INSTRUCTIONS-PARTS LIST
308–125
Rev. D
Supersedes Rev. B
and PCN D
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
First choice when
quality counts.t
INSTRUCTIONS
Roof Rigst
GM 1230
GASOLINE-POWERED AIRLESS SPRAYER
1200 psi (8.3 MPa, 83 bar) MAXIMUM
WORKING PRESSURE
Model 231–148
With one gun, Heavy Duty RAC IVR
DripLesst Tip Guard,
and 861 size tip,
90 foot (28 m) hose
Model 224–483, Series A
Without hose or gun
0394A
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1991, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
equipment if you do not follow the instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.
D
D
If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately Do not use the equipment until you identify and correct the problem.
.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D
D
D
D
D
D
D
D
Keep the spray area free of debris, including solvent, rags, and gasoline.
Disconnect all electrical equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
Use only electrically conductive hoses.
308-125
3
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WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury
.
INSTRUCTIONS
D
D
D
D
D
D
This equipment is for professional use only
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
.
.
Check equipment daily. Repair or replace worn or damaged parts immediately
.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 39 for the maximum working pressure of this equipment.
D
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D
D
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D
D
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Wear hearing protection when operating this equipment.
D
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
D
D
Keep clear of all moving parts when starting or operating the sprayer
.
Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly
.
4
308-125
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WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury
.
D
Fluid injected into the skin may look like just a cut, but it is a serious injury
cal attention.
.
Get immediate medi-
D
D
D
D
D
D
D
D
D
Do not point the gun at anyone or at any part of the body
.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
D
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D
D
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer
.
308-125
5
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Notes
6
308-125
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Setup
0015
ENGINE
OIL LIGHT
ENGINE
ON/OFF
SWITCH
TRIGGER LOCK
SHOWN IN
ENGAGED OR
“SAFE” POSITION
0016
TRIGGER LOCK
SHOWN IN
DISENGAGED OR
“OFF–SAFE” POSITION
THROTTLE
CHOKE
40 ft (12 m) HOSE
SPRAY GUN
FUEL
SHUTOFF
LEVER
40 ft (12 m) HOSE
WAND HANDLE
50 ft. (15 m)
MAIN HOSE
AIR CLEANER
SPARK PLUG CABLE
GROUNDING CLAMP
MUFFLER
0398
PRESSURE
CONTROL KNOB
PRESSURE CONTROL
PRESSURE CONTROL
ON/OFF SWITCH
PRESSURE
RELIEF VALVE
shown in closed
position
DISPLACEMENT PUMP
QUICK DISCONNECT ELBOW
SIPHON TUBE
0394A
Fig.
1
308-125
7
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Setup
General Information
Pressure Relief Procedure
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
WARNING
INJECTION HAZARD
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ
ARD on page 3.
Fluid under high pressure can be in
jected through the skin and cause seri
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol
low the Pressure Relief Procedure whenever you:
-
-
-
-
D
D
D
D
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tips.
Grounding
1. Sprayer: plug the power supply cord, or extension
cord into a properly grounded outlet. Do not use an
adapter. All extension cords must have three wires
and be rated for 15 amps.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF
.
2. Fluid hoses: use only grounded hoses with a
maximum of 150 m combined hose length to
3. Unplug the power supply cord.
ensure grounding continuity
.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun to relieve pressure.
3. Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer
.
5. Engage the gun safety latch.
4. Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to
6. Open the pressure drain valve, having a container
ready to catch the drainage. Leave the valve open
until you are ready to spray again.
local code. Use only metal pails, which are con
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter
rupts the grounding continuity
-
7. Disconnect the spark plug cable.
-
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, wrap a rag around the
tip guard retaining nut or hose end coupling and very
slowly loosen the part to relieve pressure gradually
Now clear the tip or hose.
.
7. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
gun firmly to the side of a grounded metal pail,
then trigger the gun.
.
8
308-125
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Setup
1. Read and follow the warnings on pages 3–3
before setting up or operating this sprayer
6. Fill the gas tank. See FUELING, below.
.
7. Flush the pump to remove the protective light-
weight oil. See FLUSHING GUIDELINES on page
12.
2. Install the hoses and gun.
3. Clamp the siphon hose to the pump. Be sure the
gasket is in the quick disconnect elbow; air leaks will
prevent priming.
8. AGITATE OR MIX THE MATERIAL THOROUGH-
LY! Make sure the heavier material on the bottom of
the container is completely mixed in.
4. Check the engine oil level. Refer to the Honda en
-
gine manual, supplied. In summary: remove one oil
fill plug – the oil should be almost overflowing. See
Fig. 1. Add oil as necessary. Also read the MAINTE-
NANCE section on page 15.
9. Start the sprayer See page 10.
.
CAUTION
o avoid damaging the pressure control, follow these
Recommended engine oil: Use a high–quality, deter
-
T
gent oil, SAE 10W–40, classified “FOR SERVICE
SE or SF”.
precautions.
1. Always use spray hose at least 90 ft. (27 m)
long.
5. Ground the sprayer before operating it. Connect
the grounding clamp (32) to a true earth ground. Fol
-
2. Do not allow water or water-base material to
freeze in the pressure control.
low the FIRE OR EXPLOSION HAZARD on page
3.
Fueling
3. General. Do not use oil and gasoline mixtures or
contaminated gasoline. Avoid getting dirt, dust or
water in the fuel tank.
WARNING
Gasoline is extremely flammable and explosive
under certain conditions. To reduce the risk of a fire
or explosion:
4. Tank capacity: 0.95 gallons (3.6 liter). Leave 1/2 in.
(13 mm) at the top of the tank for gas expansion.
5. Shut off the engine switch before refueling.
6. After refueling, tighten the fuel tank cap firmly.
1. Always shut off the engine before refueling.
2. Refuel in a well-ventilated area.
3. Do not smoke or allow flames or sparks in the
area where the engine is refueled or where the
gasoline is stored.
FILL CAP
4. Do not overfill the tank. Make sure the filler cap
is securely closed after refueling.
5. Fuel vapor or spilled fuel can ignite. If any fuel
is spilled during refueling, make sure the are is
dry before starting the engine.
ENGINE
ON/OFF
SWITCH
1
2
Fuel specifications. Use automotive gasoline with
a
pump octane number of 86 or higher. If the engine
knocks or pings, use a higher octane fuel. Unleaded
fuel minimizes combustion chamber deposits.
Gasolines containing alcohol (gasohol). Do not
use gasohol which contains methanol, if the gasohol
does not contain cosolvents and corrosion inhibitors
for methanol. Even if it does contain such additives,
do not use the gasohol if it contains more than
5% methanol.
NOTE: The HONDA engine warranty does not cover
damage resulting from the use of gasolines con
-
0015
taining alcohol. See the HONDA engine manual
for more information.
0141D
Fig.
2
308-125
9
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Start Up
3. Turn OFF the pressure control switch.
Before You Start The Sprayer
1
See FLUSHING GUIDELINES, page 12, to deter-
mine if the unit should be flushed.
4. To start the engine:
a. Turn the pressure adjusting knob all the way
counterclockwise to the lowest pressure setting.
2
3
Be sure the gas tank is full.
Check the engine oil level.
b. Slide the metal throttle lever away from the fuel
tank to the maximum position (fully left).
NOTE: The engine stops automatically, or will not start,
if it is low on oil. If you try to start it again without
c. If the engine is cold, close the choke by moving
adding more oil, a red light near the engine on/of
f
the gray lever
.
switch glows as you pull the starter rope.
