Graco Inc Paint Sprayer 233710 User Manual

INSTRUCTIONS-PARTS LIST  
This manual contains important  
warnings and information.  
READ AND KEEP FOR REFERENCE.  
INSTRUCTIONS  
GMaxt 5900 Convertible  
Airless Paint Sprayers  
309411E  
–For Portable Airless Spraying of Architectural Coatings and Paints –  
5.5 HORSEPOWER, GASOLINE POWERED  
3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure  
Model Series  
Description  
Sprayer, gas powered  
233709  
233710  
A
A
R
Sprayer, gas powered, with RAC X tip,  
gun and hose  
233711  
233712  
233713  
233714  
233715  
A
A
A
A
A
Sprayer, gas powered, with electric  
motor kit  
Same as 233711 except with ETL  
approval to CSA and UL standards  
Sprayer, gas powered, with Lo-Boy  
suction set kit  
233709  
ti1852a  
Sprayer, gas powered, with RAC X tip,  
gun and hose and Lo-Boy suction set kit  
Sprayer, gas powered, with Lo-Boy  
suction set kit and electric motor kit  
Related Manuals  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
COPYRIGHT 2002, GRACO INC.  
Graco Inc. is registered to I.S. EN ISO 9001  
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WARNING  
SKIN INJECTION HAZARD  
Spray from the spray tip, hose leaks or ruptured components can inject fluid into your body and cause  
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin  
can also cause can also cause serious injury.  
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D Always have the tip guard and the trigger guard on the in-line valve when spraying.  
D Be sure the trigger safety lever operates before operating the in-line valve.  
D Lock the trigger safety lever when you stop spraying.  
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stop spraying; check, clean, or service any system equipment; or install or change spray tips.  
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nently coupled hoses cannot be repaired.  
D Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and  
hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures  
above 150_ F (65_ C) or below –40_ F (–40_ C).  
TOXIC FLUID HAZARD  
Hazardous fluids or toxic fumes can cause a serious injury or death if the fluid is swallowed or  
splashed in the eyes or on the skin or if the fumes are inhaled.  
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state and national guidelines.  
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personal respirator, gloves, and clothing.  
RECOIL HAZARD  
Due to the high pressure fluid emitted, a strong recoil action may occur when you trigger the pole gun.  
If you are unprepared, your hand could be forced back toward your body or you could lose your bal-  
ance and fall, resulting in serious injury.  
309411  
3
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WARNING  
FIRE AND EXPLOSION HAZARD  
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and  
result in fire or explosion and serious injury.  
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sprayed.  
D Extinguish all the open flames or pilot lights in the spray area.  
D Electrically disconnect all the equipment in the spray area.  
D Keep the spray area free of debris, including solvent, rags, and gasoline.  
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.  
D Do not smoke in the spray area.  
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correct the problem.  
EQUIPMENT MISUSE HAZARD  
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result  
in serious injury.  
INSTRUCTIONS  
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distributor.  
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.  
D Check the equipment daily. Repair or replace worn or damaged parts immediately.  
D Do not exceed the maximum working pressure of the lowest rated system component. This equip-  
ment has a 3600 psi (25 MPa, 248 bar) maximum working pressure.  
D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not  
expose Graco hoses to temperatures above 150_ F (65_ C) or below –40_ F (–40_ C).  
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D Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical  
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.  
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bends near the couplings.  
D Comply with all applicable local, state and national fire, electrical and other safety regulations.  
D Wear hearing protection when operating this equipment.  
HAZARD OF USING FLUIDS CONTAINING HALOGENATED HYDROCARBONS  
Never use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids  
containing such solvents in this equipment. Such use could result in a serious chemical reaction, with  
the possibility of explosion, which could cause death, serious injury and/or substantial property dam-  
age.  
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc  
parts.  
