DutyMax Hydraulic Sprayers

Repair DutyMax Hydraulic Sprayers 3A2247A EN - For professional use only - - Not approved for use in European explosive atmosphere locations - Models: 24M054 (EH200DI), 24M055 (GH200DI), 24M056 (EH300DI), 24M057 (GH300DI) 3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information. 3A2246 311845 3A2248 308491 - Blue Texture Gun 309495 - Inline Texture Gun ti18188a

Table of Contents Models................................... 3 General Repair Information.................. 8 Pressure Relief Procedure................... 9 Maintenance............................... 9 Troubleshooting........................... 10 Hydraulic Pump........................... 12 Removal.............................. 12 Installation............................. 13 Fan Belt................................. 14 Removal.............................. 14 Installation............................. 14 Electric Motor Starter...................... 15 Removal.............................. 15 Installation............................. 16 Electric Motor............................. 18 Removal.............................. 18 Installation............................. 20 Hydraulic Motor Rebuild.................... 23 Removal.............................. 23 Installation............................. 23 Hydraulic Motor......................... 24 Hydraulic Oil/Filter Change.................. 25 Removal.............................. 25 Installation............................. 25 Displacement Pump........................ 26 Removal.............................. 26 Installation............................. 27 Check Valve Repair........................ 28 Removal.............................. 28 Installation............................. 28 Wiring Diagram........................... 29 Notes.................................... 30 Technical Data............................ 31 Graco Standard Warranty................... 32 2 3A2247A

Models Models GH200DI GH300DI EH200DI 240 VAC 50 Hz 1 Phase EH300DI CSA 400VAC 50 Hz 3 Phase BLUE GUN 1/4 in. x 3 ft WHIP 3/8 in. x 50 ft HOSE INLINE GUN 3/8 in. x 12 in. WHIP 1/2 in. x 50 ft HOSE 24M054 24M055 24M056 24M057 Electric Motor Kit Options Kit Number Sprayer Model Description 24M666 EH200DI Gas Conversion Kit 24M667 EH300DI Gas Conversion Kit 24M668 GH200DI Electric Conversion Kit 24M669 GH300DI Electric Conversion Kit 3A2247A 3

Models Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. DANGER HIGH VOLTAGE ELECTRIC SHOCK HAZARD This equipment uses high voltage power. Improper contact with high voltage equipment will cause death or serious injury. Turn off and disconnect power cord before servicing equipment. This equipment must be grounded. Connect only to grounded power source. Use only 3-wire extension cords for 240V and single phase models. Use only 5-wire extension cords for 400 AC and three phase models. Ensure ground prongs are intact on power and extension cords. Do not expose to rain. Store indoors. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 4 3A2247A

Models WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: Use equipment only in well ventilated area. Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline. Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. Ground all equipment in the work area. See Grounding instructions. Use only grounded hoses. Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive. Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem. Keep a working fire extinguisher in the work area. SKIN INJECTION HAZARD High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment. Do not aim the gun at, or spray any person or animal. Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body. Always use the nozzle tip guard. Do not spray without nozzle tip guard in place. Use Graco nozzle tips. Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean. Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and follow the Pressure Relief Procedure for turning off the unit. Check hoses and parts for signs of damage. Replace any damaged hoses or parts. This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated a minimum of 3300 psi. Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly. Verify that all connections are secure before operating the unit. Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls. PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. 3A2247A 5

Models WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. Do not operate the unit when fatigued or under the influence of drugs or alcohol. Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer s warnings. For complete information about your material, request MSDS from distributor or retailer. Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only. Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards. Make sure all equipment is rated and approved for the environment in which you are using it. Use equipment only for its intended purpose. Call your distributor for information. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not kink or over bend hoses or use hoses to pull equipment. Keep children and animals away from work area. Comply with all applicable safety regulations. PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents. Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility. SUCTION HAZARD Powerful suction could cause serious injury. Never place hands near the pump fluid inlet when pump is operating or pressurized. CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. Do not operate in an enclosed area. 6 3A2247A

Models WARNING TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. Read MSDSs to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation. To avoid severe burns: Do not touch hot fluid or equipment. PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. 3A2247A 7

