Graco Inc. GM 1230 manual

308–125 Rev . D Supersedes Rev . B and PCN D First choice when quality counts.  INSTRUCTIONS-P ARTS LIST INSTRUCTIONS This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. Roof Rigs  GM 1230 GASOLINE-POWERED AIRLESS SPRA YER 1200 psi (8.3 MPa, 83 bar) MAXIMUM WORKING PRESSURE Model 231–148 With one gun, Hea[...]

  T able of Contents W arnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fueling 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Up 10 . . . . . . . . . . . . . .[...]

  Symbols W arning Symbol W ARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. Caution Symbol CAUTION This symbol alerts you to the possibility of damage to equipment if you do not follow the instructions. W ARNING FIRE AND EXPLOSION HAZARD Improper grounding, p[...]

  W ARNING INSTRUCTIONS EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .  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 pur[...]

  W ARNING 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 .  Fluid injected into the skin may look like just a cut, but it is a [...]

  Notes[...]

  Setup 0394A 0015 0016 PRESSURE CONTROL QUICK DISCONNECT ELBOW SIPHON TUBE PRESSURE CONTROL ON/OFF SWITCH PRESSURE CONTROL KNOB W AND HANDLE SPRA Y GUN SP ARK PLUG CABLE AIR CLEANER CHOKE FUEL SHUTOFF LEVER THROTTL E GROUNDING CLAMP ENGINE OIL LIGHT ENGINE ON/OFF SWITCH MUFFLER DISPLACEMENT PUMP PRESSURE RELIEF V AL VE show[...]

  Setup General Information NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing. W ARNING 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. Grounding 1. [...]

  Setup 1. Read and follow the warnings on pages 3–3 before setting up or operating this sprayer . 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. 4. Check the engine oil level. Refer to the Honda en - gine manual, supp[...]

  Start Up Before Y ou Start The Sprayer 1 See FLUSHING GUIDELINES, page 12, to deter- mine if the unit should be flushed. 2 Be sure the gas tank is full. 3 Check the engine oil level. NOTE: The engine stops automatically , or will not start, if it is low on oil. If you try to start it again without adding more oil, a red[...]

  Start Up 6. T o start the pump: a. Place a container under the pressure drain valve and open the valve. b. Reduce the engine speed by moving the metal throttle lever away from the fuel tank about half way to the left. c. T urn the pressure control knob to minimum. d. T urn ON the pressure control switch. e. T urn the pr[...]

  Flushing Guidelines W ARNING To reduce the risk of serious injury , including fluid injection, always follow the Pressure Relief Proce - dure W arning on page 8 before checking, adjust - ing, cleaning, or shutting down the sprayer . When T o Flush 1. Flush a new sprayer to remove the protective oil. Before using water?[...]

  Spray T ip and T ip Guard W ARNING 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. Installation 1. Insert the housing through the back of the retaining nut and [...]

  Spray T echniques 0551 OVERLAP EACH STROKE BY 50% HOLD THE GUN PERPENDICULAR T O AND 24” (610 MM) ABOVE THE SURF ACE MOVE HORIZONT ALL Y A T A STEADY RA TE Fig. 12 T ype of Coating 1 Fibered? Recommended Tip Size 2 Primers N/A 0.031 or larger Aluminum Solvent–Base No 0.041 or larger Aluminum Emulsion No 0.051 or lar[...]

  Maintenance W ARNING T o reduce the risk of serious injury , always follow the Pressure Relief Procedure on page 8 before checking, adjusting, cleaning, or shutting down the sprayer . CAUTION For detailed engine maintenance and specifications, refer to the HONDA engine manual. CAUTION Close the black fuel shutof f lever[...]

  T roubleshooting W ARNING T o reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. Check everything in the guide before disassembling the sprayer . Relieve the pressure before disassembling the spray - er . PROBLEM CAUSE SOLUTION Engine[...]

  PROBLEM CAUSE SOLUTION Engine starts but dies Oil level drops below oil sensor Add oil. Displacement pump output low on upstroke Siphon hose strainer is clogged Clean strainer . Piston ball check not seating Service piston ball check. See page 19. Piston packings worn or damaged Replace packings. See page 19. Sleeve o?[...]

  Removing a n d I nstallin g a D isplacemen t P ump Removal W ARNING To reduce the risk of serious injury , always follow the Pressure Relief Procedure on page 8 before repairing the sprayer . 1. Flush the sprayer . Remove the suction hose, if used. W ARNING To reduce the risk of pinching or amputating a finger , keep yo[...]

  Removing a n d I nstallin g A D isplacemen t P ump 4. Check the back of the bearing housing to be sure the parts are installed properly . 5. Lift the pump to align the mounting holes and install the mounting screws. IMPORT ANT – torque the screws to 20 ft-lb (27 N.m). See Fig. 13. 6. Plug in the power cord so the notc[...]

  Displacement Pump Repair Kit 1A Packing Repair Kit, Part No. 224–523, is available. Use all the parts in the kit for the best results. 2 Parts included in the kit are marked with an asterisk in the text and drawings. For example, 408*. Reassemble the pump NOTE: Refer to Fig. 13 for reassembly except where noted. NOTE:[...]

  Displacement Pump 7* POL Y LIPS OF V–P ACKINGS MUST F ACE UP 18* LEA THER LIPS OF V–P ACKINGS MUST F ACE DOWN *13 LEA THER LIPS OF V–P ACKINGS MUST F ACE UP * 8 U–CUP SEAL LIPS MUST F ACE DOWN * 2 POL Y LIPS OF V–P ACKINGS MUST F ACE DOWN 10 4* * 4 19* 20 3* 1 5 *12 14 6* 16 *15 21 TORQUE NUT (14) T O HOUSING [...]