If the engine is warm
the gray lever only half way or not at all.
,
close the choke by moving
4
5
Push the spark plug cable firmly onto the spark
plug.
d. Turn ON the engine switch.
If the sprayer in not primed, remove the spray tip.
Refer to Fig. 3 as you start the sprayer
.
WARNING
A starter rope that recoils too quickly may hit
Start Up
someone and cause serious injury. The rope could
1. Place the siphon tube into the coating, water or
solvent container, depending on whether you are
also jam in the recoil assembly
.
flushing or are ready to spray
.
e. Hold the frame of the sprayer with one hand and
pull the starter rope rapidly and firmly. Continue
2. Open the black fuel shutoff lever by pushing it in
the direction of the arrow
.
holding the rope as you let it return. Pull and re
-
turn the rope until the engine starts.
f. Open the choke as soon as the engine starts, ex
-
CAUTION
Never start the engine unless fluid pressure is re
cept in cold weather. In cold weather, leave the
choke closed for 10 to 30 seconds before open
ing it to keep the engine running.
-
-
lieved and the pressure control switch is turned OFF
.
Attempting to start the engine when it is pressurized
could damage the recoil system.
5. Engage the gun trigger safety latch by tipping the
gun forward.
ENGINE
OIL LIGHT
0015
ENGINE
ON/OFF
SWITCH
0016
TRIGGER LOCK
shown in
THROTTLE
engaged or
“safe” position
CHOKE
shown in
choked position
TRIGGER LOCK
shown in
disengaged or
“off–safe” position
FUEL SHUTOFF
LEVER
shown in off position
PRESSURE
CONTROL KNOB
SPARK PLUG CABLE
0398
0394A
Fig.
3
10
308-125
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Start Up
6. To start the pump:
WARNING
o reduce the risk of serious injury from fluid injec-
a. Place a container under the pressure drain valve
and open the valve.
T
tion, never operate the spray gun with the tip guard
removed.
b. Reduce the engine speed by moving the metal
throttle lever away from the fuel tank about half
way to the left.
8. Install the tip guard and spray tip. See page 13.
c.
Turn the pressure control knob to minimum.
d. Turn ON the pressure control switch.
CAUTION
Use the lowest fluid pressure and the lowest throttle
e. Turn the pressure control knob 1/4 turn from
minimum pressure. Run the pump until fluid
flows smoothly from the pressure drain valve.
setting needed. Higher settings cause excessive
clutch cycling and premature tip and pump wear
.
f. Close the pressure drain valve.
WARNING
Hold the handle of the wand firmly when triggering
the gun to reduce the risk of it kicking back from
the surge of pressure, which could cause serious
injury.
9. Adjust the engine speed and pump pressure be
-
fore transporting the hoses to the roof. Trigger
the gun onto a test paper to check the spray pattern
and atomization. Turn the pressure adjusting knob
until you get a good pattern. Then slowly lower the
throttle setting as far as you can without changing the
spray pattern (the clutch does not cycle).
g. Disengage the gun safety latch. Hold a metal
part of the gun firmly against a grounded metal
container. Holding the gun firmly with both
hands, squeeze the trigger until fluid flows from
the gun.
10. Read SPRAY TECHNIQUES on page 14.
CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayer to prevent fuel from flooding
the engine.
h. Release the trigger. Engage the safety latch.
7. If you have not primed the unit with the coating
yet, move the siphon tube to the coating container.
Release the trigger safety latch. Trigger the gun into
the water/solvent pail just until coating appears. Tip
the gun forward and fully release the trigger to en-
gage the trigger safety latch.
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber, which
makes start up very difficult.
0016
TRIGGER LOCK
shown in
THROTTLE
engaged or
“safe” position
CHOKE shown in
choked position
TRIGGER LOCK
shown in
disengaged or
“off–safe” position
FUEL SHUTOFF
LEVER
shown in off position
PRESSURE
CONTROL KNOB
0398
PRESSURE CONTROL
ON/OFF SWITCH
PRESSURE DRAIN VALVE
0394A
Fig.
4
308-125 11
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Flushing Guidelines
2. Put the siphon tube in a grounded metal pail of water
WARNING
or compatible solvent.
To reduce the risk of serious injury, including fluid
injection, always follow the Pressure Relief Proce
3. Start the sprayer. Trigger the gun into the coating
container just until water or solvent comes from the
-
dure Warning on page 8 before checking, adjust
-
nozzle. Release the trigger
.
ing, cleaning, or shutting down the sprayer
.
4. Move the gun to the grounded flushing container.
Trigger the gun until clean water or solvent comes
from the it. See Fig. 6. Release the trigger and en-
gage the safety latch. Open the drain valve to clean
it.
When To Flush
1. Flush a new sprayer to remove the protective oil.
Before using water–base coating, flush with a com-
patible solvent, then warm, soapy water, and then
5. Check all fluid connections for leaks. Relieve pres-
sure before tightening any connections. Start the
sprayer. Recheck the connections for leaks.
clean water
.
Before using oil–base coating, flush with a compat-
ible solvent.
6. Remove the siphon tube from the solvent pail. Disen
-
gage the gun safety latch. Trigger the gun to force
water or solvent from the hose. Do not let the pump
run dry for more than 30 seconds to avoid damaging
the pump packings! Relieve pressure.
2. Changing coatings. Use a compatible solvent.
3. Changing from water–base to oil–base coating.
Flush with warm, soapy water, and then a compatible
solvent.
4. Changing from oil–base to water–base coating.
Flush with a compatible solvent, then warm, soapy
water, and then clean water
.
5. Storage.
Flush the pump only with a compatible solvent, fol-
lowed by an oil–base solvent, such as mineral spirits.
Leave the drain valve open!
6. Startup after storage.
Before using water–base coating
patible solvent with warm, soapy water
clean water
,
flush out the com
-
,
and then with
PRESSURE
.
DRAIN VALVE
shown in closed
position
When using oil–based coating, flush out the compat
ible solvent with the coating to be sprayed.
-
0553
Fig.
5
How To Flush The Pump Only
1. Relieve pressure. Leave the drain valve open. See
Fig. 5.
2. Disconnect the siphon assembly
.
3. Put the pump in a grounded metal pail of water or
compatible solvent.
4. Start the sprayer – see page 10. Flush until the ball
in the foot valve is clean and moves up and down
easily.
Maintain firm
metal-to-metal contact
when flushing to
reduce the chance of
static sparking and
splashing.
How To Flush The Entire Fluid System
1. Relieve pressure. Leave the drain valve open. See
Fig. 5.
0406
Fig.
6
12
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Spray Tip and Tip Guard
HOUSING
WARNING
RETAINING NUT
To reduce the risk of fluid injection or splashing in
the eyes or on the skin, completely relieve the fluid
pressure before installing, cleaning, or changing
tips. See the Pressure Relief Procedure on page
8.
0464
Fig.
7
Installation
RETAINING NUT
HOUSING
1. Insert the housing through the back of the retaining
nut and pull it forward. See Fig. 7.
SEAL
2. Install the metal seal in the housing, flat side first.
See Fig. 8.
0465
Fig.
8
3. Install the cylinder tip in the housing so its small ori
-
fice faces front. See Fig. 9.
HOUSING
4. Snap on the tip guard. Install the screw and the white
gasket. See Fig. 10.
