Instructions -- Parts List GH Series Roof Rigs Gas--Hydraulic Airless Sprayers Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. GH5030 Model 687100, Series C 4900 psi (33.8 MPa, 337 bar) Maximum Working Pressure GH3640 Model 687327, Series D 3600 psi (24.5 MPa, 245 bar) Maximum Working Pressure GH2560 Model 965168, Series B 2400 psi (16.6 MPa, 166 bar) Maximum Working Pressure GH2075 Model 965171, Series B 1800 psi (12.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 5 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING SKIN 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. Get immediate surgical treatment. D Do not point the gun at anyone or at any part of the body. D Do not put your hand or fingers over the spray tip.
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 If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem. D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
Component Identification HYDRAULIC RETURN LINE TO MOTOR HYDRAULIC SUPPLY LINE TO MOTOR MOTOR RESET BUTTON HYDRAULIC MOTOR HYDRAULIC RESERVOIR GASOLINE FILL CAP SUCTION TUBE CHECK VALVE PRESSURE HYDRAULIC PUMP DRAIN VALVE DISPLACEMENT PUMP Fig 1 SUCTION HOSE 9089d PRESSURE CONTROL KNOB Setup 1. Connect the Hose and Gun a. Remove the plastic cap plug from the outlet tee and screw an accessory, conductive or grounded spray hose onto the 1/4 npsm(f) outlet nipple. See Fig 1. b.
Setup 3. Check the Hydraulic Oil Level a. Unscrew the hydraulic oil fill cap. See Fig 2. The dipstick is attached to the cap. The oil should be up to the full line on the dipstick. GASOLINE FILL CAP OIL DIPSTICK CAUTION To prevent damage to the cooling system and hydraulic pump, use only Graco Hydraulic Fluid, 169236 (5 gal./20 liter) or 207428 (1 gal/3.8 liter). Other types of hydraulic oil may damage the hydraulic components. b. Add oil as needed to the proper level.
Setup 5. Fill the Fuel Tank 6. Grounding WARNING WARNING FIRE AND EXPLOSION HAZARD Fuel spilled on a hot surface can cause a fire or explosion and serious bodily injury and property damage. Shut off engine and let it cool before filling the tank. Carefully follow steps 5.a. to 5.c., below, being sure not to spill any fuel. a. Close the fuel shutoff valve. See Fig 3.
Flushing When to Flush 1. New sprayer. Your new sprayer was factory tested with lightweight oil which was left in to protect pump parts from corrosion. Before using oil- base paint, flush with mineral spirits only. Before using water- base paint, flush with mineral spirits, followed by soapy water, then a clean water rinse. 2. Changing colors. Flush with a compatible solvent such as mineral spirits. 3. Changing from water--base to oil--base paint. Flush with soapy water, then mineral spirits.
Flushing WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of static sparking and splashing when flushing, always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of a grounded metal pail. 11. Making firm metal-to-metal contact, hold the gun firmly to the side of the grounded solvent pail. Trigger the gun. At the same time, slowly turn the pressure control knob clockwise just enough to start the pump. 12. Circulate the solvent until the system is thoroughly flushed.
Operation Pressure Relief Procedure WARNING SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury.
Operation If the motor stalls during operation, turn OFF the ignition key. With your hand, firmly press straight down on the motor reset button. Now try to restart the sprayer. If it will not start, refer to the separate motor manual, 307158. CAUTION Never use a hammer to depress the reset button, as it could cause serious internal motor damage. 4. Prime the Pump a. Be sure the gun safety latch is engaged. b. Don’t install the spray tip yet! c.
Maintenance 1. Always stop the pump at the bottom of its stroke when you take a break and at the end of the day. This helps keep fluid from drying on the rod and damaging the packings. 2. Keep the displacement pump packing nut/wet cup 1/3 full of TSL at all times. The TSL helps protect the packings and rod. 3. Check the tightness of the packing nut daily. It should be tight enough to stop leakage but no tighter.
Troubleshooting WARNING SKIN INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 10. Check everything in the troubleshooting chart before disassembling the sprayer. PROBLEM CAUSE SOLUTION Gas engine doesn’t work properly. Consult engine manual, supplied. Gas engine will not start. Check battery. Gas engine operates, but displacement pump doesn’t operate. Hydraulic motor stalled.