4
309411  
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Component Identification and Function  
Pump On/Off Switch  
Pressure Control  
Engine On/Off Switch  
Engine Controls  
Prime/Drain Valve  
ti1852a  
Motor On/Off Switch  
Spray Gun Trigger Lock  
Reference your Spray Gun Manual  
ti1854a  
309411  
5
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Maintenance  
CAUTION  
For detailed engine maintenance and specifications,  
refer to separate engine manual, supplied.  
WARNING  
INJECTION HAZARD  
System pressure must be manually  
relieved to prevent system from starting  
or spraying accidentally. Fluid under high  
pressure can be injected through skin and cause  
serious injury. To reduce risk of injury from injec-  
tion, splashing fluid, or moving parts, follow Pres-  
sure Relief Procedure whenever you:  
DAILY: Check engine oil level and fill as necessary.  
Manual 309410.  
DAILY: Check that V-belt (60) is centered on pulleys  
and is not inverted. Replace if worn or damaged.  
D are instructed to relieve pressure,  
D stop spraying,  
DAILY: Check and fill gas tank.  
DAILY: Check hoses for wear and damage.  
DAILY: Check gun safety for proper operation.  
D check or service any system equipment,  
D or install or clean spray tip.  
DAILY: Check pressure drain valve for proper opera-  
tion.  
Pressure Relief Procedure  
AFTER THE FIRST 20 HOURS OF OPERATION  
AND EACH 100 HOURS THEREAFTER: Change  
engine oil.  
1. Lock gun safety latch.  
2. Turn engine or electric motor ON/OFF switch to  
OFF.  
DAILY: Keep TSL in packing nut to help lubricate  
pump packings. One full squirt of TSL is usually  
enough.  
3. Unplug power supply cord (electric motor).  
4. Move pressure control switch to OFF and turn  
pressure control knob fully counterclockwise.  
WEEKLY: Remove cover of air filter (C) and clean  
element. Replace element, if necessary. If operating in  
an unusually dusty environment, check filter daily and  
replace it, if necessary.  
5. Rotate RAC 5 tip, if used, to reverse position.  
6. Unlock gun safety latch. Hold metal part of gun  
firmly to grounded metal pail. Trigger gun to relieve  
pressure.  
7. Lock gun safety latch.  
Repack connecting rod (22) top needle bearing after  
every pump change.  
8. Open pressure drain valve. Leave pressure drain  
valve open until ready to spray again.  
Replacement elements can be purchased from your  
local HONDA dealer.  
If suspected that spray tip or hose is completely  
clogged, or that pressure has not been fully relieved  
after following steps above, VERY SLOWLY loosen tip  
guard retaining nut or hose end coupling to relieve  
pressure gradually, then loosen completely. Now clear  
tip or hose obstruction.  
SPARK PLUG: Use only an BPR6ES (NGK) or  
W20EPR–U (NIPPONDENSO) plug. Gap plug to  
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug  
wrench when installing and removing plug.  
6
309411  
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Troubleshooting  
Relieve pressure; page 6.  
PROBLEM  
CAUSE  
SOLUTION  
E=XX is displayed  
Engine won’t start  
Fault condition exists  
Engine switch is OFF  
Engine is out of gas  
Engine oil level low  
Determine fault correction from table, page 14.  
Turn engine switch on.  
Refill gas tank. Honda Engines Owner’s Manual.  
Try to start engine. Replenish oil, if necessary.  
Honda Engines Owner’s Manual.  
Spark plug cable disconnected or  
spark plug damaged  
Connect spark plug cable or replace spark plug.  
Oil seepage into combustion  
chamber  
Remove spark plug. Pull starter rope 3 or 4 times.  
Clean or replace spark plug. Try to start engine.  
Keep sprayer upright to avoid oil seepage.  
False tripping of WatchDog  
system. EMPTY is dis-  
Operating conditions out of WatchDog  
parameters  
Turn pressure down. Contact Graco Technical Ser-  
vice to adjust WatchDog parameters.  
Operate without WatchDog active; Manual 309410.  
played. Pump does not run.  
Low pump output; page 8.  
Pressure control switch turned OFF  
Pressure setting too low  
Turn on.  
