Graco 308327F 5.5 HORSEPOWER, GASOLINE POWERED GM 5000 Convertible Airless Paint Sprayer Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

308–327

First choice when quality counts.

Rev. F

Supersedes Rev. B and PCN E

INSTRUCTIONS

5.5 HORSEPOWER, GASOLINE POWERED

GM 5000 Convertible

Airless Paint Sprayer

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

Model 231-316, Series A

Basic sprayer, without hose or gun

Model 231-330

Basic sprayer, without hose or gun, gas powered with electric motor kit

Model 231-331

Complete sprayer, with hose and Contractor gun,

RAC IV DripLess Tip Guard, and 517 size SwitchTip

Optional Electric Motor Kit

Model 236–379

This 2 HP electric motor accessory converts the unit to an electric powered sprayer in just seconds.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1993, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

7340A

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Function . . . . . . . . . . . .

Setup

Fueling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

10

2

5

6

7

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair

Bearing Housing and Connecting Rod

Drive Housing

. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

13

Pinion

Clutch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field and Wiring Harness . . . . . . . . . . . . . . . . . . . . .

15

16

17

18

19

Symbols

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Replacement

Displacement Pump

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

Parts

Basic Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Housing Alternator . . . . . . . . . . . . . . . . . . . .

Complete Sprayer

Pressure Control

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Schematic

Technical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Symbol Caution Symbol

19

21

22

24

30

31

31

31

32

26

28

29

30

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 the you do not follow the instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

INSTRUCTIONS

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 31 for the maximum working pressure of this equipment.

D Use fluids and solvents compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

D Do not use hoses to pull equipment.

D 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 Do not lift pressurized equipment.

D 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.

308–327

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.

Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medical attention.

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 10 if the spray tip clogs and before cleaning, checking or servicing the equipment.

Tighten all fluid connections before operating the equipment.

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.

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.

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.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

FUEL HAZARD

The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.

Do not fill the fuel tank while the engine is running or hot.

EXHAUST HAZARD

The exhaust contains poisonous carbon monoxide which is colorless and odorless.

Do not operate this equipment in a closed building.

308–327 3

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.

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.

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.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of all moving parts when starting or operating the pump.

Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the equipment from starting unexpectedly.

NOTE: This is an example of the DANGER label on your sprayer . This label is available in other languages, free of charge. See page 31 to order.

FIRE AND

EXPLOSION HAZARD

SKIN INJECTION

HAZARD

Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.

Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.

Avoid all ignition sources such as static electricity from plastic drop cloths, open flames such as pilot lights, hot objects such as cigarettes, arcs from connecting or disconnecting power cords or turning light switches on and off.

Failure to follow this warning can result in death or serious injury.

Liquids can be injected into the body by high pressure airless spray or leaks – especially hose leaks.

Keep body clear of the nozzle. Never stop leaks with any part of the body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.

Never spray without a tip guard.

In case of accidental skin injection, seek immediate

“Surgical Treatment”.

Failure to follow this warning can result in amputation or serious injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

4 308–327

Component Identification and Function

K

202

M

A B

18

N

2

D

C

60

203

L

5

H

G

F

1

53

15

E 27

204

J

202 Main hose

203 Whip end hose

204 Contractor gun with RAC IV

DripLess tip guard and 517 size SwitchTip

Fig. 1

A Pressure Control Switch

B Pressure Adjusting Knob

C Air Cleaner*

D Fuel Tank*

E Muffler*

F Spark Plug Cable*

ON/OFF, enables/disables clutch function

Controls fluid outlet pressure

Filters air entering the carburetor

Holds 0.95 gallons (3.6 liter) of 86 octane gasoline

Reduces noise of internal combustion

Routes electrical current to spark plug

G Fuel Shutoff Lever*

H Choke*

J Throttle*

K Engine Switch*

On/off lever to regulate fuel flow from gasoline tank to carburetor

Enriches air/gasoline mixture for cold starting

Adjusts engine speed for large or small orifice spray tips

L Secondary Fluid Outlet

M Pressure Control

N Primary Fluid Outlet

1 Engine*

Enables/disables engine operation

Second hose and spray gun is connected here

Controls clutch cycling to maintain fluid pressure.

Hose and spray gun is connected here

5.5 HP gasoline engine

*

2

5

15

27

Clutch Housing

53 Pail Hanger

60

Drive Housing

Displacement Pump

18 Fluid Filter

Grounding Clamp and Wire

Pressure Drain Valve

Transfers power from engine to drive assembly

Transfers power from clutch to displacement pump

Provides fluid to be sprayed through spray gun

Filters fluid between source and spray gun

Grounds sprayer system

Provides a hanger for paint pail

Relieves fluid pressure when open

For more detailed explanations of these controls, refer to the Honda engine manual; supplied

308–327

7203A

5

WARNING

If you are supplying your own hoses and spray gun, be sure the hoses are electrically conductive, that the gun has a tip guard, and that each part is rated for at least 3000 psi (210 bar, 21 MPa) Maxi mum Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or over-pressurization and rupture of the hose or gun.

Setup

2.

Connect the hose and gun. Screw the 50 ft.

(15.2 m) main fluid hose (126) onto the outlet nipple (55). Screw on the whip end hose (127).

Screw on the gun (128). Do not use thread sealant on swivels, and do not install the spray tip yet! See

Fig. 2.

3.

Two gun hookup. Remove the cap (56) from the secondary hose outlet and attach an accessory hose and gun to the 1/4 npsm(m) nipple.

See Fig. 2.

CAUTION

To avoid damaging the pressure control, which may result in poor equipment performance and component damage, follow these precautions.

4.

Fill the packing nut/wetcup (416). One full squirt of Graco Throat Seal Liquid (TSL) is usually enough.

1. Always use nylon spray hose at least 50 ft. (15.2

m) long.

2. Never use a wire braid hose; it is too rigid to act as a pulsation dampener.

Fill with TSL

Do not install any shutoff device here.

