces, l’utilisation de peinture ou de solvant in -
compatibles, l’utilisation de pièces usées ou abîmées
peuvent entraîner la rupture de l’équipment et causer
des blessure graves, un incendie, une explosion et des
dégâts
matérials.
Ne changez et ne modifiez jamais aucune pièce de cet
équipment;
ceci pourraît entraîner une surpression et un
mauvais fonctionnement.
Vérifier régulièrement toutes les pèces du système et
réparez ou remplacez les pièces usées ou abîmées
immédiatement.
ADVERTENCIA
Asegurarse de que todos los operadores de este equipo lean, entiendan y respeten las
precauciones e instrucciones indicadas en este manual.
PUESTA A TIERRA
La puesta a tierra es esencial para reducir el riesgo de
sufrir un choque eléctrico u otras lesiones corporales
graves debido a chispas estáticas. Leer y seguir las in-
strucionnes
dadas en la pàgina 4 de este manual.
SEGURIDAD EN GENERAL
Tener extremo cuidado de no salpicarse los ojos con pin -
tura, agua de enjuague contaminada o solvente. Usar
gafas
protectoras.
Asegurarse de que el lugar de trabajo tenga buena venti -
licón, para evitar la cumulación de vapores de pintura
nocivos.
Para reducir el riesgo de sufrir un choque eléctrico,
no
dejar
este sistema expuesto a la lluvia. Siempre guardar -
lo
bajo techo.
PELIGRO POR MAL USO DEL EQUIPO
Este sistema está diseñado para una PRESION DE
TRABAJO
MAXIMA de 17.5 barias (250 lbs/pulg
2
). Usar
componentes o accesorios diseñados para usarse con
el
sistema.
El uso indebido de este equipo, tal como modificación de
las piezas, uso de pintura o solvente incompatible, o de
piezas dañadas o desgastadas, podria causer la rotura
del
equipo y terminar en graves lesiones personales, in -
cendio,
explosión y daños a la propiedad.
Nunca alterar or modificar ninguna pieza del equipo;
el hacerio podria causer sobrepresión o malfunciona-
miento.
Revisar con regularidad todas las piezas del sistema y
reparer or sustituir de
inmediato las que estén dañadas
o desgastadas.

4307–959
Motor
The motor drives the connecting rod which moves
the
diaphragm.
Pressure Switch
The pressure switch at the pump outlet turns the
motor
on and of f to control material pressure.
Diaphragm
Driven by the connecting rod and motor , the move -
ment
of the diaphragm draws material from the suc -
tion
tube and through to the outlet valve.
Priming V alve
The priming valve assists in priming the pump
during
startup.
Outlet V alve
The outlet valve has a ball check which pre-
vents
material from flowing backwards into the
pump. This helps keep an even supply of mate -
rial
each time you trigger the spray valve.
Inlet V alve
As the diaphragm draws material from the suction
tube, the material passes through the inlet valve
which
opens to allow material into the pump.
Outlet Hose
The hoses have swivel–type couplings for easy as -
sembly. A larger diameter outlet hose and chemi-
cal–resistant outlet and suction hoses are avail-
able.
See ACCESSORIES on page 18.
Spray V alve
The spray valve controls material flow by triggering
it on and of f.
SETUP
1. Remove all parts from the boxes and assemble them
as shown in Fig 1, following the notes on the drawing.
2. Prepare the material according to the manufactur-
er’s recommendations. Remove any skin that may
have formed on the top of the material. If necessary ,
thin
the material.
3. Plug the power supply cord into a properly grounded,
120 V electrical outlet. See Fig 2. Do not use an
adapter. All extension cords must have three wires.
Use
the chart at the right for selecting the appropriate
wire gauge for the extension cord.
WARNING
Never
remove the grounding pin of the power supply
cord plug. Be sure the outlet is properly grounded. In
the event of an electrical short circuit, grounding re-
duces
the risk of an electric shock by providing an es -
cape
wire for the electric current.
Inspect the power supply cord and extension cord be -
fore
each use. Be sure they are in good condition and
have undamaged three-pin plugs. Replace immedi-
ately
if either cord shows signs of wear or damage.
Fig 2
Extension Cord Chart
Cord Length Gauge
Feet Meters
1 – 100
100–200
200–300
1–30
30–61
61–92
18
16
14
PRIMING
VALVE
STRAINER
TWO 25 FT (15 M) HOSES.
JOIN WITH THE 3/8NPT NIP -
PLE
SUPPLIED
SUCTION TUBE
PRIMING TUBE
INLET V ALVE
ON/OFF
SWITCH
SPRA Y V ALVE
SPRA
Y W AND
Fig 1
POSITION ABOUT
15 IN. (380 MM)
FROM STRAINER
SYSTEM DESCRIPTION