CYLINDER TIP
SMALL ORIFICE
Operation
0466
Be sure the tip arrow handle is in the FULL SPRAY posi
tion before operating the gun. See Fig. 10.
-
Fig.
9
WARNING
SCREW
Keep clear of the nozzle. High pressure fluid from
leaks or spray can penetrate the skin and cause
extremely serious injury, including the need for
amputation. The tip guard provides extra protection
against injection, but does not prevent it. Never cut
off the tip guard.
GASKET
TIP GUARD
0467
Fig. 10
Clearing a clogged spray tip See Fig. 11.
GUN NOZZLE
1. Engage the trigger safety latch.
2. Turn the arrow handle to the FULL CLEAN position.
3. Disengage the trigger safety latch and trigger the gun
RAC IV
DripLess
TIP GUARD
into the waste container
.
SwitchTip
HANDLE
4. Engage the trigger safety latch. Return the arrow
handle to the FULL SPRAY position.
FULL SPRAY POSITION
FULL CLEAN POSITION
Maintenance
Replace the gasket and seal whenever you replace a tip;
these parts wear at about the same rate.
0093
Fig.
11
308-125 13
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Spray Techniques
HOLD THE GUN PERPENDICULAR T
O
AND 24” (610 MM) ABOVE THE SURFACE
MOVE HORIZONTALLY
T A STEADY RATE
A
OVERLAP EACH STROKE BY 50%
0551
Fig. 12
Start the spray stroke 24” (610 mm) above the target sur
-
1
Type of Coating
Fibered? Recommended
face and pull the trigger as the gun is moving. Then, while
the gun is still moving, and as you approach the other
edge, release the trigger. This method avoids excess
material build-up at the end of each stroke.
2
Tip Size
Primers
N/A
No
0.031 or larger
0.041 or larger
0.051 or larger
0.051
Aluminum Solvent–Base
Aluminum Emulsion
Asphalt Solvent–Base
Asphalt Emulsion
Do not try to increase coverage by increasing the fluid
pressure! Use a slower stroke. Use the lowest pressure
necessary to get the results you want; this helps prolong
the life of your sprayer and minimizes coating lost by
overspray.
No
No
No
0.051
Aluminum Solvent–Base
Aluminum Emulsion
Asphalt Emulsion
Yes
Yes
Yes
0.061
If there is a wind, angle the spray pattern into the wind to
minimize drifting.
0.061
0.061
The best way to control the rate of coverage is with the
1
gun tip size. A small tip orifice applies less coating. A larg
er tip orifice applies more coating. The width of the pat-
tern depends on the fan pattern of the tip you choose.
-
Roof coatings vary greatly. The formulas, batch,
temperature, and age of the coating all affect its vis
cosity. If the sprayer does not atomize the coating
well, thinning and/or agitating it should help. Apply
thinned coating more heavily to get an equal dry film
thickness. For example, coating that is thinned 10%
-
should be applied about 10% thicker
.
2
A 0.061 tip is standard with the sprayer
.
14
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Maintenance
DAILY: Check the engine oil level and fill as necessary
.
WARNING
To reduce the risk of serious injury, always follow
DAILY: Check and fill the gas tank.
the Pressure Relief Procedure on page 8 before
checking, adjusting, cleaning, or shutting down the
sprayer.
AFTER THE FIRST 20 HOURS OF OPERATION AND
EACH 100 HOURS THEREAFTER: Change the oil.
CAUTION
For detailed engine maintenance and specifications,
refer to the HONDA engine manual.
WEEKLY: Remove the air filter cover and clean the ele
-
ment. In very dusty environments, check the filter daily.
Replace the element as needed. Replacement elements
CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayer to prevent fuel from flooding
the engine.
can be purchased from your local HONDA dealer
.
SPARK PLUG: Use only a (NGK) BP6ES or BPR6ES
plug. Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).
Always use a spark plug wrench.
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber, which
makes startup very difficult.
308-125 15
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Troubleshooting
Check everything in the guide before disassembling
the sprayer
WARNING
o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
.
Relieve the pressure before disassembling the spray
er.
-
T
PROBLEM
CAUSE
SOLUTION
Engine/sprayer won’t start
Engine switch not on
Out of gas
T
urn on engine switch.
Refill gas tank.
Engine oil level low
Try starting engine. If light on rear of engine
glows, replenish oil.
Spark plug cable disconnected or
spark plug damaged
Connect cable on top of engine or replace
spark plug.
Adjusting the pressure control knob Return pressure control to authorized Gra-
doesn’t start pump
co dealer for repair.
Engine won’t “fire” or
“pull over”
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or 4
times. Clean and replace plug. Try to start.
Keep sprayer upright to avoid oil seepage.
Engine operates, but
Pressure control switch turned OFF
Pressure setting too low
Turn on pressure control switch.
displacement pump doesn’t
Also see manual 308–126.
Increase pressure.
Clean tip.
Tip clogged
Displacement pump rod seized by
dry coating
Service pump. See page 19.
Connecting rod worn or damaged
Drive housing worn or damaged
Replace connecting rod. See page 22.
Replace drive housing. See page 23.
Electrical power not energizing field Check wiring connections. See page 28.
With pressure control switch ON and pres-
sure turned to MAXIMUM, use a test light to
check continuity across black and white
wires from pressure control.
Have pressure control checked by autho-
rized Graco dealer
.
Clutch worn or damaged
Service clutch. See page 26.
Pinion assembly worn or damaged
Service pinion assembly. See page 24.
16
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PROBLEM
CAUSE
SOLUTION
Engine starts but dies
Oil level drops below oil sensor
Add oil.
Displacement pump output low Siphon hose strainer is clogged
on upstroke
Clean strainer.
Piston ball check not seating
Service piston ball check. See page 19.
Replace packings. See page 19.
Piston packings worn or damaged
Sleeve o–ring in displacement pump Replace o–ring gasket. See page 19.
worn or damaged
Displacement pump output low Siphon hose strainer is clogged
on downstroke or both strokes
Clean strainer.
Piston packings worn or damaged
Replace packings. See page 19.
Intake valve ball check not seating
properly
Clean and service intake valve. See page
19.
Clutch worn or damaged
Replace clutch. See page 26.
Coating leaks into wet–cup
Low fluid delivery
Loose wet–cup
Tighten wet–cup just enough to stop
leakage.
Throat packings worn or damaged
Replace packings. See page 19.
Displacement rod worn or damaged Replace displacement rod. See page 19.
Siphon hose strainer is clogged.
Pressure setting too low
Clean strainer.
Increase pressure. See Startup,
Step 9, page 11.
Engine RPM too low
Increase throttle setting. See Startup,
Steps 4b and 9, pages 10 and 11.
Large pressure drop in hose
Air in fluid pump or hose
Use larger diameter hose.
Spitting from gun
Change gasket in siphon hose quick discon-
nect coupling, if worn or missing. Replace
pump cylinder o–ring. Then prime the
pump. See Startup, page 10.
Fluid supply is low or empty
Refill and prime the pump. See Startup,
page 10. Check fluid supply often to prevent
running the pump dry
.
308-125 17
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Removing
Removal
and Installing a Displacement Pump
7. Remove the two mounting screws while supporting
the weight of the pump with your free hand.
WARNING
Installation
To reduce the risk of serious injury, always follow
the Pressure Relief Procedure on page 8 before
1. Push the pin just barely into the connecting link, but
not into the mating hole of the displacement pump.
repairing the sprayer
.