Do not use thread sealant on swivels

3. Never install any shutoff device between the filter and the main hose. See Fig 2.

56

55

4. Always use the main filter outlet (55) for one gun operation. Never plug this outlet.

1.

Be sure your system is properly grounded.

Read and follow the warning section, FIRE OR

EXPLOSION HAZARD, on page 4. If you are using the sprayer with the gasoline engine, secure the ground wire to a true earth ground. If you are using the sprayer with an electric motor, plug it into a properly grounded outlet.

128 416

127

7205A

126

Fig. 2

6 308–327

Setup

5.

Check the engine oil level. Refer to the Honda engine manual, supplied. This is a summary of the information: Remove one of the oil fill plugs (C); the oil should be almost overflowing. See Fig 3.

Add oil as necessary.

Recommended lubrication oil: Use a high-quality, detergent oil, SAE 10W-40, classified “FOR SER-

VICE SE or SF”, for regular use and for breakingin a new engine.

6.

Fill the gas tank. See the Fueling section, below.

7.

Flush the pump to remove the lightweight oil which was left in the pump to protect it from rust.

See page NO TAG.

B

A

8.

Prepare the paint according to the manufacturer’s recommendations. Remove any paint skin. Stir the paint to mix pigments. Strain the paint through a fine nylon mesh bag to remove particles that could clog the filter or spray tip. This is probably the most important step toward trouble-free spraying.

Fig. 3

Fueling

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

Always shut off the engine switch (A) before refueling. See Fig 3.

C

7206A

2.

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.

Refuel in a well-ventilated area.

Do not smoke or allow flames or sparks in the area where the engine is refueled or where the gasoline is stored.

NOTE: The Honda engine warranty does not cover damage resulting from the use of gasolines containing alcohol. See the Honda engine manual for more information.

Do not overfill the tank. Close the gas fill cap

(B) securely after refueling. See Fig 3.

3.

General. Do not use oil and gasoline mixtures or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank.

Do not spill fuel when fueling. Fuel vapor or spilled fuel can ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

4.

Tank capacity: 0.95 gallons (3.6 liter). Always leave at least 1/2 in. at the top of the tank for expansion.

1.

Fuel specifications. Use automotive gasoline with a pump octane number [(R + M)/2] of 86 or higher, or a research octane number of 91 or higher. Unleaded fuel minimizes combustion chamber deposits.

5.

Shut off the engine before refueling.

6.

After refueling, tighten the fuel tank cap firmly.

308–327 7

Trigger safety latch shown engaged

0137

Fig. 4

NOTE: For the startup procedure, refer to Fig. 5 except where noted otherwise.

Before you start the sprayer

1. Become familiar with how to operate the gun’s trigger safety latch.

See Fig. 4 and refer to your gun instruction manual.

2. Become familiar with the proper way to relieve pressure.

See the Pressure Relief Procedure on page 10.

3. Determine if you should flush the sprayer. See

Flushing on page NO TAG.

4. Check the gas tank level.

See page 7.

5. Check the oil level. See page 7.

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 light near the engine on/off switch glows as you pull the starter rope.

6. Push the spark plug cable (F) firmly onto the plug.

7. If starting a sprayer that IS NOT PRIMED, remove the spray tip.

8. If a secondary hose and gun is not installed, be sure the cap (L) is securely plugging the secondary outlet fitting.

9. Place the suction tube (50) into the material container.

10. Open the black fuel shutoff lever (G). Push it in the direction of the arrow.

11. Turn OFF the pressure control switch (A).

Startup

CAUTION

Never try to start the engine unless fluid pressure is relieved and the pressure control switch is OFF.

Trying to start the engine when it is pressurized could damage the recoil system.

To start the engine

1. Turn the pressure adjusting knob (B) counterclockwise to the lowest pressure setting.

2. Slide the metal throttle lever (J) away from the fuel tank to the maximum position (fully left).

3. If the engine is cold, close the choke (H) by moving the gray lever.

If the engine is warm , close the choke (H) by moving the gray lever half way or not at all.

4. Turn ON the engine switch (H).

WARNING

A rope which recoils too quickly may hit someone and cause serious bodily injury. The rope could also jam in recoil assembly.

5. Hold the frame of the sprayer with one hand and pull the starter rope rapidly and firmly. Hold the rope as you let it return. Pull and return the rope until the engine starts.

6. Open the choke (G) as soon as the engine starts, except in cold weather.

In cold weather, leave the choke closed for 10 to 30 seconds before opening it to keep the engine running.

7. Disengage the gun safety latch.

To start and prime the pump

1. Open the filter’s pressure drain valve (60).

2. Turn ON the pressure control switch (A).

3. Turn the pressure control knob (B) about 1/4 turn from minimum pressure. Run the pump until fluid is flowing smoothly from the pressure drain valve, indicating the pump is fully primed.

8 308–327

Startup

4. Close the pressure drain valve (60). See Fig. 5.

Squeeze the trigger until fluid flows from the gun.

This primes the hoses. Release the trigger. Engage the gun safety latch. See Fig. 4, page 8.

Adjust the engine speed and pump pressure

1. Disengage the trigger safety latch. Trigger the gun onto a test paper to check the spray pattern and atomization. Turn the pressure adjusting knob (B) until you get a good pattern. Then slowly lower the throttle (J) setting as far as you can without changing the spray pattern.

WARNING


To reduce the risk of static sparking and splashing when priming, flushing or relieving pressure, always hold a metal part of the gun firmly to the side of and aimed into a grounded metal pail.

CAUTION

Always use the lowest needed fluid pressure and the lowest needed throttle setting, to increase the life of the sprayer. Higher settings cause excessive clutch cycling, premature tip wear and premature pump wear.

5. If you have not primed the sprayer with paint yet, move the suction tube to the paint container.

Disengage the trigger safety latch. Trigger the gun into the solvent pail just until paint appears. Release the trigger and engage the trigger safety latch. Repeat for the second gun, as needed.

6. Install the spray tip (P) in the gun.

See the separate tip instruction manual, 308–644, supplied.