Engine operates, but dis-  
placement pump doesn’t  
Increase pressure.  
Clean filter.  
Displacement pump outlet filter dirty  
Tip or tip filter clogged  
Clean tip or tip filter.  
Replace belt.  
Broken drive belt  
Displacement pump rod seized by  
dry paint  
Service pump. See page 16.  
Connecting rod worn or damaged  
Drive housing worn or damaged  
Replace. See page 9.  
Replace. See page 10.  
Electrical power is not energizing clutch field Check wiring connections. Page 23.  
Reference pressure control repair. Page 14.  
Reference wiring diagram. Page 23.  
With pump switch ON and pressure turned to  
MAXIMUM, use a test light to check for power be-  
tween clutch test points on control board.  
Remove 7–pin connector from control board and  
measure resistance across clutch coil. At 70_ F,  
the resistance must be 1.7 0.2Ω; if not, replace  
pinion housing.  
Have pressure control checked by authorized Gra-  
co dealer.  
Clutch is worn, damaged, or incorrectly  
positioned  
Replace clutch. Page 11.  
Pinion assembly is worn or damaged  
Repair or replace pinion assembly. Page 11.  
309411  
7
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PROBLEM  
CAUSE  
SOLUTION  
Strainer (31) clogged  
Clean.  
Pump output low  
Piston ball (25) not seating  
Piston packings worn or damaged  
Displacement pump o-ring (227) is damaged  
Intake valve ball not seating properly  
Engine speed is too low  
Service piston ball check. Manual 309277.  
Replace packings. Manual 309277.  
Replace o-ring. Manual 309277.  
Clean and service. Manual 309277.  
Increase throttle setting. See Manual 309410.  
V–belt slipping  
Tighten V–belt with tension bar (101). Adjust  
bracket until it takes 15 lb of force to lock  
tension bar down.  
Clutch worn or damaged  
Pressure setting is too low  
Replace. See page 11.  
Increase pressure. Manual 309410.  
Clean filter. Manual 309410 or 309091.  
Fluid filter (318), tip filter or tip is clogged or  
dirty  
Large pressure drop in hose with heavy  
materials  
Use larger diameter hose and/or reduce overall  
length of hose. Use of more than 100 ft of 1/4  
in. hose significantly reduces performance of  
sprayer. Use 3/8 in. hose for optimum perfor-  
mance (50 ft minimum).  
Excessive paint leakage into Throat packing nut is loose  
throat packing nut  
Remove throat packing nut spacer. Tighten  
throat packing nut just enough to stop leakage.  
Throat packings worn or damaged  
Displacement rod worn or damaged  
Replace packings. Manual 309277.  
Replace rod. Manual 309277.  
Spitting from gun  
Air in fluid pump or hose  
Check and tighten all fluid connections.  
Reprime pump. Manual 309410.  
Tip partially clogged  
Clear tip. Manual 309091.  
Fluid supply is low or empty  
Refill and prime pump. See Startup, Manual  
309410. Check fluid supply often to prevent  
running pump dry.  
Pump is difficult to prime  
Air leak  
Check and tighten all fluid connections.  
Reduce engine speed and cycle pump as  
slowly as possible during priming.  
Intake valve is leaking  
Shut off pump and relieve pressure. Disas-  
semble and clean intake valve. Be sure ball  
seat is not nicked or worn and that ball seats  
well. Reassemble.  
Worn packings  
Fluid is too thick  
Repack pump. Manual 309277.  
Thin fluid according to supplier’s recommenda-  
tions.  
Engine speed is too high  
Decrease throttle setting before priming pump.  
Manual 309410.  
Clutch squeaks each time  
clutch engages  
Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other.  
when new and may cause noise  
Noise will dissipate after a day of run time  
Reset throttle to 3700 engine rpm at no load  
Replace or service engine governor  
Misadjusted throttle setting  
High engine speed at no  
load  
Worn engine governor  
Gallon counter not working  
Bad sensor, broken or disconnected wire  
Check connections. Replace sensor or wire.  