2. Pull the displacement rod out of the pump 2 to 3 in.
(50–75 mm).
1. Flush the sprayer. Remove the suction hose, if used.
3. Align the flats of the pump piston rod and the pump
outlet. Lift the pump into position and gently push on
the pin while moving the pump slightly until the pin
slips into the hole. Be sure the retaining ring snaps
down over the end of the pin.
WARNING
To reduce the risk of pinching or amputating a
finger, keep your fingers away from the area of the
connection rod and pin while jogging the engine.
WARNING
Be sure the retaining spring is firmly in the groove
of the connecting link, all the way around, to pre
vent it from working loose due to vibration. See Fig.
13.
2. Start the engine. Jog the pressure control ON/OFF
switch until the connecting link stops near the bottom
of the stroke and is fully exposed. See Fig. 13. Shut
off the engine.
-
3. Unscrew the collar of the power supply cord and un
-
plug the cord from the pressure control. See Fig. 14.
If the pin work loose, it or other parts could break
off due to the force of the pumping action and
result in serious injury or property damage, includ
ing damage to the pump, connecting link or bearing
housing.
4. Relieve the pressure
.
5. Remove the outlet hose. Slightly loosen the two
mounting screws. See Fig. 13.
-
6. Use a small screwdriver to push in the connecting
link pin just until you can gently pry the retaining ring
up from the back of the connecting link. Then push
the pin in so it falls out the back.
Procedure continued on page 19.
CUTAWAY VIEW
SHOWS HOW PIN GOES
THROUGH CONNECTING ROD
BACK OF PUMP
PIN
PUMP PISTON ROD
CONNECTING LINK
PIN
BEARING HOUSING
RETAINING RING
FRONT OF PUMP
RETAINING RING
CONNECTING LINK
MOUNTING SCREWS
Torque to
20 ft–lb (27 N.m)
FRONT VIEW OF PUMP AND
SPRAYER CONNECTING LINK
0407
Fig. 13
18
308-125
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Removing
and Installing A Displacement Pump
4. Check the back of the bearing housing to be sure the
parts are installed properly
PRESSURE CONTROL
.
5. Lift the pump to align the mounting holes and install
the mounting screws. IMPORTANT – torque the
screws to 20 ft-lb (27 N.m). See Fig. 13.
TAB
6. Plug in the power cord so the notch in the collar and
the tab in the socket align. Screw on the collar. See
Fig. 14.
NOTCH
COLLAR
0408
Fig. 14
Displacement Pump
423
WARNING
To reduce the risk of serious injury, always follow
416
401
414
415*
the Pressure Relief Procedure on page 8 before
repairing the sprayer
.
406*
420
*419
Disassemble the pump
413*
*407
1
See page 18 for how to remove the pump.
412*
408*
2
Use a hard rubber mallet on the tabs of the lug nut
(421) to loosen the foot valve housing.
*402
*403
418*
3
Disassemble the pump, but do not disassemble the
piston rod (401) from the piston housing (416) unless
one of those needs to be replaced. Due to the high-
strength Loctiter used at the joint of these two parts,
the joint must be heated before disassembly. Refer
to Fig. 15.
422
410
411*
417
409
*404
Clean and inspect all parts
1
Use a compatible solvent to thoroughly clean all
parts and remove all traces of sealant.
*405
*404
421
2. Inspect the parts, including seats, for nicks and
scratches. Replace worn or damaged parts as they
cause the packings to wear more quickly and/or re-
sult in poor pump performance.
0412
Fig. 15
Continued on page 20.
308-125 19
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Displacement Pump
Repair Kit
7. From the top of the pump housing (417), install the
male gland (403). With the lips of the v–packings fac
-
1
A
Packing Repair Kit, Part No. 224–523, is available.
Use all the parts in the kit for the best results.
ing down, alternately install the leather packings
(418*), and poly packings (402*). Install the female
gland (419*).
2
Parts included in the kit are marked with an asterisk
in the text and drawings. For example, 408*.
8. Screw in the packing nut (420) loosely. It will be tight
ened after the pump is installed and operating.
-
Reassemble the pump
9. Grease the o–rings on the cylinder (405). Slide the
cylinder into the bottom of the pump housing (417).
NOTE: Refer to Fig. 13 for reassembly except where
noted.
10. Grease the piston rod (401) and piston packings.
Slide the piston rod assembly into the bottom of the
cylinder so it extends out of the piston housing 2–3
NOTE: Grease all packings and o–rings before installing
them.
in. (50–75 mm). Be careful not to damage any pack
ings.
-
1. Install the ball guide (409), ball (411*) and intake
housing (410) in the lug nut (421).
11. Align the holes in the top of the piston rod with the
pump outlet.
2. Place new o–rings (404*) on the cylinder (405).
NOTE: If you push the piston rod too far out of the pump
housing, using a hard rubber mallet (ONLY!) to
tap it down.
3. On the piston seat (422), install the u–cup seal
(408*), lips down. Install the female gland (412*).
With the lips of the v–packings facing up, alternately
If the piston rod does not extend out far enough,
remove the foot valve and tap the piston up.
install the leather (407*) and poly packings (413*). In
stall the male gland (406*).
-
12. Install the intake valve housing and tighten firmly
.
4. Install the nut (414) on the piston seat (422). Hand
tighten the nut very firmly
.
13. Install the pump and prime it. Check the packing nut
(20) and tighten it just enough to prevent leakage.
NOTE: If you disassembled the piston rod (401) and pis
-
ton housing (416), clean the threads thoroughly
.
Apply red LoctiteR and torque to 35–50 ft–lb
(47–68 N.m).
5. Apply LoctiteR green (supplied in the repair kit) to the
piston seat (422) threads. Install the ball (415*).
416
CAUTION
HOLE
Before assembling the piston, not that the top of the
piston seat (422) has four flutes (B) and that the
piston housing (416) has four holes (A). Together
these flutes and holes provide the fluid flow path.
FLUTE
TIP
422
Failure to align the parts properly, as instructed in
Step 6, will result in poor pump performance.
6. Back off the piston housing just until the holes and
flutes (B) mentioned in the CAUTION are perfectly
aligned, and the tips (B) are not visible when you look
through the holes (A). See Fig 20–1. Screw the pis
-
ton housing (416) down to the nut (414) and torque
to 90–125 ft–lb (122–170 N.m).
0552
Fig. 16
20
308-125
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Displacement Pump
20
19*
18*
*
2
POLY
LIPS OF
LEATHER
V–PACKINGS MUST
FACE DOWN
LIPS OF V–PACKINGS
MUST FACE DOWN
3*
*
4
5
T
ORQUE ROD (1) TO
1
HOUSING (16) T
34–50 FT–LB
(44–68 N.m)
O
*15
16
TORQUE NUT (14)
*13
T
T
O HOUSING (16)
O 110 FT–LB
LEATHER
LIPS OF
14
6*
(150 N.m)
V–PACKINGS
MUST
F
ACE UP
7*
*12
POLY
LIPS OF V–PACKINGS
MUST FACE UP
*
8
21
U–CUP SEAL
LIPS MUST
FACE DOWN
4*
10
0411
Fig. 17
308-125 21
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Bearing Housing and Connecting Rod
9. Install the screws (48) and lockwashers (49) on the
WARNING
To reduce the risk of serious injury, always follow
bearing housing. Tighten the screws evenly to
25 ft–lb (34 N.m).