CAUTION

Close the black fuel shutoff lever (G) when transporting the sprayer to prevent fuel from flooding the engine. See Fig. 5, page 9.

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.

Fig. 5

L

A

B

60

P

50

K

C

F

H

G

J

308–327

7207A

9

aintenance

WARNING


To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief

Procedure on page 10.

AFTER EACH 100 HOURS OF OPERATION:

Change the oil.

MONTHLY: Oil connecting rod.

SPARK PLUG: Use only an BPR6ES (NGK) or

W20EPR–U (NIPPONDENSO) plug. Gap the plug to

0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug wrench when installing and removing the plug.

CAUTION

For detailed engine maintenance and specifications, refer to the separate engine manual, supplied.

DAILY: Check engine oil level and fill as necessary.

See Step 5, page 7.

DAILY: Check the V-belt (60). Be sure it is centered on the pulleys and is not inverted. See Fig. 17, page

20. Replace it if it is worn or damaged.

DAILY: Check and fill the gas tank. See page 7.

WARNING


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. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tip.

DAILY: Check hoses for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check pressure drain valve for proper operation.

After the first 20 hours of operation: Drain the oil and refill with clean oil.

DAILY: Keep TSL in the packing nut to help lubricate the pump packings. One full squirt of TSL is usually enough.

Pressure Relief Procedure

1. Lock the gun trigger safety.

2. Turn the engine ON/OFF switch to OFF.

3. Move the pressure control switch to OFF.

4. Unlock the trigger safety. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve the pressure.

5. Lock the gun trigger safety.

WEEKLY: Remove the cover of the air filter (C) and clean the element. See Fig. 5, page 9. Replace the element, if necessary. If operating in an unusually dusty environment, check the filter daily and replace it, if necessary.

Replacement elements can be purchased from your local HONDA dealer.

6. Open the pressure drain valve. Leave the valve open until you are ready to spray again.

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, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling to relieve the pressure gradually, then loosen completely. Now clear the tip or hose.

10 308–327

Flushing

When to Flush

1. New Sprayer. This sprayer was factory tested in lightweight oil,which was left in to protect the pump parts.

5. Storage.

Before using water–base paint, flush with mineral spirits, followed by a soapy water flush, and then a clean water flush.

Before using oil–base paint, flush with mineral spirits.

Water base paint: flush with water, then mineral spirits and leave the pump, hose and gun filled with mineral spirits. Shut off the sprayer, remove the spark plug cable, and open the pressure drain valve to relieve the pressure. Leave the drain valve open.

2. Changing Colors. Flush with a compatible solvent such as mineral spirits or water.

3. Changing from water–base to oil–base paint.

Flush with warm, soapy water, then mineral spirits.

Oil base paint: flush with mineral spirits and leave the pump, hose and gun filled with mineral spirits.

Shut off the sprayer, remove the spark plug cable, and open the pressure drain valve to relieve the pressure. Leave the drain valve open.

4. Changing from oil–base to water–base paint.

Flush with mineral spirits, followed by warm, soapy water, and then a clean water flush.

6. Startup after storage.

CAUTION

To prevent pump corrosion, never leave water or any type of paint in the sprayer when it is not in use.

Pump the water or the paint out with mineral spirits.

Before using water–base paint, flush out the mineral spirits with soapy water, and then with clean water.

When using oil–based paint, flush out the mineral spirits with the paint to be sprayed.

308–327 11

Flushing

How to Flush

WARNING




7. Check all fluid connections for leaks. Relieve pressure before tightening any connections. Start the sprayer. Recheck the connections for leaks.

8. Remove the suction tube from the solvent pail.

Disengage the trigger safety latch. Trigger the gun to force solvent from the hose. Do not let the pump run dry for more than 30 seconds, to avoid damaging the pump packings. Relieve pressure.

NOTE: “Solvent” refers to water or oil-based solvent.

1. Follow the Pressure Relief Procedure on page

10.

2. Unscrew the filter bowl (A) and remove the screen

(B). Leave the support (C) in place. Reinstall the bowl. Clean the screen separately. See Fig 6. Also see instruction manual 307-273, supplied.

3. Close the pressure drain valve (60).

4. Put the suction tube in a grounded pail of solvent.

5. Remove the spray tip from the gun(s).

9. Remove the strainer, suction tube and suction hose and clean them separately to be sure all paint sediment is removed. Dried paint can build up in these parts and later cause performance problems.

10. Unscrew the filter bowl (A) and reinstall the clean screen (B). Reinstall the bowl and hand tighten.

11. Follow Storage or Changing colors, on page 11.

Relieve pressure.

WARNING


To reduce the risk of static sparking and splashing when priming, flushing or relieving pressure, always hold a metal part of the gun firmly to the side of and aimed into a grounded metal pail.

6. Follow Startup on page 8. Keep the gun triggered until clean solvent comes from the nozzle.

Release the trigger and engage the trigger safety latch.

NOTE: For two guns, release the trigger safety latch on the second gun and trigger that gun until clean solvent comes from the nozzle. Flush the first gun and then the second gun at least one more time.

B

C

Fig. 6

60

A

7208A

12 308–327

Troubleshooting

WARNING


To reduce the risk of serious injury, including fluid injection or splashing in the eyes or on the skin, or injury from moving parts, always follow the Pressure Relief Procedure Warning, page 10, before checking, adjusting, cleaning or shutting down the sprayer. Disconnect the spark plug!

Check everything in the chart before disassembling the sprayer.

PROBLEM

Engine/sprayer won’t start

CAUSE

Engine switch not on

Out of gas

Engine oil level low

SOLUTION

Turn on.

Engine operates, but displacement pump doesn’t

Spark plug cable disconnected or spark plug damaged

Water frozen in pressure control

Engine won’t “pull over” Oil seepage into combustion chamber

Pressure control switch turned OFF

Pressure setting too low

Displacement pump outlet filter dirty

Tip or tip filter clogged

Broken drive belt

Displacement pump rod seized by dry paint

Connecting rod worn or damaged

Drive housing worn or damaged

Electrical power not energizing field

Replenish

Try starting engine. If light on rear of engine glows, replenish oil.