Check connections. Replace display.  
No display, sprayer operates Display damaged or has bad connection  
8
309411  
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Bearing Housing and Connecting Rod  
Removal  
2. Assemble connecting rod (40) and bearing  
housing (60).  
1.  
Relieve pressure; page 6.  
3. Clean mating surfaces of bearing and drive hous-  
ings (60, 3).  
2. Stop sprayer at bottom of stroke to get crank (E) in  
lowest position. To lower crank manually, remove  
spark plug and carefully rotate crank by pulling  
starter rope.  
4. Align connecting rod (C) with crank (E) and drive  
housing locating pins (3b) with bearing housing  
(60) holes. Push bearing housing onto drive hous-  
ing or tap into place with plastic mallet.  
3. Fig. 2. Remove front cover (38). Unclip drain hose  
(74) from pump. Unscrew pump suction tube (73)  
from pump. Disconnect pump hose (167).  
CAUTION  
Do not use bearing housing screws (19) to align or  
seat bearing housing; this may cause bearing and  
drive housing misalignment and result in premature  
bearing wear.  
4. Push up retaining spring (59). Push pin (58) out  
rear.  
58  
5. Install screws and lockwashers (20, 19). Tighten  
screws evenly to 25 ft-lb (34 Nm).  
6. Install pump; page 16.  
7. Fig. 2. Install remaining parts.  
2
C
1
B
59  
2
7675B  
Fig. 1  
D
40  
5. Loosen locknut (57). Unscrew displacement  
pump (48).  
3
20, 19  
38  
6. Remove four screws and lockwashers (20, 19).  
E
7. Tap lower rear of bearing housing (60) with a  
plastic mallet to loosen from drive housing (3). Pull  
bearing housing and connecting rod assembly (40)  
straight off drive housing.  
3
107  
3b  
59  
72  
58  
8. Remove pail hanger (105) and install it on new  
bearing housing.  
167  
62  
48  
57  
60  
74  
9. Inspect crank (E) for excessive wear and replace  
parts as needed.  
A
105  
Installation  
73  
1
2
3
Oil  
1. Evenly lubricate inside of bronze bearing (B) in  
bearing housing (60) with high-quality motor oil.  
Liberally pack top roller bearing (C), lower bearing  
(D) inside connecting rod assembly (40) with  
bearing grease 114819.  
Pack with bearing grease 114819  
8697B  
Torque to 25 ft-lb (34 Nm)  
Fig. 2  
309411  
9
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Drive Housing  
Removal  
3. Install four screws (47) and lockwashers (37) to  
pinion housing (4) and drive housing (3).  
1.  
Relieve pressure; page 6.  
4. Install two screws (31) and lockwashers (37) to  
drive housing (3).  
2. Disconnect reed switch (A).  
3. Fig. 3. Remove bearing housing. Do Removal of  
Bearing Housing and Connecting Rod proce-  
dure on page 9.  
5. Fig. 3. Install bearing housing. Do 1. through 6. of  
Bearing Housing and Connecting Rod proce-  
dure on page 9.  
4. Remove two screws (31) and lockwashers (37).  
5. Remove four screws (35) and lockwashers (34)  
from pinion housing (4).  
6. Connect reed switch (A).  
6. Lightly tap around drive housing (3) to loosen drive  
housing. Pull drive housing straight off pinion  
housing (4). Be prepared to support gear cluster  
(36) which may also come out.  
1
35  
34  
A
4
CAUTION  
Do not drop gear cluster (36) when removing drive  
housing (3). Gear cluster is easily damaged. Gear  
may stay engaged in drive housing or pinion housing.  
2
3h  
3g  
3
37  
Installation  
B
1. Liberally apply bearing grease (supplied with re-  
placement gear cluster) to gear cluster (36) and to  
areas called out by note 2. Use full 0.68 pint (0.32  
liter) of grease.  