10. Refer to Installing the pump on page 18.
the Pressure Relief Procedure on page 8 before
repairing the sprayer
.
NOTE: Steps 1 to 10 refer to Fig. 18.
20
A
1. Refer to Removing the pump on page 18.
E
D
22
2. Remove the screws (48) and lockwashers (49) from
the bearing housing (23).
TORQUE
25 ft–lb
(34 N.m)
TO
3. While pulling the connecting rod assembly (22) with
one hand, lightly tap the lower rear of the bearing
housing (23) with a plastic mallet to loosen it from the
drive housing (20). Pull the bearing housing and the
connecting rod assembly off the drive housing.
23
49
48
4. Inspect the crank (A) for excessive wear and replace
the drive housing. See page 23.
B
C
5. Evenly lubricate the inside of the bronze bearing (C)
in the bearing housing (23), and the inside of the con
-
necting rod link (D), with high–quality motor oil (do
not use grease). Liberally pack the roller bearing (E)
in the connecting rod assembly (22) with bearing
grease (20d), supplied.
6. Assemble the connecting rod (22) and bearing hous
ing (23).
-
7. Clean the mating surfaces of the bearing (23) and
drive (20) housings.
8. Align the connecting rod with the crank (A) and care
-
fully align the locating pins (B) in the drive housing
(20) with the holes in the bearing housing (23). Push
the bearing housing onto the drive housing or tap it
into place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screws (48) to align
or seat it with the drive housing. These parts must be
aligned using the locating pins (B), to help avoid prema
-
0400
ture bearing wear
.
Fig. 18
22
308-125
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Drive Housing
WARNING
CAUTION
To reduce the risk of serious injury, always follow
the Pressure Relief Procedure on page 8 before
Do not drop the gear cluster (1) when removing the
drive housing (20). The gear cluster is easily damaged.
The gear may stay engaged in either the drive housing
or the pinion housing.
repairing the sprayer
.
Do not lose the thrust balls (20c and 19k) located at
NOTE: Refer to Fig. 19 for this procedure.
each end of the gear cluster. The balls, which are heavi
-
1. Disconnect the suction hose (A). Disconnect the
pressure control cord (62). Remove the front cover
(21).
ly covered with grease, usually stay in the shaft re-
cesses, but they could be dislodged. If they are caught
between the gears and not removed, the balls will seri
ously damage the drive housing. If the balls are not in
place, the bearings will wear prematurely
-
2. Disconnect the pump outlet hose.
.
3. Remove the four screws (48) and lockwashers (49)
from the bearing housing (23).
7. Liberally apply bearing grease (20d, supplied) to the
gear cluster (1). Be sure the thrust balls (20c and
19k) are in place.
4. Lightly tap the back of the bearing housing (23) with
a plastic mallet. Pull the pump, bearing housing and
connecting rod away from the drive housing (20) as
8. Place the bronze colored washer (20a) and then the
silver–colored washer (20b) on the shaft protruding
from the big bearing of the drive housing (20). Align
the gears and push the new drive housing straight
onto the pinion housing and locating pins (B).
one assembly
.
5. Remove the bearing housing screws (41) and the
pinion housing screws (3).
6. Lightly tap around the drive housing (20) with a plas
-
9. Reassemble the sprayer. Or, go to the next section
tic mallet to loosen it from the pinion housing (19p).
in this manual if further service is needed.
B
20b
20a
20
23
49
48
19p
TORQUE
TO
3
25 ft–lb
(34 N.m)
2
40
21
19k
1
20c
2
41
62
A
0401
Fig. 19
308-125 23
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Pinion, Clutch, Clamp, Field, and Engine
Disassembling these parts can start from the pinion
housing or from the clutch, if no pinion service is needed.
If starting from the pinion housing, first follow Steps
1
to 6 of DRIVE HOUSING, on page 23, and then contin
-
ue with the procedure below
.
If starting from the clutch, see page .
Pinion Housing
3
Pull the armature (9b) off the hub (19j – see Fig. 21)
of the pinion housing.
Removing the Pinion Housing
WARNING
To reduce the risk of serious injury, always follow
the Pressure Relief Procedure on page 8 before
CAUTION
Do not lose the thrust ball (19k). Refer to the CAUTION
repairing the sprayer
.
on page 23 for more information.
NOTE: Refer to Fig. 20 for Steps 1 to 3.
NOTE: To disassemble the pinion, go to Repairing the
Pinion, page 25. To disassemble more of the
1
2
Remove the two bottom screws (3) first, and then re
move the top three screws (3).
-
sprayer, go to page 27. To reassemble the spray
-
Pull the pinion housing (19p) away from the clutch
housing (17). The armature (9b) will come with it.
er from this point, go to Reassembly, page 31,
Step 7.
3
2
17
9b
19p
19k
3
2
SEE PAGE 26 FOR PINION
0171
Fig. 20
24
308-125
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Pinion Housing
CUTAWAY VIEW OF
PINION HOUSING (19a)
BACK OF PINION HOUSING (19a)
19k
PRESS PINION ASSEMBL
Y
IN HERE
19b
19a
19m**
19j**
19h**
Lubricate inner and
outer diameters
0041
19g**
Lubricate teeth
19c
19f**
Lubricate exterior
Lubricate inner and
outer diameters
19d
19c
Lubricate exterior
**Included in Repair Kit 221–032
0169
Fig. 21
If purchasing parts separately, use these instructions.
Disassemble as far as needed for the parts being
replaced.
Repairing the Pinion
NOTE: Refer to Fig. 21 except where noted.
NOTE: A hydraulic press is required if you purchase the
pinion parts individually.Otherwise, use Repair
Kit No. 221–032, which includes the shaft and
bearings pre–assembled and lubricated.
NOTE: The old bearings (19h and 19f) will be damaged
when removed. Have extra ones on hand if you
need to remove them for any reason.
If using Repair Kit 221–032, follow Steps 1 to 5, below
.
1. Remove the small ring (19m) from the hub (19j).
1. Remove the small ring (19m**) from the hub (19j) and
the large ring (19k) from the bearing recess of the
pinion housing (19a).
2. Remove the snap ring (19k) from the bearing recess
of the pinion housing (19a).
2. Push on the front of the shaft (19g**) to force the
bearing and hub assembly out of the housing (19a).
3. Push on the front of the shaft (19g) to force the bear
-
ing (19h) and hub (19j) assembly out of the housing.
3. Install the new shaft assembly into the pinion hous-
ing, pushing it to the shoulder of the housing (19a).
4. Using a hydraulic press, place pieces of steel bar
stock on the inner race of the large bearing (19h) and
press the shaft through the hub and bearing. Then
turn over the shaft and press out the small bearing
(19f). See Fig. 22.
4. Install the rings (19k and 19m**).
5. Go to Reassembly, page 31, Step 7, or continue on
page 26.
PLACEMENT OF STEEL BLOCKS WHEN
PRESSING OFF LARGE BEARING (19h)
5. Apply lubricant to the parts as shown in Fig. 21.
HYDRAULIC
PRESS
6. Press fit the following parts: Large bearing (19h) to
the large shoulder of the shaft (19g). Small bearing
(19f) to the shoulder of the shaft (19g). Hub (19j)
onto the shaft (19g) all the way to the large bearing
(19h).