Connect cable on top of engine or replace spark plug.

Return pressure control to authorized Graco dealer for repair.

Remove spark plug. Pull starter rope 3 or 4 times.

Clean or replace plug. Try to start. Keep sprayer upright to avoid oil seepage.

Turn on.

Increase pressure.

Clean filter.

Clean tip or tip filter.

Replace belt.

Service pump. See page 24.

Clutch worn or damaged

Pinion assembly worn or damaged

Replace. See page 15.


Check wiring connections. See page 19.

With pressure control switch ON and pressure turned to MAXIMUM, use a test light to check for power at black and white wires from pressure control.

Have pressure control checked by authorized

Graco dealer.

Service. See page 18.

Service. See page 17.

308–327 13

Troubleshooting

PROBLEM CAUSE SOLUTION

Displacement pump output low on upstroke

Pump inlet screen clogged

Piston ball check not seating

Piston packings worn or damaged

Sleeve gasket in displacement pump is damaged

Pump inlet screen clogged

Clean.

Service piston ball check. See page 24.

Replace packings. See page 24.


Displacement pump output low on downstroke or both strokes Piston packings worn or damaged

Clean.


Intake valve ball check not seating properly Clean and service. See page 24.

Engine RPM too low Increase throttle setting. See Step 1, page 9.

V–belt slipping Replace V–belt.

Clutch worn or damaged

Paint leaks into wet-cup Loose wet-cup

Throat packings worn or damaged

Displacement rod worn or damaged

Low fluid delivery


Tighten just enough to stop leakage.


Replace rod. See page 24.

Pump inlet screen clogged.

Pressure setting too low

Engine RPM too low

Dirty outlet filter, tip filter or tip

Clean.

Increase pressure. See Step 1, page 9.

Increase throttle setting. See Step 1, page 9.

Clean.

Spitting from gun

Pump is difficult to prime

Large pressure drop in hose

Air in fluid pump or hose

Tip partially clogged

Fluid supply is low or empty

Air leak

Use larger diameter hose.

Check for loose connections at pump intake and tighten. Then prime pump. See Startup, page 8.

Clear.

Refill and prime the pump. See Startup, page 8.

Check fluid supply often to prevent running the pump dry.

Check all hose connections and tighten as needed.

Intake valve is leaking

Worn packings

Fluid is too thick

Reduce RPM and cycle pump as slowly as possible during priming.

Shut off pump and relieve pressure. Disassemble and clean intake valve. Be sure ball seat is not nicked or worn and that the ball seats well. Reassemble.

Repack the pump. See page 24.

Thin fluid according to supplier’s recommendations.

14 308–327

Bearing Housing and Connecting Rod

WARNING




NOTE: Steps 1 to 13 refer to Fig. 7.

1. Remove the front cover and screws (7,78).

2. Remove the spring clips (49,52) and the drain hose (51). Unscrew the suction tube (50) from the pump, holding a wrench on the pump intake valve

(423) to keep the pump from loosening.

3. Disconnect the hose (63) from the pump.

4. Use a screwdriver to push aside the retaining spring (13) at the top of the pump. Push the pin

(12) out the rear.

5. Loosen the jam nut (14) with an adjustable wrench. Unscrew and remove the displacement pump.

6. Use a hex key wrench to remove the four screws

(72) and lockwashers (73) from the bearing housing (11).

7. While pulling the connecting rod (8) with one hand, lightly tap the lower rear of the bearing housing

(11) with a plastic mallet to loosen it from the drive housing (5). Pull the bearing housing and the connecting rod assembly (8,11) off the drive housing.

8. Inspect the crank (D); replace the drive housing if the crank is worn excessively.

9. Evenly lubricate the inside of the bronze bearing

(A) in the bearing housing (11) and the inside of the connecting rod link (B) with high-quality motor oil. Liberally pack the roller bearing (C) in the connecting rod (8) with bearing grease.

10. Assemble the connecting rod (8) and bearing housing (11).

11. Clean the mating surfaces of the bearing housing

(11) and drive housing (5).

12. Align the connecting rod (8) with the crank (D) and carefully align the locating pins (E) in the drive housing (5) with the holes in the bearing housing

(11). Push the bearing housing onto the drive housing or tap it into place with a plastic mallet.

CAUTION

DO NOT use the bearing housing screw (73) to align or seat the bearing housing with the drive housing.

These parts must be aligned using the locating pins

(F), to help avoid premature bearing wear.

13. Install the screws (72) and lockwashers (73) on the bearing housing. Tighten evenly to 300 in-lb (34

N.m).

14. Refer to Installing the Pump on page 24 to install the pump.

78

7

Torque to 300 in-lb (34 N.m)

Lubricate with high-quality motor oil

Pack with bearing grease

C

4

10

B

A

72

73

D

5

8

11

Fig. 7

12

14

423

50

13

63

52

51

49

308–327

E

02693

15

WARNING




NOTE: Refer to Fig. 8 for this procedure.

1. Remove the front cover and screws (7,78).

2. Unscrew the hose from the pump. Remove the spring clips (40,52) and the drain hose (51) from the pump.

3. Remove the four screws (72) and lockwashers

(73) from the bearing housing (11).

4. Lightly tap the back of the bearing housing (11) with a plastic mallet. Pull the pump, bearing housing and connecting rod away from the drive housing as one assembly (C).

5. Remove the two drive housing screws (10) and lockwashers (4). Remove the four pinion housing screws (215) and lockwashers (214).

6. Lightly tap around the drive housing (5) to loosen it. Pull the drive housing straight off the pinion housing (219). Be prepared to support the gear cluster (16) which may also come out.

Drive Housing

CAUTION

Do not drop the gear cluster (16) when removing the drive housing (5). The gear cluster is easily damaged. The gear may stay engaged in the drive housing or pinion housing.

Do not lose the thrust balls (5c or 219d) located at each end of the gear cluster, or allow them to fall between the gears. The balls, which are heavily covered with grease, usually stay in the shaft recesses, but could be dislodged. If the balls are caught between the gears and not removed, they will damage the drive housing. If the balls are not in place, the bearings will wear prematurely.