1
31  
62  
36  
61  
62  
2. Place bronze colored washer (3g) on shaft protrud-  
ing from large shaft of drive housing (3). Note: If  
replacing a washer with pin holes with a washer  
without pin holes, remove guide pins from housing.  
Place silver colored washer (3h) on pinion housing.  
Assemble washers (61) and (62) onto gear (36).  
Align gears and push new drive housing straight  
onto pinion housing and locating pins (B).  
A
1
Torque to 200 in-lb  
2
Apply remaining grease to these areas  
Ti1889a  
Fig. 3  
10  
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley  
Removal  
6. Remove four screws (16) and lockwashers (37).  
Install two screws in threaded holes (E) in rotor.  
Alternately tighten screws until rotor comes off.  
1. If pinion assembly (4) is not removed from clutch  
housing (169), do 2. through 5. Otherwise, do 2.  
and then start at 6.  
16  
37  
2.  
Relieve pressure; page 6.  
E
3. Disconnect field cable (X) from pressure control  
and reed switch (A).  
8701B  
Fig. 6  
7. Fig. 7. Remove retaining ring (169b).  
8. Tap pinion shaft (169c) out with plastic mallet.  
169b  
169c  
A
8703B  
Bottom View  
Fig. 7  
ti1842a  
X
Fig. 4  
9. Fig. 9. Remove belt guide bracket (171), belt guard  
(117) and vee belt (103).  
4. Fig. 5. Remove five screws (47) and lockwashers  
(37) and pinion assembly (4).  
10. Hold pulley (53) and remove four screws (88) and  
washers (37) from hub (94). Remove armature  
(86) and spacer (169f).  
47  
37  
4
11. Engine Detail, page 20. Remove screw (101) and  
washer (166) from engine drive shaft. Remove  
pulley (53) and motor shaft sleeve (170). Remove  
pulley and key (41).  
12. Fig. 9. Remove three screws (63) from beneath  
mounting plate (D).  
47  
37  
ti1888a  
13. Lift off clutch housing (169).  
Fig. 5  
5. Fig. 6. Place pinion assembly (4) on bench with  
rotor side up.  
14. Remove retaining ring (169b). Pull jack shaft as-  
sembly (169c) out.  
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley  
Installation  
8. Hold pulley (53) and install four screws (88) and  
washers (37) in hub (94). Torque to 125 in-lb  
(14 Nm).  
1. Fig. 9. Install jack shaft assembly (169c). Install  
retaining ring (169b).  
9. Install belt guard (117), belt guide bracket (171)  
and vee belt (103).  
2. Fig. 8. Lay two stacks of two dimes on smooth  
bench surface.  
10. Fig. 7. Tap pinion shaft (169c) in with plastic  
mallet.  
3. Lay armature (86) on two stacks of dimes.  
4. Press hub (94) down on bench surface.  
11. Install retaining ring (169b).  
86  
94  
12. Fig. 6. Place pinion assembly on bench with rotor  
side up.  
0.12 .01 in. (3.0 .25 mm)  
13. Apply Loctite to screws. Install four screws (16)  
and lockwashers (37). Alternately torque screws  
to 125 in-lb until rotor is secure.  
dimes  
8705A  
Fig. 8  
14. Push pinion housing (4) assembly onto clutch  
housing (169e). Tap lightly on front of bearing  
housing (17) with a plastic mallet to push drive  
housing and pinion housing assembly onto clutch  
housing.  
5. Fig. 9. Place spacer (169f) and armature (94, 86)  
on jack shaft assembly (169c).  
6. Install three screws (63) through mounting plate  
(D) and into clutch housing (169).  
15. Install pinion assembly with five screws (47) and  
lockwashers (37).  
R
7. Apply Loctite to screw (101). Install screw,  
washer (166), key (41) and pulley (53) in end of  
jack shaft assembly (169c). End of jackshaft  
(169c) must be 0.090 in. below flush with end of  
bushing.  