ROUND STEEL
BAR TO PUSH
ON SHAFT
(19g)
HUB (19J)
STEEL BAR
STOCK
LARGE
BEARING
(19h)
7. Install the shaft assembly, pushing it to the shoulder
of the housing (19a).
TWO STEEL
BLOCKS
(only one shown)
8. Install the snap ring (19k). Install the small ring
(19m).
9. Go to Reassembly, page 31, Step 7, or continue on
PRESS PLATFORM
0043
Fig. 22
page 26.
308-125 25
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Clutch
NOTE: The clutch assembly (9) includes the armature
(9b) and rotor (9a). The armature and rotor must
be replaced together so they wear evenly
5. Remove the armature from the pinion.
.
6. There are two ways to remove the rotor (9a):
NOTE: If the pinion assembly (19) is not yet separated
from the clutch housing, follow Steps 1 to 4.
Otherwise, start at Step 5.
a. Remove the capscrews (4) and lockwashers (2).
Install two of the screws in the threaded holes in
the rotor (9a). Alternately tighten the screws until
the rotor comes off. See Fig. 23.
1. Relieve the pressure.
2. Disconnect the hose from the displacement pump.
Disconnect the cord set (62) from the pressure
control.
b. Use
a
standard steering wheel puller (A) with two
1/4–28 x 3 or 4 in. long screws (B). Replace the
short screws of the steering wheel puller with the
longer screws. Turn the screws (B) into the
threaded holes of the rotor (9a). Tighten the cap
screw (C) of the tool until the rotor comes off.
See Detail in Fig. 23.
3. Remove the bottom two screws (3) from the clutch
housing (17) and then remove the remaining three
screws (3).
-
4. Tap lightly on the back of the bearing housing (23)
with a plastic mallet to loosen the assembly (D) from
the clutch housing (17). Pull the assembly away; the
armature (9b) will come with it.
7. Skip ahead to Reassembly
,
page 31, Step 6, or con-
tinue on page 27.
3
2
17
9a
TORQUE
TO 7 ft–lb (9.5 N.m)
2
4
9b
19
23
3
2
THREADED
HOLES
PINION SHAFT
INSIDE THIS
HOUSING
D
A
B
C
62
Ref 9a
USE A STEERING WHEEL
PULLER TO REMOVE ROTOR
0402
Fig. 23
26
308-125
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Engine
1
2
Working under the mounting plate (A) of the cart, re
-
move the screw (5), lockwasher (6) and washer (7).
See Fig. 24.
Remove the engine-mounting locknuts (43) and
screws (42). Disconnect the mating black, white and
green wires. Pull the wires carefully through the
grommets (8) before removing the engine. See Fig.
24 and 25.
3
4
Lift the engine carefully and place it on a work bench.
Remove the Field and Wiring Harness, Clamp and
Clutch Housing, as instructed on pages 28 and 29.
5
Go to Reassembly, page 30, Step 1.
NOTE: All service to the engine must be performed by
an authorized HONDA dealer
.
A
42
B
7
8
6
43
5
0153
Fig. 24
FROM ENGINE
RED
GREEN W/RED COVER
WHITE
TO FIELD
62
BLACK
0405
VIEW FROM UNDER ENGINE MOUNTING PLATE
Fig. 25
308-125 27
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Field and Wiring Harness
NOTE: Refer to Fig. 26.
3
Pull the caps (A) off the wire screws (57) in both
places on the field. Loosen the screws and release
the wires of the harness (69).
1
2
Remove the engine. See page 27.
Loosen the setscrews (16). Unplug the wiring har-
ness (69) from under the engine mounting plate. Pull
the field out to expose the black and white wires.
4
Go to Reassembly page 30, Step 4.
,
16
69
57
A
0046
Fig. 26
28
308-125
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Clamp
NOTE: A standard steering wheel puller and two1/4–28
x 3 or 4 in. long screws are required to remove
the clamp.
NOTE: Refer to Fig. 27.
1
2
3
Loosen the two screws (4) on the clamp (15), work
ing through the slot at the bottom of the clutch hous
ing (17).
-
-
17
Install two screws (B) of the tool (A) in two of the
threaded holes in the clamp. Tighten the screw (C)
until the clamp comes off.
A
B
Go to Reassembly, page 30, Step 3, or continue
below.
C
4
TORQUE
125 in–lb
(14 N.m)
TO
15
0155
Fig. 27
Clutch Housing
NOTE: Refer to Fig 29–2.
1
Remove the capscrews (11) and
lockwashers (12) which hold the
clutch housing (17) to the engine (45).
45
2
3
4
Remove the engine key (14).
14
Pull off the clutch housing (17).
17
Go to Reassembly page 30, Step 1.
,
12
11
0156
Fig. 28
308-125 29
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Reassembly
1. Install the clutch housing (17), capscrews (11) and
4. Connect the wires of the harness (69) to the screws
(57) in both places on the field. Pull the plastic caps
(C) up and snap them over the screws. Guide the
wires of the harness (69) through the slot in the clutch
housing. Slide the field (10) into the clutch. Align the
setscrew chamfers in the field and the clutch housing
(17). Tighten the setscrews (16) oppositely and
evenly, to 25 in–lb (2.8 N.m). See Fig. 29.
lockwashers (12) on the engine. See Fig. 29.
2. Install the engine shaft key (14). See Fig. 29.
3. Install the clamp (15) onto the engine shaft (A).
Maintain the 1.99 in. +/– 0.01 (50.54 mm) dimension
shown in Fig. 30.
To check the dimension, place a rigid, straight steel
bar (B) across the face of the clutch housing (17).
Use an accurate measuring device to measure the
distance between the inside of the bar and the face
of the clamp. Adjust the clamp as necessary
.
Torque
the two screws (4) to 125 in–lb (14 N.m).
17
FACE OF
HOUSING
1.99”
(50.54 mm)
T
ORQUE OPPOSITEL
Y
AND EVENLY T
O
25 in–lb
(2.8 N.m)
14
A
16
17
12
B
11
15
10
A
4
TORQUE TO
125 in–lb
(14 N.m)
69
C
D
SIDE CUTAWAY VIEW OF CLUTCH HOUSING
0050
57
Fig. 30
4
TORQUE T
O
125 in–lb (14 N.m)
CONNECT WIRING HARNESS
(69) HERE BEFORE SLIDING
FIELD (10) INTO HOUSING (17)
0049
Fig. 29
30
308-125
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Reassembly
NOTE: Refer to Fig. 31 for Steps 5–9.
7. Be sure the face of the armature (9b) is clean. As-
semble the armature to the shaft in the pinion hous
-
ing (C). A retaining ring located within the armature
makes it difficult to assemble these parts. For the
best results, first engage a few splines of both parts,
then use a screwdriver to gently push the retaining
5. Place the engine (45) on the cart. Align the mount
-
-
ing holes. Guide the engine wire (A) and wiring har
ness (69) through the mounting plate grommets (8).
Install the screws (42) and nuts (43) and torque to 15
ft–lb (20 N.m). Install the capscrews (5), lockwash-
ers (6) and washer (7) from under the engine mount
ing plate to secure the clutch housing (17). Connect
the like-colored wires as shown in the Detail A.
ring into the armature, and then engage the remain
ing splines. Push the armature onto the shaft until it
contacts the ring.
-
-
6. Be sure the face of the rotor (9a) and the field (10)
is free of all oil and contaminants. Install the rotor,
8. Assemble the drive/pinion housing (C) to the
clutch housing, using the capscrews (3) and lock-
washers (2).
lockwashers (2) and capscrews (4). Torque the cap
-
screws to 7 ft–lb (9.5 N.m).