  Bearing Housing and Connecting Rod W ARNING To reduce the risk of serious injury , always follow the Pressure Relief Procedure on page 8 before repairing the sprayer . NOTE: Steps 1 to 10 refer to Fig. 18. 1. Refer to Removing the pump on page 18. 2. Remove the screws (48) and lockwashers (49) from the bearing housing ([...]

  Drive Housing W ARNING To reduce the risk of serious injury , always follow the Pressure Relief Procedure on page 8 before repairing the sprayer . NOTE: Refer to Fig. 19 for this procedure. 1. Disconnect the suction hose (A). Disconnect the pressure control cord (62). Remove the front cover (21). 2. Disconnect the pump [...]

  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 clut[...]

  Pinion Housing 0169 0041 19f** Lubricate inner and outer diameters 19g** Lubricate teeth 19h** Lubricate inner and outer diameters 19j** 19m** 19k 19b 19a 19c Lubricate exterior 19c Lubricate exterior 19d BACK OF PINION HOUSING (19a) PRESS PINION ASSEMBL Y IN HERE CUT AW A Y VIEW OF PINION HOUSING (19a) **Included in Re[...]

  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 . NOTE: If the pinion assembly (19) is not yet separated from the clutch housing, follow Steps 1 to 4. Otherwise, start at Step 5. 1. Relieve the pressure. 2. Disconnect th[...]

  Engine 1 Working under the mounting plate (A) of the cart, re - move the screw (5), lockwasher (6) and washer (7). See Fig. 24. 2 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[...]

  Field and W iring Harness NOTE: Refer to Fig. 26. 1 Remove the engine. See page 27. 2 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. 3 Pull the caps (A) off the wire screws (57) in both places on the field. Loosen [...]

17 15 4 TORQUE T O 125 in–lb (14 N.m) B C A 0155 Fig. 27 14 0156 11 12 17 45 Fig. 28   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 Loosen the two screws (4) on the clamp (15), work - ing through the slot at the bottom o[...]

  Reassembly 1. Install the clutch housing (17) , capscrews (1 1) and 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. T o check the dimension, place a[...]

  Reassembly NOTE: Refer to Fig. 31 for Steps 5–9. 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-[...]

  Parts – Displacement Pump Model 224–527, Series A Includes items 401–423 Ref No. Part No. Description Qty 401 187–067 ROD, piston 1 402 187–071* V–P ACKING, poly 3 403 187–069* GLAND, male, steel 1 404 1 1 1–486* O–RING 2 405 187–066 CYLINDER 1 406 187–074* GLAND, male 1 407 187–072* V–P ACKING[...]

  Parts – Pinion Assembly Ref No. 19 Pinion Housing Includes items 19a to 19f REF NO. P ART NO. DESCRIPTION QTY 19a 221–032 PINION SHAFT ASSEMBL Y Includes items 19b to 19f 1 19b 183–395 .SHAFT , pinion 1 19c 108–797 .BEARING, ball 1 19d 108–798 .BEARING, ball 1 19e 108–796 .RING, retaining, external 1 19f 183[...]

  Parts – Complete Sprayer COMPLETE SPRA YER Model 231–148 Includes items 101 to 104 Ref No. Part No. Description Qty Ref 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 1 102 224–472 MASTIC FLOW V AL VE See manual 308–124 for parts 1 103 224?[...]

  Parts – Suction Kit and Roofing Pump SUCTION KIT Model 224–442 Includes items 301 to 306 Ref No. Part No. Description Qty 301 1 1 1–338 COUPLER, 90  , quick disconnect 1 302 187–123 HOSE, 2” ID 1 303 187–131 SUCTION TUBE 1 304 187–1 19 STRAINER 1 305 – CLAMP (clamp supplied with sprayer requires speci[...]

  Parts – Drive 41 40 21 56 48 49 23 61 60 22 2 20 39 20a 20b 1 19K 20c 19 2 3 36 33 29 28 35 Ref 37 Ref 34 SEE DET AIL ABOVE 37 34 42 32 31 8 43 26 25 24 27 7 65 6 5 44 4 2 57 14 16 3 2 12 17 11 15 10 9a 2 4 9b 59 ID LABEL W ARNING LABEL 38 W ARNING LABEL 68 ID LABEL SEE P ARTS ON P AGE 33 63 62 66 45 DANGER LABEL SEE [...]

  Parts – Drive SPRA YER DRIVE ASSEMBL Y Model 224–482, Series A Includes items 1 to 69 REF NO. P ART NO. DESCRIPTION QTY REF NO. P ART NO. DESCRIPTION QTY 1 220–919 GEAR REDUCER 1 2 105–510 LOCKW ASHER, 1/4” 17 3 100–644 CAPSCREW , hex sch; 1/4–20 x 3/4” 9 4 108–803 CAPSCREW , hex sch; 1/4–28 x 1” 6[...]

  Accessories USE ONL Y GENUINE GRACO P AR TS AND ACCESSORIES French 185–956 Spanish 185–961 German 186–041 Greek 186–045 Korean 186–049 English 185–953 Apply other language here DANGER LABELS The English language DANGER label shown on page 1 is also on your sprayer . If you have painters who do not read Engli[...]

  T echnical Data Engine 5 Horsepower , Honda . . . . . . . . . . . . . . . . . . . . . . Maximum W orking Pressure 1200 psi . . . . . . . . . . . . . . (8.3 MPa, 83 bar) Cycles/Gallon (liter) 42 (1 1) . . . . . . . . . . . . . . . . . . . . . . . . Maximum Delivery 3 GPM (1 1 liter/min) . . . . . . . . . . . . . Fuel T a[...]

  Graco Standard W arranty 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 Grac[...]