7. Apply the full 6 oz. (160 grams) of bearing grease, which is supplied with a replacement gear, to the gear cluster (16). Be sure the thrust balls (5c and

219d) are in place.

8. Place the bronze colored washer (5a) and then the silver–colored washer (5b) on the shaft protruding from the big gear of the drive housing (5). Align the gears and push the new drive housing straight onto the pinion housing and locating pins (A).

9. Starting at Step 4, work backwards to reassemble the sprayer. Or, move ahead to the next section in this manual if further service is needed.

Torque to 300 in-lb (34 N.m)

Apply a full 6 oz. (160 grams) of bearing grease (supplied with replacement gear – 16) 5

5a

5b

16

A

215,214

78

7

72

73

C

10

4

5c

219d

219

52

51

49

02694 Fig. 8

16 308–327

Remove the Pinion Housing

WARNING




Pinion

Repairing the Pinion

NOTE: Repair Kit No. 236–394 includes the shaft and bearings pre-assembled and lubricated. A hydraulic press is not required. Use the repair procedure below.

NOTE: If purchasing the pinion parts separately, the repair must be done by a qualified technician since parts must be press fit. Refer to the parts drawing on page 28.

NOTE: Refer to Fig. 9 for Steps 1 to 2.

NOTE: Refer to Fig. 10 except where noted.

1. First remove the two bottom screws (3) and lockwashers (4) from the clutch housing (222), and then remove the top three screws and lockwashers.

1. Remove the retaining ring (218e).

2. Remove the large ring (217) from the bearing recess of the pinion housing (219).

2. Pull the pinion housing (219) away from the clutch housing (222). The armature (212b) will come out still attached to the clutch housing. Pull the armature off the hub inside the pinion housing.

3. Pull the the pinion output shaft (218) out of the housing (219).

NOTE: To disassemble the pinion, go to Repairing

the Pinion. To disassemble more of the sprayer, go to page 18. To reassemble the sprayer from this point, skip ahead to Reassembly, page 21, Steps 3 and 4.

4. Install the new pinion output shaft (218) into the pinion housing, pushing it to the shoulder of the housing (219).

5. Install the rings (218e and 217).

See Fig. 10

222

4

3

6. Go to Reassembly, page 21, Steps 3 and 4, or continue on page 18.

219

212b

217

218

219

218e

Drive housing shown removed for visual purposes only

02787 Fig. 9 02695

Fig. 10

308–327 17

NOTE: The clutch assembly (212) includes the armature (212a) and rotor (212b). The armature and rotor must be replaced together so they wear evenly.

NOTE: If the pinion assembly (219) is not yet separated from the clutch housing (222), follow Steps 1 to

4. Otherwise, start at Step 5.

NOTE: Refer to Fig. 11 for this procedure.

Clutch

4. Tap lightly on the back of the bearing housing (11) with a plastic mallet to loosen the drive housing assembly (5) from the clutch housing (222). Pull the assembly away.

5. Remove the armature (212b) from the hub inside the pinion housing (219).

6. There are two ways to remove the rotor (212a).

WARNING




a. Remove the four screws (213). Install two of the screws in the threaded holes in the rotor.

Alternately tighten the screws until the rotor comes off.

1. Relieve the pressure.

2. Disconnect the hose (63). Remove the spring clips

(49,52) and drain hose (51).

3. Remove the bottom two screws (3) and lockwashers (4) from the clutch housing (222) and then remove the top three screws and lockwashers.

b. Use a standard steering wheel puller (A) and two 1/4–22 x 3 or 4 in. long screws (B). Replace the short screws of the steering wheel puller with the longer screws (B). Turn the screws (B) into the threaded holes of the rotor.

Tighten the long screw (C) until the rotor comes off. See the Detail in Fig. 11.

222

Skip ahead to Reassembly, page 21, Step 2, or continue on page 19.

4

3

212b

213

215

212a

219

5

52

51

49

63

11

DETAIL

222

A

B

C

Fig. 11

18 308–327

02699

210

Fig. 12

See Fig 13 for a detail of where 64 connects

Field and Wiring Harness

211

NOTE: Refer to Fig. 12.

1. Pull the plastic caps (A) off the wire screws (22) in both places on the field. Loosen the screws and release the wires (64).

2. Loosen the four setscrews (211). Pull off the field

(210).

3. Skip ahead to Reassembly, page 21, Step 1 or continue on page 19.

64

22

A

02702

Ref 64

Ref 206

Fig. 13

Alternator

2. Remove the screws (43) and belt guard (35).

Remove the belt (40). See Fig. 15.

7210A

A

95

35

43

B

40

222

100

Fig. 14 7209

A

Disassembly

1. Remove the engine. Loosen the knob (95). Grasp the engine as shown in Fig. 14 and raise side A.

Slide the engine out of the channel (B).

Fig. 15

3. Remove the clutch housing (222) by removing screws (100) from below the cart. See Fig. 15.

NOTE: This procedure is continued on page 20.

308–327 19

Alternator

202

200

201

A

207

205

204

202

222

204

203

221

220

201

207

208

206

205

C

Fig. 16

B

209

See Fig. 13 for a detail of where 206 connects

NOTE: Refer to Fig. 16 which also shows the assembly in a cutaway view.

4. Remove the screws (A) from the bushing (201) and screw them into the threaded holes of the bushing. Tighten the screws until the sheave (202) separates from the bushing. Remove these parts and the key (200).

NOTE: If necessary, use a steering wheel puller as described in Step 6.b on page 18.

5. Remove the retaining ring (203).

6. Press the shaft (B) of the alternator shaft rotor

(209) to free it from the clutch housing.

NOTE: The bearing (204) must be replaced if you remove the alternator rotor shaft (209).