5
307–959
STARTUP
WARNING
To
reduce the risk of serious bodily injury , including
injury from moving parts or electric shock, always
follow this procedure whenever you shut of f the
system,
when checking or servicing any part of the
system, and whenever you stop dispensing.
1. T urn the ON/OFF switch to OFF .
2.
Unplug the power supply cord.
3. T rigger the spray valve to relieve pressure.
If you suspect that pressure is not fully relieved af -
ter following the steps above,
open the priming
valve
2 turns counterclockwise.
1. Place the suction tube in the pail of material.
2. Plug in the sprayer .
3. Open the priming valve 2 turns counterclockwise ,
which drains the material into the pail through the
priming
tube.
4. T urn the ON/OFF switch ON.
5. As soon as you see material flow through the priming
tube, close the priming valve (clockwise) . Priming
usually
takes less than 30 seconds.
CAUTION
Failure
to completely close the priming valve after
the system is primed will cause the valve to erode,
greatly shortening the valve life.
6. If your system is hard to prime, force feed the suc -
tion
tube. Hold the suction tube in a vertical position
and pour material into it. Turn on the system. If the
system
does not prime within one minute, shut it of f.
7. If the system still does not start, push the inlet
open
with a pencil eraser , and try priming the system
again.
NOTE: Heavy viscosity material may need to be
thinned.
Be sure to follow the material manufac -
turer’s
recommendations on thinning.
6. When the outlet hose is fully primed, the motor runs
when there is material demand, but appears to shut
itself off when there is no material demand.
NOTE: An occasional start and stop of the motor when
the spray valve is of f is normal.
OPERATION
To reduce the risk of electric shock, do not expose
the system to rain. Always store the system
indoors.
WARNING
CAUTION
Always
allow cold equipment to warm to room tem -
perature
before using to prevent damaging the sys -
tem.
Always store the system indoors.
1. With the system fully primed, trigger the spray valve
until an even flow of material is spraying out of the tip.
2. Hold the spray tip approximately 12 in. (300 mm)
from
the surface and start spraying.
3. For low pressure spraying , use the tip supplied
with
the wand. This tip develops a spray pattern at a
very low pressure when spraying fluids about the vis -
cosity of water, such as wetting agents, penetrating
encapsulants
and lock-downs.
4. For fine-finish spraying, use the fine-finish tip
which produces a fine mist for “glove-bag” applica-
tions.
5. Whenever
you are done spraying, turn the switch to
OFF and trigger the spray valve.
6. Flush the system thoroughly and immediately after
each
use to keep it in good working order . See page
6.

6307–959
MAINTENANCE
Thorough flushing and proper maintenance are es -
sential
to keep your system working properly!
Improper flushing or maintenance may prevent the
system from working the next time you need it, and
may result in costly damage to the system.
ALWAYS flush your system thoroughly and imme -
diately
after each use.
ALWAYS drain all water out of the spray valve and
extension and leave the system filled with mineral
spirits to prevent corrosion.
CAUTION
NOTE: A
power flush Adapter , Graco part no. 220–331,
can be used if you are using penetrating or lock-
down encapsulants. This accessory is placed at
the pump inlet and uses a standard city water
supply to aid in flushing. See ACCESSORIES,
page 18, to order. Instructions on hose to use it
are included with the adapter .
Flushing (Non–oil based materials only)
1. Turn the switch to OFF .
2. Place the suction tube in the pail of warm soapy
water. Hold the spray wand over the material pail.
Turn on the system and. T rigger the spray valve to
drain
and save the material in the hoses. Release the
trigger. Shut the pump off just as soon as all material
is drained, to avoid contaminating the material with
the
flushing water .
3. Hold the spray wand over the flushing pail. Turn on
the pump and trigger the spray valve. Circulate the
solution
for three to five minutes (five to ten minutes
if it is cold).Then open the priming valve for a few sec -
onds
to clean the priming tube. Close the valve.
4. Raise the suction tube above the water and run the
pump
for a few seconds to drain the flushing solution.
Shut of f the pump.
5. Wash of f all external parts of the hoses, spray wand,
spray valve and pump.
6. Using clean water, flush again. Changing water as
often as necessary until the system is thoroughly
cleaned.
7. Finally,
flush the system with clean mineral spirits for
just a few seconds. Open the priming valve and turn
off the pump. Some mineral spirits must be left in the
system to prevent corrosion.
8. Oil the needle in the spray valve and trigger the valve
a few times to distribute the oil. See Fig 3.
Fig 3
OIL
REGULARLY
SPRA Y
VALVE
Never leave water or water–based material (latex)
in the system. To protect the pump from freezing
and to prevent corrosion in the pump, spray valve
and spray wand, your final flush must be mineral
spirits.
CAUTION
Flushing (Oil–based materials only)
NOTE: Follow the instructions above except use mineral
spirits. Do not heat the mineral spirits.
TROUBLESHOOTING GUIDE
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
injury from moving parts or electric shock, always
follow this procedure whenever you shut of f the
system,
when checking or servicing any part of the
system, and whenever you stop spraying.
1. T urn the ON/OFF switch to OFF .
2.
Unplug the power supply cord.
3. T rigger the roller valve to relieve pressure.
If you suspect that pressure is not fully relieved af -
ter following the steps above,
open the priming
valve
two turns counterclockwise.
WARNING CAUTION
Thoroughly flush the system after each use to re-
duce
down time and costly repair bills.
NOTE: If you are not able to determine the cause of the
problem, or the problem and solution is not dis -
cussed in this chart, return the system to an
authorized
service agency for repair .