General Repair Information General Repair Information DANGER DA HIGH VOLTAGE ELECTRIC SHOCK HAZARD This equipment uses high voltage power. Improper contact with high voltage equipment will cause death or serious injury. Turn off and disconnect power cord before servicing equipment. This equipment must be grounded. Connect only to grounded power source. Use only 3-wire extension cords for 240V and single phase models. Use only 5-wire extension cords for 400 AC and three phase models. Ensure ground prongs are intact on power and extension cords. Do not expose to rain. Store indoors. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. Grounding Ground sprayer with grounding clamp to earth ground for safe sprayer operation. SAE O-Ring Installation 1. Unscrew lock nut to touch fitting. A 2. Lubricate o-ring (A). 6250 ti5414a 3. Screw in fitting hand tight. To reduce risk of serious injury, do not touch moving parts with fingers or tools while testing repair. Shut off sprayer when repairing. Install all covers, gaskets, screws and washers before operating sprayer. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies. Test repair after problem is corrected. If sprayer does not operate properly, review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting, page 10, for other possible solutions. Install belt guard before operation of sprayer and replace if damaged. Belt guard reduces risk of pinching and loss of fingers; see preceding warning. Install hydraulic motor shield before operation and replace if damaged. Hydraulic motor shield reduces risk of pinching and loss of fingers; see preceding warning. ti5415a 4. Unscrew fitting until oriented properly. ti5416a 5. Tighten lock nut to indicated torque. (Make sure washer is seated properly without pinching o-ring). ti5417a 8 3A2247A

Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. 5. Turn prime valve down. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Set pump valve OFF. ti5266b If after following these steps you suspect the spray tip or hose is still clogged or that pressure has not been fully relieved, very slowly loosen tip guard retaining nut or hose end coupling to relieve pressure gradually. Then loosen completely. Maintenance NOTE: For detailed engine maintenance and specifications, see separate Honda owner s engine manual (supplied). ti9686a 2. Turn gas engine or electric motor OFF. DAILY: Check hydraulic oil level and fill as necessary. DAILY: Check gas engine oil level and fill as necessary. O I Electric Models Single Phase 3. Unplug power cord. I O Electric Models Three Phase OFF ON Gas Models DAILY: Check hose for wear and damage. DAILY: Check gun safety for proper operation. DAILY: Check pressure drain valve for proper operation. DAILY: Check that displacement pump is tight. DAILY: Check level of Throat Seal Liquid (TSL) in displacement pump packing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion. WEEKLY/DAILY: Remove any debris or media from hydraulic rod. ti18812a ti7529a 4. Turn pressure to lowest setting. Trigger gun into pail to relieve pressure. AFTER EACH 100 HOURS OF OPERATION: Change engine oil (see Honda engine owner s manual for correct oil viscosity). SEMI-ANNUALLY: Check belt wear, replace if necessary. YEARLY OR 2000 HOURS: Replace belt. Replace hydraulic oil and filter with Graco hydraulic oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter) and filter 116909. SPARK PLUG: Use only BPRGES or W20EPR-U (NIPPONDENSO) plugs. Gap plug to 0.028-0.031 in (0.7-0.8 mm). Use spark plug wrench when installing or removing plug. 3A2247A 9

Troubleshooting Troubleshooting PROBLEM CAUSE SOLUTION Gas engine pulls hard (won't start) Hydraulic pressure is too high Turn hydraulic pressure knob counter clockwise to lowest setting. Gas engine does not start Switch OFF, low oil, no gasoline Consult engine manual, supplied. Gas engine doesn't work properly Faulty engine Consult engine manual, supplied. Elevation Consult engine manual, supplied. Electric motor does not start or starts slowly Electric motor does not work properly No power Cord not connected to power source Switch OFF Incorrect power source Incorrect amp setting on motor starter (3 phase motor only) Over current switch has tripped Hydraulic pressure is too high Incorrect power source Low voltage to motor 3 phase motors: A phase of three phase power has open circuit Faulty motor Check power source; check circuit breakers and/or fuses. Reset/replace as required. Connect plug to receptacle (grounded with properly sized circuit breaker and/or fuses). 1 phase motors: Turn on/off switch to ON. 3 phase motors: Push ON switch. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. NOTE: If using the EH300DI (24M056) sprayer, the generator must be sized for 15 kw output minimum. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. Turn hydraulic pressure knob counter clockwise to lowest setting. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. Have a certified electrician or authorized Graco Repair Center evaluate and repair. See Technical Data, page 30. 10 3A2247A