7. Remove the cable clamp (220) and screw (221).

8. Remove the screws (207) and lockwashers (208) and the stator (206).

9. Remove the retaining ring (205).

10. Remove the bearing (204) from inside the clutch housing (222).

Reassembly

1. Clean all parts.

2. Reassemble in the reverse order of disassembly.

Route the wires of the stator (206) through the clutch housing (222) and through the hole (C) in

20 308–327

Fig. 17

209

206

CUTAWAY VIEW

41

B

222

D, 203

02728 the mounting bracket. When pressing the shaft

(209) through the bearing (204), press it until the groove D is exposed, then install the retaining ring

(203).

3. Mount the engine or motor (1) without the belt guard in place. Place a straight edge (E) along the surfaces of the clutch pulley (202) and engine pulley (41) as shown in Fig. 17 to be sure they are vertically aligned. Readjust the bushing screws (A) as needed to align the pulleys and recheck the alignment.

222

E

202

1

02747

Reassembly

1. Install the field (210) in the clutch housing (222).

Working through the slot in the clutch housing, connect the wires of the harness (64) to the screws (22) in both places on the field. Pull the plastic caps (A) up and snap them over the screws. With the setscrew holes in the field and the clutch housing aligned, tighten the setscrews

(211) oppositely and evenly, to 27 in-lb (3.2 N.m).

See Fig. 18.

3. Be sure the face of the armature (212b) is clean.

Assemble the armature to the hub in the pinion housing (219). A retaining ring located within the armature makes it difficult to assemble these parts. Follow this procedure for the best results.

First, engage a few splines of both parts. While they are engaged, use a screwdriver to gently push the retaining ring into the armature, and finish engaging the splines. Push the armature onto the shaft until it contacts the ring. See Fig. 19.

Torque to 27 in-lb (3.2 N.m)

210

211

4. Assemble the pinion housing (219) to the clutch housing, using the capscrews (3) and lockwashers

(4). See Fig. 19.

22

A

02702 Fig. 18

2. Be sure the face of the rotor (212a) and the field

(210) is free of all oil and contaminants. Remove any burrs on the outside edge of the rotor. Install the rotor, lockwashers (215) and capscrews (213).

Torque the capscrews to 7 ft-lb (9.5 N.m). See Fig.

19.

After installing the rotor (212a), pull the engine recoil rope to assure the engine turns freely, and there is no friction between the rotor (212a) and the field (6). If there is friction, loosen the setscrews (12) and reposition the field. Tighten the setscrews oppositely and evenly to 27 in-lb

(3.2 N.m).

5

219

212b

213

215

212a

222

4 3

Fig. 19

Torque to 7 ft-lb (9.5 N.m)

02699

308–327 21

Pressure Control Replacement

WARNING




4. Remove two screws (54) from filter bracket (111).

See Fig. 22.

5. Disconnect the filter (18) from the pressure control

(74) while holding nipple (317) firmly.

6.

Remove the screws (67) and lock washers (110) from the back mounting bracket (76) and remove the pressure control (74).

1

2

To the pump.

To the filter.

Front view

318

18 317 74

63

2 1

63

Fig. 20

1.

Relieve pressure.

06873

CAUTION

DO NOT allow the elbow (318) to turn when removing or connecting the hose. Turning the elbow can damage the pressure control.

2. Disconnect the hose (63) while holding elbow

(318) firmly. See Fig. 20.

3. Working under the cart, disconnect the wires (A).

See Fig. 21.

54

Fig. 22

111

76

67

110

7211A

Fig. 21

A

308–327

7210A

Pressure Control Replacement

7. Remove the four mounting screws and washers

(302, 303, 304) from the pressure control cover

(301). See Fig. 23.

8. Carefully remove the pressure control cover (301) so as not to stress the cables.

304

301

302

B

C

317

310

9. Disconnect the black and white wires of the pressure control cable (314) from the pressure control cover.

304

303

10. Disconnect the potentiometer cable assembly

(310) from the pressure control cover.

Fig. 23

11. Disconnect the red power lead (B) from the

ON/OFF switch.

WARNING

Do not attempt to adjust or calibrate the pressure control. If the pressure control is faulty, replace it.

314

06872A

12. Loosen the ground terminal screw (317) and disconnect the ground lead (C).

13. Pull off the pressure control cover.

14. Reassemble in the reverse order; attach ground wire (C), power lead (B), and the black and white connectors. Attach the pressure control cover

(301) with the four mounting screws and washers

(302, 303, 304). Torque the mounting screws to

22 2 in-lb (2.5 0.23 N m).

308–327 23

Displacement Pump

WARNING




Removing the pump.

(See Fig. 24.)

1. Relieve pressure.

Repairing the pump.

See manual 307–806 for displacement pump repair.

Installing the pump.

(See Fig. 25.)

1. Screw the pump about 3/4 of the way into the bearing housing (21). Hold the pin (25) up to the pin hole on the connecting rod (22) and continue screwing in the pump until the pin slides easily into the hole.

2. Flush the pump. See page NO TAG.

2. Back off the pump until the top threads of the pump cylinder are flush with the face of the bearing housing and the outlet nipple faces back.

3. Remove the hose (55). Remove the two spring clips (74, 80) and drain hose (76).

4. Push the retaining spring (26) up. Push the pin

(25) out the rear.

3. Push the retaining spring (26) into the groove all the way around the connecting rod. Tighten the locknut (27) to 90 ± 5 ft-lb (122 ± 6.8 N m) using a wrench and a light hammer.

5. Loosen the locknut (27). Unscrew the pump.

4. Connect the pump outlet hose. Install the suction tube parts. Install the spring clips and drain hose.

The face of the bearing housing.

Torque to 90 ± 5 ft-lb (122 ± 6.8 N m)

26

55 25

27

28

80, 74

76

25

22

26

27

21

7179A

Fig. 24 Fig. 25 0031

24 308–327

Notes

308–327 25

Model 231–316, Series A

1

2

3

See alternate view of 74 below

See exploded view on page 28

See parts in manual 307–806

Parts – Basic Sprayer

4 See engine detail on page 27

5 See parts on page 30

5a

5b

16

6

5

8

10

4

Ref 219d

2

78

53

72

73

11

5c

96

37

7

77

46

Ref 63

4

21

44

3

2

13

3

14

12

47

15

52

51

50

49

89

1

17

45

100

95

94

18

71,

112 74 5

Ref 63

44

66

119

90

21

54

60

118

111

Ref 51

76

67

110

120

45

40

102

25

43

35

4

27

30

31

32

33

7213A

26 308–327

Parts – Basic Sprayer

Model 231–316, Series A

Ref.