7
307–959
Pump will not prime, or takes Clogged suction tube strainer Clean.
long time to prime
Material too thick Thin; try pouring material into suction tube;
use 3/8” ID hose, if necessary
Inlet valve stuck or damaged Depress valve gently and pour in 1 teaspoon
mineral spirits. T
ry to prime pump. Replace
valve if necessary . See Inlet V alve, page 10.
Loose inlet hose nut Tighten.
Pump will not start Power cord unplugged Plug in.
ON/OFF switch turned off T urn on.
Brushes worn Check brushes and replace, if necessary.
Damaged motor Replace. See page 13.
Fuse burned out
Replace. See page 8. If it burns out again soon,
return the system to an authorized repair agency
for repair .
Low or no material flow Clogged spray tip Clean thoroughly after each use.
Loose inlet hose nut Tighten.
W
orn or damaged priming valve Replace. See page 1 1.
Priming valve is open Close.
Material too thick Thin according to manufacturer ’ s recommendations.
Damaged pressure switch Replace. See page 9.
W orn inlet and/or outlet valve Replace. See page 9 & 10.
Pump runs after spray valve W orn or damaged pressure switch Replace. See page 9.
trigger is released
W orn or damaged inlet valve Replace. See page 10.
W orn or damaged priming valve Replace. See page 1 1.
W
orn spray valve packings or needle Repair . See page 14.
PROBLEM CAUSE SOLUTION
DEPRESS LIGHTL Y.
POUR IN 1 TEASPOON
MINERAL SPIRITS.

8307–959
SPRAYER REPAIR
WARNING
These
repair procedures should be performed only
by qualified repair personnel with an electrical
background, using the proper tools. Failure to do
the procedures correctly can result in electric
shock, or other serious injury and damage to the
pump.
WARNING
Pressure
Relief Procedure
To reduce the risk of serious bodily injury , including
injury from moving parts or electric shock, always
follow this procedure whenever you shut of f the
system,
when checking or servicing any part of the
system, and whenever you stop spraying.
1. T urn the ON/OFF switch to OFF .
2.
Unplug the power supply cord.
3. T rigger the roller valve to relieve pressure.
If you suspect that pressure is not fully relieved af -
ter following the steps above, open the priming
valve two turns counterclockwise.
NOTE: For all electrical repair , follow the Pressure Re -
lief Procedure W arning above, and then re-
move
the pump base cover (42). When reinstall -
ing
the cover , make sure all wires are tucked in
neatly before checking or operating the system.
Fuse (See Fig 4)
1. Pull the old fuse out of the fuse holder (65). Install a
new fuse (67). Use only a 3AG fuse, rated at 1-1/4
amps.
Rectifier
(See Fig 5)
1. Disconnect the four leads from the rectifier .
2. Remove the rectifier (39).
3. Install a new rectifier so the positive terminal (+) is
closest to the fuse holder (65) and then install the
screw (33b).
4. Connect the power white lead to an unmarked termi -
nal, and the pressure switch lead to the other un-
marked
terminal. Connect the black motor lead to the
negative (–) terminal, and the red motor lead to the
positive (+) terminal.
ON/OFF Switch
1. Remove the outlet adapter (2a) from the pump hous -
ing (9). See Fig 6. Remove the screws (28), handle
(32)
and shield (79). Refer to the Parts Drawing.
Be very careful not to let the ball drop into the pres -
sure switch cavity (12). If that happens, and the
outlet fitting (2a) is screwed into the pump, the
switch
will be permanently damaged.
CAUTION
2. Disconnect the two leads from the ON/OFF switch.
See
Fig 5.
3. Remove the boot (36). Pull the switch (34) out of the
base. Remvoe the nut (34a). Remove the ground
wire
(84). See Fig 4.
4. Remove the top nut (34a) from the new switch. Place
the connector of the ground wire (84) on the switch
and
reinstall the nut. Install the new switch, aligning
the tab in the base with the slot in the switch. See Fig
4. Install the boot.
5. Connect a pressure switch lead to the power out ter -
minal,
and a jumper wire lead to the power-in termi -
nal.
6. Reinstall
the shield, handle and screws, and the out -
let
adapter . Refer to the CAUTION to the left.
65
Fig 4
Fig 5
80
81
26
41
26
82
33
25
28
33b
43
33
42
67
68
34
37
38
34a 84
36
31
34
37 38
65 33 25
82,81,80
PRESSURE
SWITCH
LEADS
(2)
JUMPER WIRE
GREEN WIRE
MOTOR
LEADS
WHITE
OUT
IN
RED
39
33