Troubleshooting PROBLEM CAUSE SOLUTION Gas engine / electric motor operates but displacement pump does not operate Displacement pump operates, but output is low on upstroke Displacement pump operates but output is low on downstroke and/or on both strokes Paint leaks and runs over side of wetcup Hydraulic pump valve is OFF Set hydraulic pump valve ON. Pressure setting too low Increase pressure, page Operation manual. Displacement pump outlet filter (if used) Clean the filter. is dirty or clogged Tip or tip filter (if used) is clogged Remove tip and/or filter and clean. Hydraulic fluid too low Shut off sprayer. Add fluid*. Belt is off pulley, worn or broken Replace. See Repair manual. Hydraulic pump worn or damaged Bring sprayer to Graco distributor for repair. Dried paint seized paint pump rod Service pump. See manual 311845. Hydraulic motor not shifting Set pump valve OFF. Turn pressure down. Turn engine OFF. Pry rod up or down until hydraulic motor shifts. See Repair manual. For 3 Phase electric motor only: Red phase sequence light is ON, indicating motor rotating in the wrong direction Remove plug from receptacle and rotate plug phase screw. See Operation manual. Piston ball check not seating properly Service piston ball check. See manual 311845. Piston packings worn or damaged Replace packings. See manual 311845. Piston packings worn or damaged Intake valve ball check not seating properly Displacement pump air leak Tighten packing nut or replace packings. See manual 311845. Service intake valve ball check. See manual 311845. Loosen wet-cup Tighten wet-cup enough to stop leakage. Throat packings worn or damaged Replace packings. See manual 311845. Excessive leakage around hydraulic Piston rod seal worn or damaged Replace these parts. See Repair manual. motor piston rod wiper Fluid delivery is low Pressure setting too low Increase pressure, see Operation manual. Displacement pump outlet filter (if used) Clean filter. is dirty or clogged Hydraulic motor is worn or damaged Bring sprayer to Graco distributor for repair. Large pressure drop in fluid hose Use larger diameter or shorter hose. Sprayer overheats Paint build up on hydraulic components Clean hydraulic components. Oil level is low Fill with oil. See Operation manual. Inlet to hydraulic pump pulley/cooling fan Remove obstructions. is obstructed Inlet to 3 phase electric motor cooling fan Remove obstructions. is obstructed. Spitting from gun Air in fluid pump or hose Check for loose connections on siphon assembly, tighten, then reprime pump. Fluid supply is low or empty Refill supply container. Excessive hydraulic pump noise Low hydraulic fluid level Turn sprayer OFF. Add fluid*. Air in hydraulic lines Bleed lines. See Repair manual. *Check hydraulic fluid level often. Do not allow it to become too low. Use only Graco approved hydraulic fluid. 3A2247A 11

Hydraulic Pump Hydraulic Pump Removal 5. Raise electric motor (or gas engine) and remove belt (44). This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. Let hydraulic system cool before beginning service. 1. Relieve pressure, page 9. 2. Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair. 3. Remove drain plug (202) and oil filter (227) and allow hydraulic oil to drain. ti18350a 6. Remove two set screws (197) and fan pulley (96). 197 96 44 227 ti18351a 7. Remove case drain tube (225). 197 225 ti18348a 202 4. Remove screw (172), nut (173) and belt guard (117). 8. Remove elbow (221). ti18352a 117 221 173 172 ti18349a ti18353a 12 3A2247A

Hydraulic Pump 9. Remove hose (276) from elbow (226). Remove elbow (226) from hydraulic pump (220). 12. Remove four screws (277) and hydraulic pump (220) from reservoir cover (209). 220 209 220 226 276 ti18354a 277 10. Remove hydraulic hose (288) from reservoir cover (209). 209 ti18357a Installation 1. Install hydraulic pump (220) to reservoir cover (209) with four screws (277) (ensure o-rings 210 and 211 are in place); torque 90-110 in-lb (10-12 N m). 288 11. Remove eight screws (212) reservoir cover (209) filter assembly (206) and gasket (203). 212 209 ti18355a 2. Install gasket (203) filter assembly (206) and reservoir cover (209) with eight screws (212). Torque 110-120 in-lb (12-14 N m). 3. Install hydraulic hose (288) to reservoir cover (209). 4. Install elbow (226) in hydraulic pump (220). Install hose (276) in elbow (226). Torque to 15 ft-lb (20.3 N m). 5. Install elbow (221); torque to 15 ft-lb (20.3 N m). 6. Install case drain tube (225); torque to 15 ft-lb (20.3 N m). 7. Install fan pulley (96) with two set screws (197). 206 8. Raise electric motor (or gas engine) and install belt (44). 203 ti18356a 9. Install belt guard (117) with screw (172) and nut (173). 10. Install drain plug (202). Install oil filter (227); tighten 3/4 turn after gasket contacts base. Fill hydraulic pump with Graco hydraulic oil, page 6, through elbow (221) port until full. Fill reservoir with remaining hydraulic oil. 11. Start up and allow pump to operate at low pressure for approximately 5 minutes to purge all air. 12. Check oil hydraulic oil and top off, if required. 3A2247A 13