8. Pull the pump straight off the pump support. Replacing the Hydraulic Pump 1. Follow the Pressure Relief Procedure Warning on page 10. Let the hydraulic system cool before beginning the service procedure. 9. Loosen the setscrews (108) on the pump half of the coupler (109). See Fig 9. 10. Remove all fittings from the old pump and install them on the new pump in the same order. 2. Unscrew the reservoir drain plug (51, page 36), having a container ready to catch the draining fluid. 11.
c. Replacing the Cooler and Blower 1. Follow the Pressure Relief Procedure Warning on page 10. Let the hydraulic system cool before beginning the service procedure. Pull the pump support and blower off far enough for the blower to fall out of the bottom of the housing. d. Install a new blower. Secure the pump support (117) to the engine. See Fig 8. 2. Remove the hydraulic pump as instructed in the previous section. e. Check Dimension A as shown in Fig 9 and tighten the coupler setscrews (108).
Displacement Pump Service 210208 Displacement Pump Disconnect the Displacement Pump 1. Flush the pump if possible. Stop the pump on the down stroke. 2. Follow the Pressure Relief Procedure Warning on page 10. 3. Reference Roof Rig Parts Drawings, page 30. 4. Remove the suction tube and fluid hose from the displacement pump. 5. Unscrew the three tie rod locknuts (48). See appropriate sprayer parts drawing. 6. Unscrew the shouldered nut (35). Pull the displacement pump (46) off the tie rods (47). 9.
Displacement Pump Service 237510 and 222801 Displacement Pumps Disconnecting the Displacement Pump 1. Flush the pump, if possible. Stop the pump at the bottom of its stroke. Reconnecting the Displacement Pump 1. Make sure coupling nut (170) and coupling collars (80) are in place on displacement rod (Ref. 29). WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 10. 2. Relieve the pressure. 3.
GH5030 Parts Drawing 79 29 125 31 76 82 77 34 65 22 Ref 29 80 100 103 32 143 101 47 170 70 49 177 104 48 38 Ref 26 84 46 81 166 39 127 144 43 44 45 9086B Model 687100 18 308972
GH5030 Parts List REF NO. PART NO.
GH5030 Parts List (cont.) REF NO. PART NO. 121 122 123 124 125 127 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 168 169 107139 100015 178787 217286 196845 180233Y 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 245143 110755 159841 101566 110838 191958 191959 20 308972 DESCRIPTION QTY BOLT, carriage, 1/4 x 1 in. 1 NUT, hex, 1/4--10 unc 1 SHELF, battery 1 CHECK VALVE, 1 in. npt (fbe) 1 LABEL, ID, top 1 LABEL, warning 2 UNION 1 TSL, 8 oz.
GH3640 Parts Drawing Model 687327 29 79 125 31 76 82 77 34 65 22 Ref 29 80 100 103 143 32 101 47 170 70 49 177 104 48 Ref 26 38 84 46 81 166 39 127 144 43 44 45 9086B 308972 21
GH3640 Parts List REF NO. PART NO.
GH3640 Parts List (cont.) REF NO. PART NO. 120 121 122 123 124 125 127 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 168 100011 107139 100015 178787 217286 196845 180233Y 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 245143 110755 159841 101566 110838 191958 DESCRIPTION QTY WING NUT, 1/2 in. 2 BOLT, carriage, 1/4 x 1 in. 1 NUT, hex, 1/4--10 unc 1 SHELF, battery 1 CHECK VALVE, 1 in. npt (fbe) 1 LABEL, ID, top 1 LABEL, warning 2 UNION 1 TSL, 8 oz.
GH2560 Parts Drawing Model 965168 29 79 125 82 31 77 34 76 65 Ref 29 22 73 80 47 100 170 32 126 166 48 104 140 130 38 81 Ref 26 139 49 46 39 127 144 43 45 44 9087B 24 308972
GH2560 Parts List REF NO. PART NO.
GH2560 Parts List REF NO. PART NO. 121 122 123 124 125 126 127 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 168 169 107139 100015 178787 217286 196845 196663 180233Y 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 224441 110755 159841 101566 110838 191958 191959 26 308972 DESCRIPTION QTY BOLT, carriage, 1/4 x 1 in. 1 NUT, hex, 1/4--10 unc 1 SHELF, battery 1 CHECK VALVE, 1 in. npt (fbe) 1 LABEL, ID, top 1 LABEL, ID 1 LABEL, warning 2 UNION 1 TSL, 8 oz.