9
307–959
SPRAYER REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
Power Supply Cord (See Fig 4 & 5)
1. Disconnect the white lead from the rectifier (39) and
the black lead from the fuse holder (65) and the green
lead from the grounding screw (82).
2. From the inside of the base, use a screwdriver to
push out the strain relief bushing (38). Remove the
bushing
and power supply cord.
3. Slide the strain relief bushing over the new power
supply cord. Press the bushing together . Press the
bushing
into the base.
4. Connect the green ground wire to the grounding
screw
(82). Secure it with a washer (81) and nut (80).
Connect the black lead to the fuse holder (65). Con -
nect the white lead to the terminal marked ~ on the
rectifier (39).
To maintain grounding continuity in your system,
and
reduce the risk of electric shock, be sure that:
Dthe green ground wire of the power supply cord
is properly connected to the screw (33);
Dthe ground wire (84) is properly connected be -
tween the ON/OFF switch and the screw (82)
as
instructed in Step 4, above;
Dthe screw (25) is tightly screwed into the base.
See Fig 4 and 5.
WARNING
Pressure Switch (See Fig 5 & 6 except where noted)
1. Disconnect the pressure switch leads from the ON/
OFF
switch (34) and from the rectifier (39).
2. Remove the front cover (23). See Fig 7.
3. Unscrew the retainer (14) and remove the pressure
switch (12) and o–ring (13).
4. Grease and install a new o–ring (13) in the pump
housing (9).
5. Slide the retainer (14) over the pressure switch and
screw the retainer into the pump housing. T orque the
retainer to 60 in–lb (6.8 N.m).
6. Guide the pressure switch leads through the base.
Connect
a lead to the power–out side of the ON/OFF
switch (34) and a lead the terminal marked ~ on the
rectifier (39).
7.
Reinstall the front cover .
To avoid damaging the pressure switch, do not
drop
it, and do not press on the center of the switch.
CAUTION
Outlet
V alve (See Fig 6)
1. Remove the outlet hose from the outlet fitting (2a).
Unscrew
the outlet fitting and remove the gasket (2b)
and spring (2c).
2. T ip the pump forward to remove the ball (2d).
3. Use a 1/4 in. square socket wrench extension to
screw
out the seat (2e).
4. Use a pointed tool, such as a dentist’ s pick, to re-
move
the seal (2f).
5. Thoroughly clean all parts and dry .
6. Tip the pump back. Install a new seal (2f), making
sure
it lays flat.
7. Install the seat (2e) and torque it to 85 in-lb (9.7 N.m).
8. Drop in the ball, making very sure it stays there!
Be very careful not to let the ball drop into the pres -
sure switch cavity (12). If that happens, and the
outlet fitting (2a) is screwed into the pump, the
switch
will be permanently damaged.
CAUTION
9. Check the ball stop pin in the outlet fitting (2a) for
wear
or damage and replace the fitting, if necessary .
Place a new gasket (2b) around the fitting. The last
coil
on one end of the spring (2c) is turned in. Place
this end on the ball stop pin. Screw the fitting into the
pump housing, torquing to 290 in–lb (33 N.m).
Fig 6
9
1
TORQUE TO
475 in–lb
(54 N.m)
APPL Y SEALANT
TO THREADS
3
10
2f
2d 2c 2b
13
12 14
TORQUE TO
60 in–lb
(6.8 N.m)
2a
TORQUE TO
290 in–lb
(33 N.m)
2e
TORQUE TO
85 in–lb (9.7 N.m)

10 307–959
SPRAYER REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
Inlet V alve (See Fig 7)
1. Remove the suction hose (44). Remove the inlet
valve
(1). Remove the gasket (3).
2. Reinstall the gasket on the new inlet valve. Install the
valve. T orque to 480 in–lb (54 N.m).
NOTE: To torque the inlet valve, have someone firmly
hold
the pump housing (9).
Diaphragm (See Fig 8)
Replace the diaphragm whenever you remove the
pump housing (9) or after each 100 hours of use,
whichever comes first. During use, small grooves
are formed in the diaphragm which cannot be re-
aligned
properly . Reusing a diaphragm may cause
leaking which will result in costly damage to the
pump.
CAUTION
1. Remove the pump base cover (42). Remove the
screws
(28), handle (32) and shield (79). Refer to the
Parts Drawing.
2. Remove the screws (15) and lockwashers (16). Tip
the
pump housing (9) back. Be careful not to damage
the wires. Remove the front cover (23).
3. Check the diaphragm guide (1 1) for wear or damage.
If replacing the guide, clean the pump housing thor -
oughly.
Use your fingers to press the new guide, flat
side first, evenly into the housing.
4. Screw the diaphragm (17) out of the connecting rod
assembly (18).
5. Use a soft brass or nylon bristle brush to clean the top
of the connecting rod and housing. Gently clean the
bottom of the pump housing (9), avoiding damage to
the diaphragm grooves.
6. Check the rod, motor bearing and eccentric for paint
residue. If there is paint residue or damage, clean or
replace the connecting rod assembly as explained
on
page 14.
7. Screw the new diaphragm (17) into the connecting
rod
just until it bottoms out. Then turn it 1/4 to 1/2 turn
(6–8 in–lb [2.7–3.6 N.m]).
Never turn the diaphragm more than 1/2 turn when
torquing it, as that will prevent the diaphragm from
working properly .
CAUTION
8. Apply
thread lubricant to the screws (15). Install the
screws and lockwashers (16) in the pump housing.
Torque
the screws a few inch–pounds at a time, op -
positely
and evenly , until there is 85 in–lb (9.7 N.m)
of torque on each screw .
9.
Spin the motor shaft (D) to be sure it turns freely .
10. Reinstall
the front cover (23), handle (32 and screws
(28), and the shield (79).
Fig 7
44
9
24
23
1
TORQUE T O
480 in–lb
(54 N.m)
3
Fig 8
44
47
45
11
17
18
9
23
D
15,16
LUBRICATE
THREADS.
TORQUE
T O
85 in–lb
(9.7 N.m)
46