Fan Belt Fan Belt Removal This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Perform Pressure Relieve Procedure, page 9. 2. Loosen belt guard knob (55). 3. Rotate belt guard (117) up. 4. Lift electric motor or gas engine up to remove tension on belt (44). 5. Remove belt from pulley (43) and fan pulley (96). Installation 1. Thread belt (44) around drive pulley (43) and fan pulley (96). 2. Let electric motor (119) down to put tension on belt. 3. Rotate belt guard (117) down. 4. Tighten belt guard knob (55). 117 44 119 43 ti18342a 96 55 Belt Table Unit Part Number Description 24M054 116914 V-Belt AX42 24M055 119433 V-Belt AX41 24M056 125834 V-belt AX48 24M057 119432 V-Belt Ax44 14 3A2247A

Electric Motor Starter Electric Motor Starter DANGER DA HIGH VOLTAGE ELECTRIC SHOCK HAZARD This equipment uses high voltage power. Improper contact with high voltage equipment will cause death or serious injury. Turn off and disconnect power cord before servicing equipment. This equipment must be grounded. Connect only to grounded power source. Use only 3-wire extension cords for 240V and single phase models. Use only 5-wire extension cords for 400 AC and three phase models. Ensure ground prongs are intact on power and extension cords. Do not expose to rain. Store indoors. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. Removal 3 Phase, 400 VAC, 50 Hz, Electric Motor Starter 205 204 43 190 30 ti18617a 192 1. Relieve pressure, page 9. Unplug power cord. 2. Remove Fan Belt, page 14. 119 30 175 193 191 198 195 3. Loosen electric motor nut (205). Swing motor retainer bracket (204) out. 200 ti5384a 4. Remove motor assembly from sprayer. ti18749a 3A2247A 15

Electric Motor Starter 5. Remove motor junction box cover (J). 6. Tilt motor junction box cover back and disconnect three power leads (brown, black, and grey wires) and the yellow and green ground wire (see Wiring Diagram, page 29). J Installation 3 Phase, 400 VAC, 50 Hz, Electric Motor Starter 119 30 S 205 175 43 198 204 ti18700a 30 195 7. Remove cable strain relief fitting (S) from motor junction cover and pull motor power leads and motor ground wire from motor junction cover. 200 8. Remove six screws (200) from motor mounting bracket (195). 9. Remove motor starter assembly (198). 190 ti18617a 192 193 191 1. Install motor starter (198) on motor starter bracket (195). 2. Install six screws (200), into motor starter (198). Torque screws to 20 in-lb (2.3 N m). 3. Remove motor junction box cover (J). 4. Remove strain relief fitting (S) from motor junction box cover (J). 5. Slide strain relief fitting (S) over motor cable power leads. 6. Screw strain relief fitting (S) into motor junction box cover (J). J S ti18700a 16 3A2247A

Electric Motor Starter 7. Be sure gasket is in position on motor junction box cover. Connect yellow and green ground wire to motor junction box ground connection. Connect power leads as follows: Brown wire to motor terminal U1 Black wire to motor terminal V1 Grey wire to motor terminal W1 See Wiring Diagram, page 29, for connection locations. Torque power leads to 28 in-lb (3.2 N m). Torque ground lead to 28 in-lb (3.2 N m). 8. Install motor junction box cover (J) to motor junction box. Torque junction box cover to 28 in-lb (3.2 N m). NOTICE Make sure wires are completely inside motor junction box and will not be pinched between motor junction box and motor junction box cover. Wires will be damaged and create an electrical hazard if pinched. 10. Swing electric motor retainer bracket (204) in. Tighten electric motor nut (205). ti5387a 11. Install Fan Belt, page 14. 12. Check to make sure fan pulley and motor pulley are in line. Also check to make sure fan pulley shaft and motor pulley shaft are parallel. Adjust as required. 9. Install motor assembly on sprayer. ti18748a 3A2247A 17