No.

4

5

5a

5b

5c

7

8

5d

6

10

11

12

13

14

15

16

17

18

1

2

3

35

37

38

39

40

41

43

44

52

53

54

60

63

46

47

49

50

51

21

22

25

27

28

29

30

31

32

33

34

Part No.

Description Qty.

802–264 ENGINE, 5.5 HP

236–397 CLUTCH HOUSING ALTERNATOR

See separate parts list on page 28

100–644 CAPSCREW, socket head,

1/4–20 x 3/4”

1

1

9

105–510 LOCKWASHER, spring, 1/4”

220–879 DRIVE HOUSING KIT

11

Includes replaceable items 5a to 5d 1

106–227 . WASHER, bronze colored

183–209 . WASHER, silver colored

100–069 . BALL

1

1

1

110–293 . TUBE OF GREASE

185–953 LABEL, Danger

188–423 COVER, housing

220–640 CONNECTING ROD KIT

108–849 CAPSCREW, sckt hd, 1/4–20 x 3”

220–639 BEARING HOUSING

183–210 PIN, straight, 3/8 x1/8”

2

1

1

1

1

1

1

183–169 SPRING, retaining

189–969 NUT, hex, 1 13/16–16

220–872 PUMP See parts in manual 307–806 1

220–919 GEAR REDUCER

1

1

109–099 BUSHING, snap

239–286 FLUID FILTER;

1

2

See manual 307–273 for other parts 1

4 112–583 PLUG

108–860 SCREW, No. 8–32 x 1/4”

Shown on page 28

112–798 SCREW, thread forming

237–686 GROUNDING CLAMP & WIRE

102–556 RIVET, blind (not shown)

187–112 PLATE, designation (not shown)

179–811 WHEEL, semi–pneumatic

154–636 WASHER, 5/8”

101–242 RING, retaining

104–811 HUBCAP

110–837 FLANGE SCREW, hex hd,

5/16–18 x 1–1/2” 4

2

2

1

2

2

1

2

2

1

236–378 BELT GUARD 1

108–859 SCREW, 5/16–18 x 3/8” shld, 1/2” thd 2

183–401 KEY, parallel, 3/16” sq x 7/8”

109–581 BUSHING

109–582 BELT, 3V

109–580 SHEAVE

112–161 FLANGE SCREW, 1/4–20 x 1/2”

1

1

1

1

4

110–963 FLANGE SCREW, hex hd,

5/16–18 x 3/4 ”

112–746 NUT, retainer

183–461 NIPPLE, 3/8–18 npsm x 1/4–18 npt

181–102 CLIP, spring

183–423 TUBE, intake

186–495 TUBE, bypass

186–490 CLIP, spring

189–918 HANGER, pail

110–997 SCREW, flange hex hd, 1/4–20 x 5/8” 2

237–677 PRESSURE DRAIN VALVE 1

222–516 FLUID HOSE, 3/8” ID, 3/8” npt couplings, 2.5 ft. long, spring guards 1

1

1

1

1

3

2

1

1

Ref.

No.

Part No.


64

65

66

67

71

72

73

74

76

77

78

88

89

90

91

105

106

110

111

118

112

119

93

94

95

96

97

100

102

104

220–980 HARNESS, wiring, Shown on page 28 1

108–842 SCREW, cap, flange, 5/16–24 x 3/4” 4

112–386 PIN

101–344 SCREW, cap, 10–24 x 1/2”

290–375 LABEL, identification, control, top

1

3

1

110–141 CAPSCREW, 3/8–16 x 1–1/2”

106–115 LOCKWASHER, spring, 3/8 ”

239–662 PRESSURE CONTROL

See parts on page 30 1

192–225 PRESSURE CONTROL BRACKET 1

290–436 IDENTIFICATION LABEL, front cover 1

4

4

108–850

181–867

187–147

239–521

SCREW, No. 8–32 x 1–1/4”

LABEL, Warning

STRAINER

CART

206–994 THROAT SEAL LIQUID,

8 oz (0.27 liter)

236–529 MOUNTING BASE

1

1

4

1

1

1

236–388 EYE BOLT

112–392 KNOB

236–402 CART HANDLE

236–376 ENGINE GUARD

112–395 SCREW, 3/8–16 x 3/4”

177–144 LABEL, Warning

189–679 LABEL, caution (not shown)

112–756 SCREW, cap, socket hd 3

110–838 LOCKNUT, w/nylon insert, 5/16–18 4

100–214

237–831

WASHER, lock

BRACKET, filter

113–983 RING, retaining, external 1

290–437 LABEL, identification, control, bottom 1

3

1

112–818 SCREW, cap, hex, hd, flange

3

1

1

1

1

1

1

1

Replacement Danger and Warning labels, tags and cards are available at no cost.

1

88

38

41

65

39

97

93

34

308–327

02708

27

1

219b

219c

219d

1

219a

02697

Parts – Clutch Housing Alternator

217

219e

202

200

201

218b

218c

218e

218a

3

218d

218f

4

5

205

204

203

209

207

208

206

221

220

214

215

222

211

210

214

215

218

212b

213

214

212a

219

22

64 02737

1 Lubricate exterior

2

Lubricate inner and outer diameters

3

4

Lubricate teeth

Press fit before 218f

5 Press fit after 218d

Ref No. 2

Part No. 236–397

CLUTCH HOUSING ALTERNATOR KIT

Includes items 200 to 222

Ref.

No.

Part No.