16. Fig. 4. Connect field cable (X) to pressure control.  
17. Page 10. Do Drive Housing, Installation.  
41  
169e  
169f  
101  
166 53  
169b  
169c  
86  
94  
171  
117  
37  
88  
D
63  
103  
ti1853a  
Fig. 9  
12  
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On/Off Switch  
Removal  
Installation  
1. Install new ON/OFF switch (51) so tabs of switch  
1.  
Relieve pressure; page 6.  
snap into place on inside of pressure control  
housing.  
2. Fig. 10. Remove four screws (11) and  
display/cover (12).  
2. Connect ON/OFF switch connector (B) to PC  
board.  
3. Pull display connector wings (A) open on PC board  
and pull display connector out.  
3. Push display connector into PC board close dis-  
play connector wings (A) on PC board.  
4. Disconnect ON/OFF switch connector (B) from PC  
board.  
5. Press in on two retaining tabs on each side of  
ON/OFF switch (51) and remove switch.  
4. Install display/cover (12) with four screws (11).  
100a  
8
Ref 4  
44  
147  
44  
95  
A
147a  
100p  
100q  
12  
11  
B
176  
D
178  
E
141  
22  
33  
50  
51  
22  
13  
ti1849a  
Fig. 10  
309411  
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Pressure Control  
Control Board  
Removal  
Installation  
When installing replacement control board, follow  
instructions with control board to set model type.  
1.  
Relieve pressure; page 6.  
1. Fig. 10. Install control board (147) and jam nut  
(147a). Install connector (Ref 4) at backside of  
pressure control.  
2. Fig. 10. Remove four screws (11) and  
display/cover (12). Pull display connector wings  
open on PC board and pull display connector out.  
3. Fig. 17. Disconnect at control board (147):  
D Lead (D) from potentiometer.  
2. Install green ground wire and control board (147)  
with six screws (44).  
D
L
e
a
d
(
E
)
f
r
o
m
t
r
a
n
s
d
u
c
e
r
.
3. Fig. 17. Connect to control board (147):  
D
R
e
m
o
v
e
O
N
/
O
F
F
s
w
i
t
c
h
(
5
1
)
a
t
c
o
n
n
e
c
t
o
r
(
A
)
.
D Connect ON/OFF switch (51) connector (A).  
D Lead (E) to transducer.  
4. Fig. 10. Remove six screws (44) from control board  
(147) and green ground wire.  
D
L
e
a
d
(
D
)
t
o
p
o
t
e
n
t
i
o
m
e
t
e
r
.
5. Remove connector (Ref 4) at backside of pressure  
control. Remove jam nut (147a) and control board  
(147).  
4. Fig. 10. Push display connector into PC board  
close display connector wings on PC board. Install  
display/cover (12) with four screws (11).  
Pressure Control Transducer  
Removal  
5. Remove pressure control transducer (100q) and  
o-ring (100p) from filter housing (100e).  
Installation  
1.  
Relieve pressure; page 6.  
1. Fig. 10. Install o-ring (100p) and pressure control  
transducer (100q) in filter housing (100e). Torque  
to 30–36 ft-lb.  
2. Fig. 10. Remove four screws (11) and  
display/cover (12).  
2. Install transducer connector and rubber grommet  
(176) in control housing (8) . Install transducer  
guard (178) on control housing with two screws  
(141).  
3. Disconnect lead (E) from control board (147).  
4. Remove two screws (141) and transducer guard  
(178) from control housing (8). Pull transducer  
connector through rubber grommet (176).  
3. Connect lead (E) to control board (147).  
4. Install display/cover (12) with four screws (11).  
Pressure Adjust Potentiometer  
Removal  
Installation  
1. Install seal (33) on potentiometer (22).  
1.  
2. Fig. 10. Install pressure adjust potentiometer (22),  
shaft nut, lockwasher (22) and potentiometer knob  
(13).  
Relieve pressure; page 6.  
a. Turn potentiometer shaft (22) clockwise to  
internal stop. Assemble potentiometer knob  
(13) to strike pin on plate (50).  