Electric Motor Electric Motor DANGER HIGH VOLTAGE ELECTRIC SHOCK HAZARD This equipment uses high voltage power. Improper contact with high voltage equipment will cause death or serious injury. Turn off and disconnect power cord before servicing equipment. This equipment must be grounded. Connect only to grounded power source. Use only 3-wire extension cords for 240V and single phase models. Use only 5-wire extension cords for 400 AC and three phase models. Ensure ground prongs are intact on power and extension cords. Do not expose to rain. Store indoors. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. DA This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. Removal 1 Phase, 240 VAC, 50 Hz Electric Motor ti18343a 133 205 204 99 193 43 191 192 190 174 1. Relieve pressure, page 9. Unplug power cord. 2. Remove Fan Belt, page 14. 3. Loosen electric motor nut (205). Swing motor retainer bracket (204) out. 119 30 175 ti5384a 4. Remove motor assembly from sprayer. ti18192a 5. Remove four screws (30), nuts (174), handle (175), bottom isolator plate (190) and motor mounting plate (99) from electric motor. 6. Loosen set screws (133) and remove pulley (43) from electric motor. 18 3A2247A

Electric Motor 3 Phase, 400 VAC, 50 Hz, Electric Motor 119 3. Loosen electric motor nut (205). Swing motor retainer bracket (204) out. 30 205 175 ti5384a 204 43 198 4. Remove motor assembly from sprayer. 30 ti18617a 190 192 1. Relieve pressure, page 9. Unplug power cord. 2. Remove Fan Belt, page 14. 193 191 200 5. Remove motor junction box cover (J). ti18749a 6. Tilt motor junction box cover back and disconnect three power leads (brown, black, and grey wires) and the yellow and green ground wire (see Wiring Diagram, page 29). J S ti18700a 7. Remove cable strain relief fitting (S) from motor junction cover and pull motor power lead (3) and motor ground wire from motor junction cover. 8. Remove four screws (30), nuts (174) and handle (175) from motor mounting bracket (99). 9. Remove four screws (23), nuts (174), and electric motor (119) from motor mounting bracket (99). 10. Loosen set screws (2) and remove pulley (43) from electric motor. 3A2247A 19

Electric Motor Installation 3. Install motor assembly on sprayer. 1 Phase, 240 VAC, 50 Hz Electric Motor 133 205 43 119 30 175 ti18193a 4. Swing electric motor retainer bracket (204) in. Tighten electric motor nut (205). ti18343a 204 99 193 190 ti5387a 5. Install Fan Belt, page 14. 191 192 174 1. Install pulley (43) and set screws (133). Torque set screws to 60 in-lb (6.8 N m). Make sure pulley is flush with end of electric motor shaft. 2. Install handle (175), bottom isolator plate (190) and rocker plate (99) to electric motor (119) with four screws (30) and nuts (174). Motor should be positioned all the way forward on rocker plate. Torque screws (30) to 225 in-lb (25.4 N m). 6. Check to make sure fan pulley and motor pulley are in line. Also check to make sure fan pulley shaft and motor pulley shaft are parallel. Adjust as required. Motor Pulley (133) (end of motor pulley should be flush with end of motor shaft) Motor Shaft Parallel Fan Pulley Shaft Fan Pulley (43) ti18697a In Line ti18750a 20 3A2247A

Electric Motor 3 Phase, 400 VAC, 50 Hz, Electric Motor 119 30 6. Slide strain relief fitting (S) over motor cable power leads. 7. Screw strain relief fitting (5) into motor junction box cover (J). J 205 175 S 43 198 204 190 30 192 193 191 ti18617a 200 1. Install pulley (43) and tighten set screws. Torque set screws to 60 in-lb (6.8 N m). Make sure pulley is flush with end of electric motor shaft. 2. Install four screws (23), nuts (174) and electric motor to motor mounting bracket (99). Motor should be centered in motor slots. Torque screws to 225 in-lb (25.4 N m). ti18700a 8. Be sure gasket is in position on motor junction box cover. Connect three power leads and ground. Connect yellow and green ground wire to motor junction box ground connection. Connect power leads as follows: Brown wire to motor terminal U1 Black wire to motor terminal V1 Grey wire to motor terminal W1 See Wiring Diagram, page 29, for connection locations. Torque power leads to 28 in-lb (3.2 N m). Torque ground lead to 28 in-lb (3.2 N m). 9. Install motor junction box cover (J) to motor junction box. Torque junction box cover to 28 in-lb (3.2 N m). NOTICE Make sure wires are completely inside motor junction box and will not be pinched between motor junction box and motor junction box cover. Wires will be damaged and create an electrical hazard if pinched. ti18696a 10. Install motor assembly on sprayer. 3. Install four screws (30), nuts (174) and handle (175) to motor mounting bracket (99). Torque screws to 225 in-lb (25.4 N m). 4. Remove motor junction box cover (J). 5. Remove strain relief fitting (S) from motor junction box cover (J). ti18748a 3A2247A 21