11
307–959
SPRAYER REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
Priming V alve & T ube (See Fig 9)
NOTE: Each new priming valve kit includes a priming
tube
and fittings.
1. Unscrew the nut on the handle (E) of the priming
valve.
Unscrew the stem of the handle.
2. Screw the priming valve (10a) out of the pump hous -
ing (9).
3. Wrap the threads of the priming valve with
r tape as shown in Fig 9. Screw the valve
snugly into the pump housing. The valve handle
must
be parallel with the angled edge of the housing
to avoid interference with the inlet or outlet valves.
4.
Slide the nut (10d) and ferrule (10c) onto the tube
(10e).
Install the tube support (10b) in the end of the
tube. Screw the nut onto the priming valve, which will
seat the ferrule.
5. Completely screw the stem of the handle (E) onto the
priming valve, and then back it out two turns. Screw
the nut hand tight onto the priming valve, then tighten
the stem into the valve.
Suction Tube (See Fig 9)
1. Unscrew the nut (45) from the fluid inlet valve hous -
ing
(1). Remove the hose clamp (47). Slit the suction
hose to free the nipple (46).
2. Insert the nipple (46) through the nut (45). Dampen
the
new hose (44) with warm water . Press the hose
over the nipple. Screw the nut onto the inlet valve
housing. Press the hose onto the nipple, leaving
about
a 1/8 in. (3 mm) gap between the nut and hose
end.
3.
Install the hose clamp (47) and tighten snugly .
4. Remove the filter housing (48) and strainer (49) from
the old suction hose and install them on the new
hose. Soften the hose with warm water to ease
assembly.
44
45
Fig 9
48
49
10e
10d
10c
10b
10a
9
1
E
WRAP WITH
T APE
10
46
47
PTFE
PTFE

12 307–959
SPRAYER REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
Connecting Rod & Bearing (See Fig 10)
1. Remove the following parts: bottom cover (42),
screws (28), handle (32), shield (79), front cover
(23).
Refer to the Parts Drawing.
2. Remove the screws (15) and lockwashers (16). Tip
the pump housing (9) out of the way . Unscrew the
diaphragm
(17) and discard.
Replace the diaphragm (17) whenever you remove
the pump housing (9). During use, small grooves
are formed in the diaphragm which cannot be re-
aligned properly . Reusing a diaphragm may cause
leaking and result in costly damage to the pump.
CAUTION
3. Remove the motor screws (20) and lockwashers
(21).
Lift the motor (30) slightly . Hold the connecting
rod while pulling the motor away from the housing
(22).
4.
Inspect the bearing (18b) in the connecting rod (18a).
If it is worn or any rollers are broken, replace the
bearing
and rod assembly (18). Inspect the motor ec -
centric. Replace the motor if the eccentric is worn.
5.
Use your fingers to pack high–quality bearing grease
thoroughly in between the bearing rollers.
Thorough greasing of the bearing is essential to ex -
tend
the life of the bearing and the motor eccentric.
CAUTION
6.
Use a soft brass or nylon bristle brush to clean the top
of the connecting rod and housing. Gently clean the
bottom of the pump housing (9), avoiding damage to
the diaphragm grooves.
7. Install the connecting rod (18) in the connecting rod
housing (22). Screw a new diaphragm (17) into the
rod just until it touches the bottom. T urn the dia-
phragm 1/4 to 1/2 turn more (6–8 in–lb [2.7–3.6
N.m]). Do not turn more than 1/2 turn, or the dia-
phragm
will not function properly .
8. Align the motor with the pins in the connecting rod
housing (22) Guide the motor eccentric through the
connecting
rod bearing (18b). Spin the motor shaft to
be sure it moves freely .
9. Loosely install the lockwashers (21) and screws (20).
Spin the motor shaft again. Now, alternately tighten
the
screws. Spin the motor shaft again.
Spin the motor shaft while assembling the pump to
ensure that parts are properly aligned. If they are
not,
and the pump is started, serious damage could
result to the motor , bearing, and connecting rod. If
there is binding or resistance, disassemble the
parts.
Check the spin often until you determine the
cause of the binding.
CAUTION
10. Position the pump housing (9) on the sprayer . Lubri -
cate the screws (15). Install the screws and
lockwashers (16) loosely. Torque the screws a few
inch–pounds
(N.m) at a time, oppositely and evenly ,
to
85 in–lb (9.7 N.m).
11. Reinstall all parts.
34
GREASE BEARING THOROUGHLY
Fig 10
30
16
17
9
21
20 18a
18b 18
23
24
22
42
43
33
69
PRESS FIT
INT O 22
15
T ORQUE OPPOSITEL Y AND
EVENL Y A FEW IN–LB A T A
TIME T O 85 IN–LB (9.7 N.M)