After installing the rotor (9a), pull the engine recoil
rope to assure that the engine turns freely and there
is no friction between the rotor (9a) and the field (10).
9. Connect the cord set (62) to the pressure control.
45
If there is friction, loosen the setscrews (16) and re
-
position the field (10) as necessary. Tighten the
setscrews oppositely and evenly to 25 in–lb
(2.8 N.m). Also make sure there are no burrs on the
3
2
outside edge of the rotor
.
16
17
10
9a
12
TORQUE
TO
7 ft–lb (9.5 N.m) 4
42
19n,19k
B
FACES
MUST
BE CLEAN
A
69
7
8
9b
6
5
43
C
TORQUE
15 ft–lb (20.4 N.m)
TO
DETAIL
A
VIEW FROM UNDER ENGINE MOUNTING PLATE
GREEN W/
RED COVER
FROM ENGINE
RED
TO FIELD
62
WHITE
0403
62
BLACK
0405
Fig. 31
308-125 31
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Parts – Displacement Pump
Model 224–527, Series A
Includes items 401–423
Ref
No. Part No.
Description
Qty
401 187–067
402 187–071*
403 187–069*
404 111–486*
405 187–066
406 187–074*
407 187–072*
408 187–102*
409 187–064
410 224–407
411 102–973*
412 187–073*
413 187–078*
414 187–077
415 101–859*
416 187–076
417 186–951
418 187–079*
419 187–070*
420 187–068
421 187–065
422 224–408
423 183–210
ROD, piston
1
3
1
2
1
1
2
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
V–PACKING, poly
GLAND, male, steel
O–RING
423
401
CYLINDER
416
GLAND, male
V–PACKING, poly
U–CUP SEAL
GUIDE, ball
HOUSING, pump intake
BALL, intake
GLAND, female
V–PACKING, leather
NUT, 1-1/4–18
BALL, piston
HOUSING, piston
HOUSING, outlet
V–PACKING, leather
GLAND, female
PACKING NUT
LUG NUT
414
415*
406*
420
*419
413*
*407
412*
408*
PISTON SEAT
PIN
418*
*402
*403
*These parts also included in
Packing Repair Kit 224–523.
Keep a kit on hand to reduce down time.
422
409
411*
410
417
*404
*405
*404
421
0412
32
308-125
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Parts – Pinion Assembly
Ref No. 19
Pinion Housing
Includes items 19a to 19f
REF
REF
NO. PART NO. DESCRIPTION
QTY
NO. PART NO. DESCRIPTION
QTY
NOTE: Items 19h to 19p are not included in a kit. Order them
separately as needed.
19a 221–032
PINION SHAFT ASSEMBLY
Includes items 19b to 19f
.SHAFT, pinion
.BEARING, ball
.BEARING, ball
.RING, retaining, external
.HUB, armature
1
1
1
1
1
1
19h 108–692
19j 107–088
19k 100–069
19m 108–799
19n 105–489
19p 183–394
BEARING, needle, roller
BEARING, needle, needle
BALL, sst
RING, retaining, internal
PIN, dowel
1
1
1
1
2
1
19b 183–395
19c 108–797
19d 108–798
19e 108–796
19f 183–396
HOUSING, pinion
19m
19a
19n
19p
19e
19f
19h
Lubricate
exterior
19d
Lubricate inner and
outer diameters
19b
Lubricate teeth
19c
Lubricate inner and
outer diameters
19k
19j
0042
Lubricate exterior
308-125 33
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Parts – Complete Sprayer
COMPLETE SPRAYER
Model 231–148
Includes items 101 to 104
Ref
Ref
No. Part No.
Description
Qty
No. Part No.
Description
Qty
101 224–439
HOSE, coupled 3/4 npt(m) x
3/4 nspm(f) swivel, 3/4” ID,
50 ft (15 m) long
MASTIC FLOW VALVE
See manual 308–124 for parts
HOSE, coupled 3/4 npt x 1/2 npt (mbe),
5/8” ID, 40 ft. (12 m) long
104 224–483
BASIC SPRAYER
Includes items 104a – 104c
. 55 GALLON SUCTION KIT
See parts on page 35
. ROOFING PUMP and
PRESSURE CONTROL KIT
See parts on page 35
1
1
1
1
104a 224–442
104b 224–528
102 224–472
103 224–440
1
1
1
104c 224–482
. SPRAYER DRIVE ASSEMBLY
See parts on page 36
102
See manual 308–124
103
104c
See parts on page
36.
104b
See parts on page 32 and 35.
104a
101
See parts on page
35.
0395A
34
308-125
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Parts – Suction Kit and Roofing Pump
SUCTION KIT
Model 224–442
Includes items 301 to 306
ROOFING PUMP AND PRESSURE CONTROL KIT
Model 224–528
Includes items 201 to 212
Ref
Ref
No. Part No.
Description
Qty
No. Part No.
Description
Qty
201 187–181
202 187–184
203 224–711
LABEL, ON/OFF & PRES. ADJ.
COVER PLATE
PRESSURE CONTROL, 1200 PSI
Includes replaceable part 203a
. O–RING
SCREW, mach, pnh, 10–24 x 3/8”
ROOFING PUMP, 3 GPM
See parts on page 32
PIN, straight
UNION, swivel, 3/4 npt(m) x
3/4 npsm(f)
1
2
301 111–338
302 187–123
303 187–131
304 187–119
COUPLER, 90_, quick disconnect
1
1
1
1
HOSE, 2” ID
SUCTION TUBE
1
1
8
STRAINER
203a 155–463
204 110–885
205 224–527
305
–
CLAMP (clamp supplied with sprayer
requires special tool; use radiator
clamp as alternative)
GASKET
2
1
1
1
306 111–340
206 183–210
209 157–785
1
210 111–337
211 100–505
212 224–441
TEE, 3/4 npt(m) X 3/4 npt(f) x 3/4 npt(f)
BUSHING, 3/4 npt(m) x 3/8 npt(f)
BALL VALVE See 306–861 for parts
1
1
1
201
LABEL
305
204
203
303
206
210
202
204
209
203a
205
306
211
212
301
305
302
304
0396
308-125 35
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Parts – Drive
Ref 37
3
2
20b
DANGER LABEL
20a
36
39
20
2
33
22
29
28
35
Ref 34
19
41
49
SEE PARTS
ON PAGE 33
48
LABEL 56
ID
19K
1
40
20c
38
21
WARNING
LABEL
68
WARNING
LABEL
23
61
45
37
14
ID LABEL
59
SEE
DETAIL
ABOVE
16
SEE PARTS ON
3
2
PAGE 33
34
42
17
12
11
15
13
10
31
60
32
9a
2
4
9b
4
2
8
64
57
69
67
65
43
63
7
6
5
62
66
26
25
24
27
0397A
44
36
308-125
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Parts – Drive
SPRAYER DRIVE ASSEMBL
Y
Model 224–482, Series A
Includes items 1 to 69
REF
NO. PART NO.
REF
NO. PART NO.