Description

211

212

212a

212b

213

214

215

217

205

206

207

208

209

210

200

201

202

203

204

183–401 KEY

109–581 BUSHING

109–580 SHEAVE

112–132 RETAINING RING, 0.693”

112–126 BALL BEARING

112–128 RETAINING RING, 2.054”

236–395 GENERATOR STATOR

112–143 SCREW, pan head, 10–24 x 1”

100–020 LOCKWASHER

236–395 ALTERNATOR SHAFT ROTOR

188–425 FIELD

108–801 SETSCREW, 1/4–20 x .31”

221–031 CLUTCH, includes 212a and 212b

. ROTOR

. ARMATURE

112–142 CAPSCREW, 1/4–28 x 3/4”

105–510 LOCKWASHER, spring, 1/4”

100–644 CAPSCREW, 1/4–20 x 3/4”

108–799 RETAINING RING

Qty.

4

9

5

1

1

4

1

1

4

4

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

218 236–394 PINION OUTPUT SHAFT KIT

Includes replaceable items

218a to 218f

218a 188–812 . PINION OUTPUT SHAFT

218b 112–141 . RETAINING RING

218c 108–798 . BALL BEARING

218d 112–139 . NEEDLE BEARING, small

218e 108–796 . RETAINING RING

218f 112–140 . NEEDLE BEARING, large

219 236–398 PINION HOUSING KIT

Includes replaceable items

219a to 219e

219a 188–793 . PINION HOUSING

219b 108–692 . NEEDLE BEARING, large

219c 107–088 . NEEDLE BEARING, small

219d 100–069 . BALL

219e 105–489 . PIN

220 112–145 CABLE CLAMP

221

222

112–144 SCREW, pan head, 8–32 x 1/4”

188–791 CLUTCH HOUSING

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

28 308–327

Model 231–331

Includes items 125 to 128

Parts – Complete Sprayer

126

Ref.

No.

125

126

127

128

Part No.


231–316 CONVERTIBLE GM5000 Basic Sprayer

See parts list on page 27 1

238–361 HOSE, grounded, nylon; 1/4” ID; cpld 1/4 npsm(fbe); 50 ft (15 m);’ spring guards both ends

238–358 HOSE, grounded, nylon; 3/16” ID;

1 cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;

3 ft (0.9 m); spring guards both ends 1

220–955 “CONTRACTOR” SPRAY GUN

Includes RAC IV DripLess Tip Guard and 517–size SwitchTip

See 307–614 for parts 1

128

127

0160

308–327 29

Parts – Pressure Control

Basic Pressure Control for the GM5000 Convertible Sprayer

Ref

No.

Part No.

Description Qty

301

302

303

304

305

306

307

308

309

310

311

239–519 ENGINE CONTROL BOARD

107–251 SCREW, panhead, 10–24 x 1 in.

112–610 SCREW, panhead, 10–24 x 2 in.

100–020 LOCKWASHER, No. 10

189–095 HOUSING, 1

112–614 PLUG

111–930 TOGGLE SWITCH

107–255 GUARD

105–659 BOOT

236–352 POTENTIOMETER, pressure adjustment

108–358 SEAL

Parts Drawing –

Pressure Control

309

308

319

307

317

318

313

312

311

305

302

304

310

314

316

1

1

1

1

1

1

2

4

1

2

Ref

No.

Part No.

Description Qty

312

313

314

315

316

317

318

319

112–373 KNOB

185–565 LABEL

237–674 CONDUCTOR

109–078 CONNECTOR

112–376 LOCKNUT

100–078 SCREW, hex head, 8–24 x .375 in.

189–286 LABEL, warning

189–246 LABEL, warning

Replacement Danger and W arning labels, tags, and cards are available free.

1

1

1

1

1

1

1

1

Wiring Schematic –

Pressure Control

310

301 307

WHITE

301

303

315

306

05799B

GREEN

GROUND

1

2

To engine

To clutch field

BLACK

314

1

2

2

RED

03496

30 308–327

Manual Change

Summary

This manual was revised to add a freeze-resistant pressure control ( 239–518) to replace the older Bourdon Tube pressure control ( 222–369) .

Technical Data

Engine . . . . . . . . . . . . . . . . . . . .

Maximum Working Pressure

5.5 Horsepower, Honda

. . . . . . 3000 psi (210 bar)

Cycles/Gallon (liter)

Maximum Delivery

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

104 (28)

1.25 gpm (4.7 liter/min)

Fuel Tank Capacity

Maximum Tip Size

. . . . . . . . . . . 0.95 gallons (3.6 liter)

. . . . . . . . . . . . . . 1 gun with 0.035 tip

Inlet Paint Strainer . . . . . . . . . . .

2 guns with 0.025 tip

16 mesh (1190 micron)

Stainless steel screen, reusable

Outlet Paint Filter

Pump inlet Size

Fluid Outlet Size

. . . . . . . . . . . . . 60 mesh (250 micron)

Stainless steel screen, reusable

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

3/4 npt (m)

1/4 npsm from fluid filter

Wetted Parts

Displacement Pump . . Stainless steel, Carbon steel,

Polyurethane, UHMW polyethylene,

Filter . . . . . .

NOTE: Delrin

Delrin , Leather

Aluminum, Carbon steel, Stainless steel

Dimensions

Weight (dry, without packaging)

Height

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

145 lb (66 kg)

31.6 in. (803 mm)

Length

Width

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

30.5 in. (775 mm)

22.5 in. (572 mm)

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

Accessories

DISPLACEMENT PUMP REPAIR KIT 220–877

* These parts are included in the repair kit. Repair instructions are in manual 307–806 and are also included with the kit. Purchase separately.

SLEEVE REMOVAL TOOL 224–788

Required for removing the displacement pump sleeve.

Purchase separately.

DANGER LABELS

The English language DANGER label shown on page 4 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. Toll Free: 1–800–328–0211

Apply other language here

French 185–956

Spanish 185–961

German 186–041

Greek 186–045

Korean 186–049

English 185–593

03497A

308–327 31

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 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 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 or 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.

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, gas engines, 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.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty

Program”.

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.

32 308–327

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. 308–327 October, 1993, Revised May 1997

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