13
307–959
SPRAYER REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
Motor Repair
1. Remove the following: bottom cover (42), screws
(28),
handle (32), shield (79), front cover (23). Refer
to the Parts Drawing.
2. Disconnect the motor leads from the positive and
negative
rectifier terminals. See Fig 1 1.
3. Remove the motor screws (20) and lockwashers
(21).
Lift the motor (30) slightly . Hold the connecting
rod while pulling the motor away from the housing
(22).
See Fig 10.
4. Inspect the bearing (18b) in the connecting rod (18a).
If it is worn or any rollers are broken, replace the
bearing
and rod assembly (18). See Fig 10.
5.
Use your fingers to pack high–quality bearing grease
thoroughly between the bearing rollers. See Fig 10.
6. Guide the motor leads through the grommet (69).
Align the motor with the pins in the connecting rod
housing
(22). Guide the motor eccentric through the
connecting rod bearing (18b). Spin the motor shaft to
be sure it moves freely . See Fig 10.
7. Loosely install the lockwashers (21) and screws (20).
Spin the motor shaft again. Alternately tighten the
screws.
Spin the motor shaft again.
Spin the motor shaft while assembling the pump to
ensure that parts are properly aligned. If they are
not,
and the pump is started, serious damage could
result to the motor , bearing, and connecting rod. If
there is binding or resistance, disassemble the
parts.
Check the spin often until you determine the
cause of the binding.
CAUTION
8. Connect
the red motor lead to the positive (+) termi -
nal
and the black motor lead to the negative (–) termi -
nal
of the rectifier (39). See Fig 1 1.
9.
Reinstall all parts.
Fig 11
34
37 38
65 33 25
82,81,80
PRESSURE
SWITCH
(2)
LEADS
JUMPER WIRE
GREEN WIRE
MOTOR
LEADS
WHITE
OUT
IN
RED
39
Motor
Brush
1. Remove the bottom cover (42), screws (28), handle
(32) and shield (79). Refer to the Parts Drawing.
2. Remove the plug from each side of the motor and re -
move
the brushes.
3. Install the new brush so its curve aligns with the
curve
of the motor . See Fig 12.
4. Carefully push the copper contact into the brush
housing so its side tabs fit inside the holder. Tilt the
top of the contact so an edge of it catches in one
of
the thread grooves. This holds the brush in place
temporarily.
See Fig 13.
NOTE: If necessary, start one tab into the holder , and
then
use a small screwdriver to gently guide the
other tab into the holder .
5. Install
the plug, applying even pressure so the brush
stays in place. If the plug does not turn in easily , re -
move it. Forcing the plug will damage the contact.
6. Repeat for the other side.
7. Reinstall all parts.
Fig 12
Fig 13
PLUG
Note
curve of
brush. install curve
so it is parallel
with the curve of
the motor .
T ABS OF
COPPER
CONTACT
BRUSH HOUSING
BRUSH HOUSING
T
abs of copper
contact fit squarely
in brush holder
Side view of brush installation does
not show curve of motor or brush
T ilt copper
contact so it is
held in place by
thread grooves in
brush housing.
BRUSH HOLDER

14 307–959
SPRAY VALVE REPAIR
WARNING
Always follow the Pressure Relief Procedure
Warning
on page 8 before doing any repair .
NOTE: Order
repair kit no. 218–960 to repair this spray
valve.
1.
Tap out the pin (A). Remove the trigger (B). See Fig
14.
2.
Remove the cap (C).Unscrew the fluid housing (D)
Remove
the o–ring (J). See Fig 14.
3. Pull the needle (K) out with needle nose pliers.
4. T ap out the seat (G). See Fig 17.
5. Remove the ball (F) and spring (E). See Fig 14.
6.
Turn the nylon screw (L) into the packing (H). Insert
the needle (K) through the bottom of the housing (D)
and push the packing out the top of the fluid housing.
See Fig 15.
7. Clean all parts thoroughly . Use a cotton–tipped swab
or pipe cleaner to clean small orifices.
8. Grease the needle (K) and packing (H). Insert the ta -
pered
end of the needle into the back (flat) side of the
packing. See Fig 16.
9. Guide the tapered end of the needle into the assem -
bly
tool (M) and press the lips of the packing over the
end of the tool. See Fig 16.
10. Grease the free end of the needle (K). Guide the tool
(M) into the fluid housing (D) until the needle pro-
trudes
through the bottom of the housing. Lightly tap
the tool end until you “hear” the packing bottom in the
housing. Remove the tool with pliers. See Fig 16.
11. Grease the seat (G) and place it on the fluid housing
so the indentation on the inside diameter faces out.
See
Fig 17.
12. Install the spring (E) in the cavity of the valve handle
(N). Install the ball (F) so it is centered on the spring.
See Fig 17.
13. Place the o–ring (J) around the fluid housing. Push
lightly with your fingers to start the threads of the
housing
into the valve handle. T orque the housing to
17.5 in–lb (2 N.m). See Fig 14.
14. Push on the needle until you feel some
resistance.
15. Grease the cap (C) and place it on the end of the
needle.
See Fig 17.
16. Slide the trigger (B) into place. Install the pin (A) in
the trigger
. See Fig 14.
Fig 14
Fig 15
Fig 16
Fig 17
TAPERED END
DKH M
LIPS F ACING OUT
OF HOUSING (D)
L
H
D
K
E
F
G
H
N
J
K
D
C
B
A
TORQUE TO
17.5 in–lb
(2 N.m)
CD GFE
N
SEA T MUST F ACE
BALL AS SHOWN