2. Fig. 10. Remove four screws (11) and  
display/cover (12).  
3. Disconnect lead (D) from control board (147).  
b. After adjustment of step a., tighten both set  
screws in knob 1/4 to 3/8 turn after contact  
with shaft.  
4. Loosen set screws on potentiometer knob (13) and  
remove knob, shaft nut, lockwasher (22) and  
pressure adjust potentiometer (22).  
3. Connect lead (D) to control board (147).  
5. Remove seal (78) from potentiometer (22).  
4. Install display/cover (12) with four screws (11).  
14  
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Pressure Control Repair  
Digital Display Messages  
Relieve pressure before repair; page 6. No display does not mean that sprayer is not pressurized.  
DISPLAY  
SPRAYER  
OPERATION  
INDICATION  
ACTION  
No Display Sprayer may be pressurized.  
Loss of power or display  
not connected  
Check power source. Relieve  
pressure before repair or dis-  
assembly. Verify display is  
connected.  
Sprayer may be pressurized.  
Pressure less than  
200 psi (14 bar, 1.4 MPa)  
Increase pressure as needed  
Sprayer is pressurized. Power is ap-  
plied. (Pressure varies with tip size and  
pressure control setting.)  
Normal operation  
Spray  
psi  
bar  
MPa  
Sprayer stops. Engine is running.  
Exceeded pressure limit  
Remove any filter clogs or  
flow obstructions. Make sure  
gun trigger is locked open if  
using AutoClean valve.  
Sprayer stops. Engine is running.  
Sprayer stops. Engine is running.  
Pressure transducer faulty, Check transducer connections  
bad connection or broken  
wire.  
and wire. Replace transducer  
or control board, if necessary.  
High clutch current  
1. Check clutch 7–pin bulk-  
head connector. Clean  
contacts.  
2. Measure 1.7 0.2Ω  
across clutch field at 70_ F  
3. Replace clutch field as-  
sembly  
Sprayer stops. Engine is running.  
Display alternates E=06.  
High clutch temperature  
1. If clutch is new, let spray-  
er cool down and then re-  
start  
2. Inspect clutch. Replace  
clutch if there is excessive  
wear.  
3. Remove pump pin, sepa-  
rate pinion housing from  
clutch housing. Rotate  
rotor clockwise to check  
for excessive drag.  
Sprayer stops. Engine is running.  
Pressure greater than  
2000 psi (138 bar, 14 MPa)  
while in Flush Timer Mode  
1. Flush paint from hose be-  
fore operating Flush Timer  
Mode  
2. Verify AutoClean is acti-  
vated and gun valve and  
prime valve are open  
After a fault, follow these steps to restart sprayer:  
1. Correct fault condition  
2. Turn sprayer OFF  
3. Turn sprayer ON  
309411  
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Displacement Pump  
Removal  
58  
1. Flush pump.  
2.  
Relieve pressure; page 6.  
3. Fig. 11. Cycle pump with piston rod (222) in its  
lowest position.  
7675B  
Fig. 12  
4. Fig. 11. Remove suction tube (73) and hose (167).  
6. Fig. 13. Loosen jam nut by hitting firmly with a  
20 oz (maximum) hammer. Unscrew pump.  
222  
167  
73  
7672B  
Fig. 11  
5. Fig. 12. Use screwdriver: push retaining spring up  
7673B  
Fig. 13  
and push out pin (58).  
Repair  
See manual 309277 for pump repair instructions.  
Installation  
2. Fig. 12. Push pin (19) into hole. And push retaining  
spring into groove all the way around connecting  
rod.  
WARNING  
3. Fig. 15. Screw jam nut down onto pump until  
stops. Screw pump up into bearing housing until it  
is stopped by jam nut. Back off pump and jam nut  
to align pump outlet to back. Tighten jam nut by  
hand, then tap 1/8 to 1/4 turn with a 20 oz (maxi-  
mum) hammer to approximately 75" 5 ft–lb (102  
Nm).  