Electric Motor 11. Swing electric motor retainer bracket (204) in. Tighten electric motor nut (205). Motor Pulley (133) FLUSH (Motor pulley to end of motor shaft) ti5387a 12. Install Fan Belt, page 14. 13. Check to make sure fan pulley and motor pulley are in line. Also check to make sure fan pulley shaft and motor pulley shaft are parallel. Adjust as required. Parallel Motor Shaft ti18705a Fan Pulley Shaft Fan Pulley (43) In Line 22 3A2247A

Hydraulic Motor Rebuild Hydraulic Motor Rebuild Removal Installation This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Perform Pressure Relief Procedure, page 9. 2. Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair. 3. Remove Displacement Pump, page 26. 4. Remove hydraulic lines (271, 288) from fittings (226) at top left and right side of hydraulic motor. 5. Loosen jam nut (264). 6. Unscrew and remove hydraulic motor cap (265). 7. Slide piston rod/hydraulic motor cap assembly (A) from hydraulic motor cylinder (263). FLYING PARTS HAZARD Detent spring has high energy potential. If detent spring is released without due care detent spring and balls could fly into the eyes of the disassembler. Wear safety glasses when removing or installing detent spring and balls. Failure to wear safety glasses when removing detent spring could result in eye injury or blindness. 1. Slide piston rod assembly (A) into hydraulic motor cylinder (263). 2. Screw down hydraulic motor cap (268). Unscrew hydraulic motor cap until inlet and outlet align with hydraulic line fittings and test hole in hydraulic motor cap points toward belt guard (117). 3. Torque jam nut (264) against hydraulic motor cap (268) to 150 ft-lb (17 N m). 4. Install hydraulic lines (271, 288) to fittings (226) to top left and right side of hydraulic motor; torque to 40 ft-lb (54.2 N m). 5. Do Displacement Pump, Installation, page 27. 6. Start engine and operate pump for 30 seconds. Turn engine OFF. Check hydraulic oil level and fill with Graco hydraulic oil, page 25. 3A2247A 23

Hydraulic Motor Rebuild Hydraulic Motor 266 265 test hole 288 271 ti8817a A 264 263 ti8818a 24 3A2247A

Hydraulic Oil/Filter Change Hydraulic Oil/Filter Change Removal This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 227 1. Perform Pressure Relieve Procedure, page 9. 2. Place drip pan or rags under sprayer to catch hydraulic oil that drains out. 3. Remove drain plug (202) page 12. Allow hydraulic oil to drain. 4. Unscrew filter (227) slowly - oil runs into groove and drains out rear. Installation 1. Install drain plug (202) and oil filter (227). Tighten oil filter 3/4 turn after gasket contacts base. ti18348a 2. Fill with five quarts of Graco hydraulic oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter). 3. Check oil level. 3A2247A 25

Displacement Pump Displacement Pump NOTE: It is recommended that the check valve be repaired at the same time as the pump. For check valve repair, see manual 3A2338. Removal 6. Open clamp (247). 247 ti8833b This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Flush pump. 2. Perform Pressure Relief Procedure, page 9. 3. Remove hydraulic motor guard. 7. Slide coupler cover (180) up to fully expose rod couplers (179). 180 179 8. Remove rod couplers (179). 179 ti8829b 179 ti18701a 4. Separate drain hose from sprayer. ti8830b 9. Remove pump (111) from sprayer. 111 ti18703a 5. Remove pin. ti8832b 10. Remove paint hose fitting (67) and paint hose (63) from pump fitting. ti8831b NOTE: Support pump with your hand before opening T-handle. 63 67 ti9951b 26 3A2247A

Displacement Pump Installation 1. If needed, place pump rod in adjustment casting and pull pump to lengthen rod. 5. Slide coupler cover (180) up to expose pump rod. Install rod couplers (179) over rod. 180 179 179 ti8834b 2. Install pump (111) in sprayer. ti8956b 6. Slide couple cover (180) down over rod couplers (179). ti8959b 111 3. Close clamp (247) around pump (111) and push it closed. 247 179 180 7. Install hydraulic motor guard. ti8955b ti8958b 4. Install paint hose fitting (190) and paint hose (63) to pump connection. ti18701a 8. Install pin. ti 8954b 63 67 ti8957b 3A2247A 27