DESCRIPTION
QTY
DESCRIPTION
QTY
1
2
3
4
5
220–919
105–510
100–644
108–803
100–469
GEAR REDUCER
LOCKWASHER, 1/4”
CAPSCREW, hex sch; 1/4–20 x 3/4”
CAPSCREW, hex sch; 1/4–28 x 1”
CAPSCREW, hex hd; 3/8–16
x 3/4”
1
17
9
6
31
32
112–798
237–686
SCREW, mach, hex washer hd,
No. 8–32 x 3/8”
GROUNDING CLAMP
w/25 ft (7.6 m) wire
BUTTON, snap
1
1
2
1
4
2
1
1
1
4
2
33
34
35
36
37
38
39
40
41
42
179–777
224–002
108–795
185–188
220–918
181–867{
185–953{
108–850
108–849
110–837
1
1
1
2
CART
6
7
8
9
100–133
108–851
108–805
221–031
LOCKWASHER, 3/8”
SCREW, mach, pnh, 10–32 x 0.312
BUSHING
HANDLE w/hose rack
LABEL, WARNING on engine
WASHER, plain, 3/8”
BUSHING, snap
CLUTCH ASSEMBLY
Includes items 9a and 9b
.ROTOR
.ARMATURE
FIELD
CAPSCREW, sch, 5/16–24 x 3/4”
LOCKWASHER, 5/16”
PIN, dowel; 5/16 x 1”
KEY, shaft
CLAMP, mounting, rotor
SETSCREW, 1/4–20
x 5/16” long, cone point
HOUSING, clutch
PINION HOUSING
See parts on page 33
DRIVE HOUSING
Includes items 20a – 20d
.WASHER, bronze colored
.WASHER, silver colored
.BALL
.TUBE, grease (not shown)
COVER, drive housing
CONNECTING ROD
BEARING HOUSING
RETAINING RING, ext
WASHER
1
1
1
1
4
4
1
1
1
LABEL, DANGER on drive housing
1
9a
9b
10
11
12
13
14
15
16
183–399
108–806
183–400
108–842
100–214
108–800
183–401
183–517
108–801
SCREW, mach, filh; 8–32 x 1– / ”
4
CAPSCREW, hex sch; 1/4–20 x 3”
SCREW, serrated flange, hex hd,
1
5/16–18 x 1– / ”
2
4
2
1
2
43
44
45
48
110–838
108–794
108–802
110–616
LOCKNUT, 5/16”
PLUG, tubing
ENGINE, gasoline, 5 HP
CAPSCREW, sch;
1
3/8–16 x 1– / ” (special)
4
4
1
2
4
1
49
56
57
106–115
187–120
108–860
LOCKWASHER, 3/8”, high collar
LABEL, ID
SCREW, mach, slotted, bdgh
8–32 x 1/4”
17
19
183–397
220–920
1
2
1
2
1
1
1
2
1
20
220–638
59
60
61
62
63
64
65
66
187–121
187–111
183–169
224–538
111–348
108–868
187–182
110–963
LABEL, ID
1
1
1
1
1
1
1
1
2
2
2
2
2
2
SCREW, quick disconnect
SPRING, retaining
CORD SET
BUSHING, strain relief
CLAMP, wire
BRACKET, power cord
SCREW, serrated flange, hex hd,
5/16–18 x 3/4”
NUT, flanged, hex hd
LABEL, warning
20a 106–227
20b 183–209
20c 100–069
20d 110–293
21
22
23
24
25
26
27
28
29
183–168
224–560
224–484
101–242
154–636
179–811
104–811
108–068
183–350
2
2
1
1
67
68
69
110–996
187–240
220–980
WHEEL
HUBCAP
PIN, spring, straight, 3/16” x 1.25”
WASHER
ELECTRICAL HARNESS
{
Replacement Warning and Danger Labels and tags avail
able at no charge.
-
308-125 37
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Accessories
GENUINE GRACO PARTS AND ACCESSORIES
USE ONL
Y
HIGH PRESSURE DISPLACEMENT PUMP
PRESSURE CONTROL, AND FILTER KIT 224–524
3000 psi (21.0 MPa, 210 bar)
MAXIMUM WORKING PRESSURE
Up to 1.25 GPM
,
DANGER LABELS
The English language DANGER label shown on
page 1 is also on your sprayer. If you have painters
who do not read English, order one of the following
labels to apply to your sprayer. The drawing below
shows the best placement of these labels for good
visibility. Order the labels directly from Graco, free
of charge.
Quickly convert your Roof Rig to a system that will spray
architectural paints, acrylics, urethanes and bonding
adhesives. Maximum recommended tip size is 0.035.
Contact your distributor for help in determining when to
use this kit. Installation and repair instructions included.
Toll Free: 1–800–328–0211
Apply other
language here
Requires gun and hose (with spring guards on both ends)
rated for at least 3000 psi (21.0 MPa, 210 bar) working
pressure.
French
Spanish
German
Greek
Korean
English
185–956
185–961
186–041
186–045
186–049
185–953
2 GPM PUMP KIT
1900 i (13.2 MPa, 1
238–053
2 bar) Maximum Working Pressure
p
s
3
2
GPM PRESSURE CONTROL
REPLACEMENT KIT
1900 i (13.2 MPa, 1
238–115
ps
3
2 bar) Maximum Working Pressure
Installation instructions are included with the kit.
DISPLACEMENT PUMP REPAIR KIT
See contents on page 30. Repair instructions are in-
cluded with the kit.
224–523
0416
SPRAY ROLLER
4050 psi (27.6 MPa, 276 bar)
MAXIMUM WORKING PRESSURE
224–470
HIGH PRESSURE SPRAY HOSES
3000 psi (21.0 MPa, 210 bar)
MAXIMUM WORKING PRESSURE
For rolling roofing coatings that require back rolling, or for
use in high wind conditions to minimize overspray. Instal
lation and and repair instructions included.
-
214–705
223–541
214–701
3/8” ID, cpld 3/8 npt(m); 50 ft (15 m),
spring guards both ends
1/4” ID, cpld 1/4 npsm (f); 50 ft (15 m),
spring guards both ends
1/4” ID, cpld 1/4 npsm (f); 3 ft (0.9 m),
spring guards both ends
ADAPTERS
157–705
150–287
156–173
Union, 1/4 npt(m) x 3/8 npsm(f)
Adapter, 1/4 npt(m) x 3/8 npt(f)
Union, 3/8 npt(f) x 3/8 npsm(f)
38
308-125
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Technical Data
Engine . . . . . . . . . . . . . . . . . . . . . .
Maximum orking Pressure
5
Horsepower, Honda
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 in. (838 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 in. (584 mm)
W
.
. . . . . . . . . . . . . 1200 psi
(8.3 MPa, 83 bar)
Fluid Outlet Size
Wetted Parts
.
. . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Cycles/Gallon (liter)
.
. . . . . . . . . . . . . . . . . . . . . . . 42 (11)
. . . . . . . . . . . . 3 GPM (11 liter/min)
. . . . . . . . . . 0.97 gallons (3.7 liter)
. . . . . . . . . . . . . . . 2” quick disconnect
Weight (dry, without packaging) . . . . . . 140 lb (63 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (813 mm)
Maximum Delivery
.
Displacement Pump
Stainless Steel, Chrome–Plated Stainless Steel,
Polyethylene, ungsten Carbide, Leather, Polyurethane
.
. . . Zinc–Plated Carbon Steel,
Fuel Tank Capacity
.
Pump Inlet Size
.
T
.
308-125 39
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Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor
dance with Graco’s written recommendations.
-
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub
-
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
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 claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser 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.
THIS
WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, 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.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais
-
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–125 May 1991, Revised October 1997
40
308-125
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