15
307–959
PARTS DRA WING
These parts numbers refer only to the parts illustrated on this page. See page 16 and 17 for the illustrations and
part numbers of other components in the system
REF
NO. PART NO. DESCRIPTION QTY
REF
NO. PART NO. DESCRIPTION QTY
60 218–954 VAL VE, spray
SEE REP AIR KIT 218–960 BELOW 1
64
108–356 HOSE, fluid, nitrile rubber; cpld
3/8 npsm(m); 25’ (7.6 m) 2
85 108–228
NIPPLE, 3/8 npt 1
87 108–408 ADAPTER 1
88 220–237 W AND, tube 1
89 180–136
ADAPTER, tip 1
90 171–602 W
ASHER, tip 1
91 185–559 50_
SPRA Y TIP; 0.036” orifice 1
92 163–622
FINE FINISH TIP; 0.022” orifice 1
93 166–969 W
ASHER, tip 1
*Recommended tool box spare parts.
E
F
A
B
D
C
H
G
SPRA
Y V AL VE REP AIR KIT 218–960
Includes items A through H
Individual parts not sold separately .
See page 14 for instructions.
87
TIGHTEN WITH
WRENCH
APPL Y SEALANT
T O THREADS.
HOLD STEADY
WITH WRENCH.
60
64
85
64
88
89
93
91
90
92

16 307–959
PARTS DRA WING
67
26
44
47
45
46
34
80
81
84
41
26
25
82
42
33
39
43
33
53
28
68
65
34a
Ref
84
37 38
31
69
30
32
70
18
23
24
20
21
17
11
48
49
52
SEE P ARTS
DRAWING ON
P
AGE 17
Part of item 10;
see parts drawing
on page 17
15
LUBRICA TE THREADS
TORQUE TO
85 in–lb (9.6 N.m)
16
27
PRESS
FIT INT O
ITEM 22
22
29
33
LABEL
79
LABEL – THIS SIDE – 83
LABEL – OPPOSITE SIDE – 78
52
LABEL 85
36

17
307–959
PARTS DRA WING & LIST
9
1
TORQUE TO
480 in–lb
(54 N.m)
APPL Y SEALANT
TO THREADS
3
10
2f 2e 2d 2c 2b
12a
12 14
TORQUE TO
60 in–lb
(6.8 N.m)
2a
TORQUE TO
290 in–lb
(32 N.m)
PRESSURE ROLLER SYSTEM
Model 222–684 , Series A
Includes items 1 – 93
(See items 60, 64, 85, and 87 to 93 on page 15.)
REF
NO. P ART NO. DESCRIPTION QTY
1 220–930 HOUSING, valve, inlet 1
2
218–977* OUTLET V AL VE KIT
Includes items 2a–2f 1
2a 222–349
.FITTING, outlet 1
2b
180–454 .GASKET 1
2c
107–521 .SPRING 1
2d
101–956 .BALL 1
2e
218–968 .HOUSING, seat, valve 1
2f
180–455 .SEAL, washer 1
3 183–419
GASKET 1
9
181–146 HOUSING, pump 1
10 218–973
* PRIMING V AL VE KIT 1
11
181–152 GUIDE, diaphragm 1
12 218–974
SWITCH, pressure
Includes item 12a 1
12a 108–195
O–RING 1
14
181–209 RET AINER 1
15
108–225 CAPSCREW, socket head;
5/16–18 x 1–1/8” long 4
16 104–008
LOCKWASHER, spring, 5/16” 4
17 275–619
* DIAPHRAGM 1
18
218–981 CONNECTING ROD & BEARING 1
20
108–237 CAPSCREW, socket head;
No. 8–32 x 5/8” 4
REF
NO. P ART NO. DESCRIPTION QTY
21
100–079 LOCKWASHER, spring, 0.168” 4
22
181–147 HOUSING, conn rod;
Always order two of Ref No. 27
when replacing housing 1
23
181–839 COVER, front 1
24 108–236 SCREW,
mach, filh,
No. 8–32 x 1.75” 4
25 102–313 CAPSCREW,
hex head;
1/4–20 x 1.75” 2
26 100–028 LOCKWASHER, internal
shakeproof; 1/4” 3
27 108–213 PIN,
dowel 2
28 108–230 SCREW , mach, hex washer head;
self tapping; 1/4–14 x 1” 2
29 185–511 LABEL,
designation, front 1
30 185–489 MOTOR, electric 1
31
181–744 BASE, pump 1
32
181–182 HANDLE 1
33 108–224 SCREW
, thd forming, pnh;
No.8 x 7/8” 6
34 105–679 SWITCH,
toggle 1
36 105–659 TOGGLE,
boot 1
37 108–192 CORD,
power supply 1
38 102–519 BUSHING,
strain relief 1
39 108–219 RECTIFIER
, bridge 1
41 183–301 TERMINAL,
ground 1
42 181–799 COVER,
base 1
43 108–220 BUMPER
1
44 181–231
TUBE, suction 1
45 181–159 NUT,
coupling 1
46 181–160 NIPPLE,
hose 1
47 108–231 CLAMP,
hose 1
48 181–163 HOUSING,
filter 1
49 181–164 FILTER
1
52 178–342 CLAMP,
hose 2
53 183–690
LABEL, designation 1
65
108–199 HOLDER, fuse 1
67
108–461* FUSE, electrical, 3A WG, 1-1/4 amp 1
68 108–223 SCREW,
thd forming, pnh;
No. 6 x 1/2” 1
69
181–218 GROMMET, rubber 1
70 596–421 TERMINAL
2
78 185–513
LABEL, identification
79 185–516 SHIELD, motor 1
80 100–072 NUT, hex,
mscr; No. 6–32 unc–2b 1
81 103–181 LOCKWASHER,
No. 6 1
82 103–854 SCREW,
mach, bdgh;
No. 6–32 unc–2a x 1/4” 1
83 185–514 LABEL,
identification 1
84 220–890 WIRE, ground 1
85 185–497** LABEL,
W arning 1
*Recommended tool box spare parts.
**Extra warning labels available at no charge.