Check Valve Repair Check Valve Repair 2. Use 1.5 in. (38 mm) wrench to securely tighten check valve to pump. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. Removal 1. Flush pump. Perform Pressure Relief Procedure, page 9. ti18702a 3. Replace Displacement Pump, page 27. 4. Connect paint hose and hand tighten to 70 in-lb (8 N m). 2. Remove Displacement Pump, page 26. 3. Remove check valve assembly (64) from displacement pump (111). ti18600a 5. Verify latch lock is in locked position. ti18699a Installation 1. Apply pipe sealant to check valve inlet (64f) threads and install o-ring (64a) to housing (64b). ti18698a 6. Attach drain hose to sprayer. 64f 64b 64a ti18598a ti18703a 28 3A2247A

Wiring Diagram Wiring Diagram EH300 Models (3 Phase Motor) V2 W1 U2 V1 W2 U1 L3 MOTOR N N 2L3 2T3 2L2 2T2 2L1 2T1 L2 L1 N PLUG GREY BLACK GREEN/YELLOW BROWN MOTOR STARTER GREY BLACK BROWN GREEN/YELLOW BLUE ti18616a 3A2247A 29

Technical Data Technical Data EH200DI U.S. Metric Maximum Pressure psi (bar) 3300 228 Hydraulic Reservoir Capacity Gallons (Liters) 1.25 4.75 Motor HP (kw) 3.0 2.2 Voltage, Amperage Frequency Phase 220 VAC, 15.0 A, 50 Hz, 1 Phase 220 VAC, 15.0 A, 50 Hz, 1 Phase Maximum Tip size (paint) 0.039 0.039 Maximum Delivery (paint) gpm (lpm) 1.56 5.9 Fluid Inlet in. [npsm (m)] 1 1 Fluid Outlet in. [npsm (m)] 3/8 3/8 Hose Connection [npt (f)] 3/8 3/8 Cycles per gallon (l) (paint) 80 21.1 Dimensions and Weight Length (handle bar retracted) in. (cm) 47.7 121 Width in. (cm) 26.5 67 Height (handle bar retracted) in. (cm) 33.4 85 Weight lb (kg) 197 89 Sound Levels (Measured at maximum normal load conditions) Engine HP 3.0 3.0 Sound Pressure db(a) 80 80 Sound Power db(a) 95 95 Maximum back fuse rating for EH300DI: Fuse type am: 63 A Fuse type gl: 80 A NOTE: Under voltage release coil in motor starter for EH300DI will not energize if voltage is less than 85% of listed voltage in Technical Data table. Under voltage release coil in motor starter for EH300DI will de-energize and sprayer will stop if voltage drops to 85% of rated nominal voltage. Voltage will need to be increased and sprayer will need to be restarted. NOTE: To operate the EH300DI (24M056) sprayer with a generator, the generator must be sized for 15 kw output (minimum). Basic Sprayer Wetted Parts: Zinc and nickel-plated carbon steel, stainless steel, PTFE, acetal, chrome plating, leather, V-Max UHMWPE, aluminum, tungsten carbide, ceramic, nylon 30 3A2247A

Technical Data GH200DI U.S. Metric Maximum Pressure psi (bar) 3300 228 Hydraulic Reservoir Capacity Gallons (Liters) 1.25 4.75 Motor HP (kw) 5.5 4.1 Maximum Tip size (paint) 0.047 0.047 Maximum Delivery (paint) gpm (lpm) 2.15 8.1 Fluid Inlet in. [npsm (m)] 1 1 Fluid Outlet in. [npsm (m)] 3/8 3/8 Hose Connection [npt (f)] 3/8 3/8 Cycles per gallon (l) (paint) 80 21.1 Dimensions and Weight Length (handle bar retracted) in. (cm) 47.7 121 Width in. (cm) 26.5 67 Height (handle bar retracted) in. (cm) 33.4 85 Weight lb (kg) 182 83 Sound Levels (Measured at maximum normal load conditions) Engine HP 5.5 5.5 Sound Pressure db(a) 96 96 Sound Power db(a) 100 100 Maximum back fuse rating for EH300DI: Fuse type am: 63 A Fuse type gl: 80 A NOTE: Under voltage release coil in motor starter for EH300DI will not energize if voltage is less than 85% of listed voltage in Technical Data table. Under voltage release coil in motor starter for EH300DI will de-energize and sprayer will stop if voltage drops to 85% of rated nominal voltage. Voltage will need to be increased and sprayer will need to be restarted. NOTE: To operate the EH300DI (24M056) sprayer with a generator, the generator must be sized for 15 kw output (minimum). Basic Sprayer Wetted Parts: Zinc and nickel-plated carbon steel, stainless steel, PTFE, acetal, chrome plating, leather, V-Max UHMWPE, aluminum, tungsten carbide, ceramic, nylon 3A2247A 31