GH2075 Parts Drawing Model 965171 29 79 125 82 31 77 34 76 Ref 29 65 22 73 80 47 170 100 32 126 166 48 104 140 130 38 81 139 Ref 26 49 46 39 127 144 45 43 44 9087B 308972 27
GH2075 Parts List REF NO. PART NO.
GH2075 Parts List (cont.) REF NO. PART NO. 121 122 123 124 125 126 127 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 107139 100015 178787 217286 196845 196662 180233 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 224441 110755 159841 101566 110838 DESCRIPTION QTY BOLT, carriage, 1/4 x 1 in. 1 NUT, hex, 1/4--10 unc 1 SHELF, battery 1 CHECK VALVE, 1 in. npt (fbe) 1 LABEL, ID, top 1 LABEL, ID 1 LABEL, warning 2 UNION 1 TSL, 8 oz.
GH1015 Parts Drawing Model 965165 29 79 125 77 82 31 76 65 34 Ref 29 22 36 89 32 35 47 100 166 101 92 91 68 90 89 104 161 125 38 Ref 26 86 37 127 49 39 33 81 144 48 46 45 44 43 9088B 9088A 30 308972
GH1015 Parts List REF NO. PART NO.
GH1015 Parts List (cont.) REF NO. PART NO. 120 121 122 123 124 125 127 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 100011 107139 100015 178787 217286 196845 180233 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 224441 110755 159841 101566 110838 32 308972 DESCRIPTION QTY WING NUT, 1/2 in. 2 BOLT, carriage, 1/4 x 1 in. 1 NUT, hex, 1/4--10 unc 1 SHELF, battery 1 CHECK VALVE, 1 in. npt (fbe) 1 LABEL, ID, top 1 LABEL, warning 2 UNION 1 TSL, 8 oz.
All Models Parts Drawing 187 183 88 LABEL 182 124 83 LABEL 1 184 72 87 189 LABEL 71 LABEL 172 LABEL 181 173 170 171 190 LABEL 72 64 LABEL 75 28 LABEL 27 31 66 26 31 60 67 58 63 41 Ref 58 To Starter To Engine Switch 122 119 185 121 13 186 118 55 20 19 120 145 119 59 40 61 56 12 21 74 28 123 64 28 74 Models 687100, 687327, 965168, 965171, 965165 14 188 57 7877c 11 308972 33
All Models Parts List REF NO. PART NO.
All Models Parts List REF NO. PART NO. 115 116 117 118 119 120 121 122 123 124 130 131 132 137 138 139 140 141 142 143 144 145 150 166 167 168 169 178788 178861 178786 102169 100016 100011 107139 100015 178787 217286 156172 206994 185016 100004 107032 184470 109213 183574 183575 237686 245143 158233 159841 101566 110838 191958 191959 DESCRIPTION QTY COOLER 1 PAD 2 SUPPORT, pump 1 CAPSCREW, hex hd, 5/16 x 1.5 4 LOCKWASHER, spring, 1/4 in. 3 WING NUT, 1/2 in. 2 BOLT, carriage, 1/4 x 1 in.
All Models Parts Drawing Models 687100, 687327, 965168, 965171, 965165 97 74 28 2 153 96 152 Ref 111 95 Ref 77 98 50 78 51 93 94 5 54 4 8 7 5 8 53 141 112 85 8 5 3 113 117 108 54 25 52 105 7879b 138 106 24 114 110 8 142 66 49 110 64 65 137 9 10 107 15 109 23 115 109 108 17 16 18 Ref 22 36 308972 7879A
Technical Data Engine . . . . . . . . . . . . . . . . KOHLER Model CH.18 OH 4 cycle twin cylinder, air cooled, 18 HP, (13.4 Kw) Gasoline . . . . . . . . . . . . . . . . . . . 6.0 gallon (22.7 liter capacity) consumes 1.3 gal/hr (4.9 liter/hr) Hydraulic Fluid Sump . . . . . . . . . . . . . . . . . . 5 gallon (19 liters) Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . 1300 psi (89 bar) 10.2 gpm (39 l/min.) Displacement Pump GH5030 . . . . . . . . . . . . . . . . . . 4900 psi (337 bar, 33.
Graco Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale 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.