18 307–959
ACCESSORIES
Do not use lacquer or lacquer thinner in the suction
and outlet hoses supplied with this system. These
fluids
quickly destroy the hose material. Use the op -
tional
chemical–resistant hoses.
WARNING
CHEMICAL–RESIST
ANT
SUCTION & OUTLET HOSES
For use with materials not compatible with the PVC inlet
or the nitrile outlet hose.
205–142 Outlet Hose; Nylon; 3/8” ID;
cpld 3/8 npsm(fbe); 25’ (7.6 m);
300 psi (21 bar) MAXIMUM WORKING
PRESSURE
219–095 Suction Hose Kit; Nylon
LARGER DIAMETER OUTLET HOSE
Use this hose when using more than 50 ft (15 m) of outlet
hose for spraying penetrating encapsulants. Not in-
tended
for use with lacquer thinners.
220–009 Outlet Hose; 3/4” ID; nitrile;
cpld 3/8 npsm(fbe); 50’ (15 m);
250 psi (17.5 bar) MAXIMUM
WORKING PRESSURE
DUAL GUN ADAPTER 220–232
1000 psi (70 bar) MAXIMUM WORKING PRESSURE
Install on the WONDER WETTER Jr . outlet to allow use
of two spray wands for multiple glove bag application.
FLUSH ADAPTER 220–231
Allows you to use city water supply to quickly flush the
WONDER WETTER Jr . of penetrating and lock-down
encapsulators.

19
307–959
TECHNICAL DA TA
Maximum Operating Pressure 250 psi (17.5 bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Requirements 120 V AC, 60Hz,1 Phase, 1.0 amp . . . . . . . . . . . . . . . . . . . . . . . .
Pump Output 1 gallon (3.8 liter) in 3 minutes using a 0.036 dia. tip, . . . . . . . . . . . . . .
or 5 minutes using a 0.022 dia. tip.
Power Supply Cord No. 16 A WG, 3 wire, 6’ (1.7 m) long . . . . . . . . . . . . . . . . . . . . . . .
Wetted Parts Aluminum, Brass, V iton ,Delrin , Polyurethane, . . . . . . . . . . . . . . . . . .
Neoprene,Tungsten Carbide, Stainless Steel, Nylon,
Plated Steel, Buna–N, Polyester , Polyvinyl Chloride
Weight 13.5 lb (6.1 Kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE: Delrin and Viton are registered trademarks
of
the DuPont Company .

20 307–959
THE GRACO W ARRANTY AND DISCLAIMERS
WARRANTY
Graco
warrants all equipment manufactured by it and bearing its name to be free from defects in mate -
rial
and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for
use. As purchaser ’ s sole remedy for breach of this warranty , Graco will, for a period of twelve months
from the date of sale, repair or replace any part of the equipment proven defective. This warranty ap -
plies
only when the equipment is installed, operated and maintained in accordance with Graco’ s written
recommendations.
This warranty does not cover , and Graco shall not be liable for , any malfunction, damage or wear
caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper mainte-
nance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall
Graco
be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manu -
facture,
installation, operation or maintenance of structures, accessories, equipment or materials not
supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an
authorized
Graco distributor for verification of the claim. If the claimed defect is verified, Graco will re -
pair
or replace free of charge any defective parts. The equipment will be returned to the original pur -
chaser
transportation prepaid. If inspection of the equipment does not disclose any defect in material or
workmanship, repairs will be made at a reasonable charge, which charges may include the costs of
parts,
labor and transportation.
DISCLAIMERS AND LIMIT ATIONS
THE TERMS OF THIS W ARRANTY CONSTITUTE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF
ANY OTHER W ARRANTIES (EXPRESS OR IMPLIED), INCLUDING W ARRANTY OF MERCHANT ABILITY OR W ARRANTY
OF
FITNESS FOR A P AR TICULAR PURPOSE, AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LI -
ABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR CON -
SEQUENTIAL
DAMAGES OR LOSS IS EXPRESSL Y EXCLUDED AND DENIED. IN NO CASE SHALL GRACO’S LIABILITY EX -
CEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF W ARRANTY MUST BE BROUGHT
WITHIN
TWO (2) YEARS OF THE DA TE OF SALE.
EQUIPMENT NOT COVERED BY GRACO W ARRANTY
GRACO MAKES NO W ARRANTY , AND DISCLAIMS ALL IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR
A P AR TICULAR PURPOSE, WITH RESPECT T O ACCESSORIES, EQUIPMENT , MA TERIALS, OR COMPONENTS SOLD BUT
NOT MANUF ACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric mo -
tor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser
with reasonable assistance in making any claim for breach of these warranties.
Factory Branches: Atlanta, Dallas, Detroit, Los Angeles, W est Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P .O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 307–959 4–89