Technical Data EH300DI U.S. Metric Maximum Pressure psi (bar) 3300 228 Hydraulic Reservoir Capacity Gallons (Liters) 1.25 4.75 Motor HP (kw) 7.5 5.5 Voltage, Amperage Frequency Phase 400 VAC, 11.0 A, 50 Hz, 3 Phase 400 VAC, 11.0 A, 50 Hz, 3 Phase Maximum Tip size (paint) 0.057 0.057 Maximum Delivery (paint) gpm (lpm) 3.0 11.3 Fluid Inlet in. [npsm (m)] 1 1 Fluid Outlet in. [npsm (m)] 1/2 1/2 Hose Connection [npt (f)] 1/2 1/2 Cycles per gallon (l) (paint) 52 13.7 Dimensions and Weight Length (handle bar retracted) in. (cm) 47.7 121 Width in. (cm) 26.5 67 Height (handle bar retracted) in. (cm) 35.5 90 Weight lb (kg) 236 107 Sound Levels (Measured at maximum normal load conditions) Engine HP 7.4 7.4 Sound Pressure db(a) 80 80 Sound Power db(a) 95 95 Maximum back fuse rating for EH300DI: Fuse type am: 63 A Fuse type gl: 80 A NOTE: Under voltage release coil in motor starter for EH300DI will not energize if voltage is less than 85% of listed voltage in Technical Data table. Under voltage release coil in motor starter for EH300DI will de-energize and sprayer will stop if voltage drops to 85% of rated nominal voltage. Voltage will need to be increased and sprayer will need to be restarted. NOTE: To operate the EH300DI (24M056) sprayer with a generator, the generator must be sized for 15 kw output (minimum). Basic Sprayer Wetted Parts: Zinc and nickel-plated carbon steel, stainless steel, PTFE, acetal, chrome plating, leather, V-Max UHMWPE, aluminum, tungsten carbide, ceramic, nylon 32 3A2247A

Technical Data GH300DI U.S. Metric Maximum Pressure psi (bar) 3300 228 Hydraulic Reservoir Capacity Gallons (Liters) 1.25 4.75 Motor HP (kw) 9.0 6.7 Maximum Tip size (paint) 0.057 0.057 Maximum Delivery (paint) gpm (lpm) 3.0 11.3 Fluid Inlet in. [npsm (m)] 1 1 Fluid Outlet in. [npsm (m)] 1/2 1/2 Hose Connection [npt (f)] 1/2 1/2 Cycles per gallon (l) (paint) 52 13.7 Dimensions and Weight Length (handle bar retracted) in. (cm) 47.7 121 Width in. (cm) 26.5 67 Height (handle bar retracted) in. (cm) 35.5 90 Weight lb (kg) 218 99 Sound Levels (Measured at maximum normal load conditions) Engine HP 9.0 9.0 Sound Pressure db(a) 96 96 Sound Power db(a) 110 110 Maximum back fuse rating for EH300DI: Fuse type am: 63 A Fuse type gl: 80 A NOTE: Under voltage release coil in motor starter for EH300DI will not energize if voltage is less than 85% of listed voltage in Technical Data table. Under voltage release coil in motor starter for EH300DI will de-energize and sprayer will stop if voltage drops to 85% of rated nominal voltage. Voltage will need to be increased and sprayer will need to be restarted. NOTE: To operate the EH300DI (24M056) sprayer with a generator, the generator must be sized for 15 kw output (minimum). Basic Sprayer Wetted Parts: Zinc and nickel-plated carbon steel, stainless steel, PTFE, acetal, chrome plating, leather, V-Max UHMWPE, aluminum, tungsten carbide, ceramic, nylon 3A2247A 33

Graco Standard Warranty Graco warrants all equipment referenced in this document 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. This warranty applies 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 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 substitution 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 reconnaissent 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 procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor. 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. Original instructions. This manual contains English. MM 3A2247 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES P.O. BOX 1441 MINNEAPOLIS MN 55440-1441 USA Copyright 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revision A - 02/2012