If pin works loose, parts could break off due to  
force of pumping action. Parts could project  
through the air and result in serious injury or prop-  
erty damage. Make sure pin and retaining spring  
are properly installed.  
CAUTION  
If the pump jam nut loosens during operation, the  
threads of the bearing housing will be damaged.  
Make sure jam nut is properly tightened.  
1. Fig. 14. Pull piston rod out 1.5 in. Screw in pump  
until holes in bearing cross link and piston rod  
align.  
7673B  
Fig. 15  
4. Fig. 16. Fill packing nut with Graco TSL, through  
one of the slits, until fluid flows onto the top of  
seal.  
1.5 in.  
7677B  
7676B  
Fig. 14  
Fig. 16  
16  
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Notes  
309411  
17  
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Parts – Basic Sprayer  
1
See exploded view on page 21  
Model 233709, Series A  
101 166 53 103  
DETAIL A  
2
See parts in manual 309277  
171  
5 Ref  
3
4
5
See Engine Detail on page 20  
See parts on page 22  
117  
175  
189  
See parts on page 24  
47  
37  
169  
123  
Label  
6
97  
99  
5
35  
188  
16  
102  
34  
37  
1
4
120  
20  
82  
3h  
3g  
36  
6
61 64  
3
124  
40  
31  
37  
87  
5
60  
19  
39  
5
63  
38  
72  
54  
6
1
62  
6
137  
3
6
106  
59  
DETAIL A  
58  
141  
151  
21  
121  
57 105  
167  
95  
107  
48 2  
23  
32  
115  
128  
102  
73  
74 Ref  
127  
71  
70  
100  
49  
140  
142  
139  
162  
110  
179  
18  
4
10  
81  
141  
152  
ti1845b  
74(Ref)  
18  
309411  
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Parts – Basic Sprayer  
Ref.  
No.  
Ref.  
Part No.  
Description  
Qty.  
No.  
Part No.  
Description  
Qty.  
3
4
245443  
245399  
HOUSING, drive (5900)  
HOUSING, pinion (5900)  
parts, page 21  
HANDLE, cart  
SWITCH, reed  
LABEL, crtl box cover, Ultra  
SCREW, cap, sch  
PLUG, tube  
WASHER, lock spring (hi–collar)  
SCREW, cap, socket hd  
SCREW, thread forming, hex hd  
CLAMP, grounding assy  
SCREW, cap, socket hd  
CORD, power, convertible  
WASHER, lock, spring  
SCREW, cap sch  
GEAR, combination  
WASHER, lock, spring hi-collar  
COVER, drive  
ROTOR, clutch, 5 in.; parts, page 24  
ROD, connecting  
SCREW, cap, sch  
PUMP, displacement  
CAP, hub  
PULLEY, engine  
LABEL, danger, English  
NUT, retaining  
1
1
76  
81  
82  
87  
88  
95  
97  
99  
206994  
FLUID, TSL 8 oz bottle  
LABEL, warning  
LABEL, instruction (English)  
STRAP, retaining  
SCREW, hex, socket head  
NIPPLE, adapter  
WASHER  
PIN, spring straight  
CLIP, axle  
SCREW, cap, hex hd  
FRAME, cart, convert.  
BELT, vee, 30 in.  
HANGER, pail  
NUT, hex  
SCREW, self–tap, filhd  
WHEEL, semi pneumatic, 12 in.  
CLIP, retainer  
1
1
1
1
4
1
2
2
2
1
1
1
1
2
4
2
2
1
4
1
2
4
2
1
9
2
3
1
1
3
2
2
1
1
1
2
1
4
1
195119  
195098  
114271  
108803  
162485  
183350  
108068  
198723  
112406  
245269  
193547  
192719  
112746  
114818  
198720  
114687  
198691  
108795  
114809  
191084  
116891  
198772  
198882  
112774  
198904  
109575  
245688  
198697  
110997  
109032  
112717  
243814  
245689  
198996  
111590  
155699  
100078  
245406  
Y
5
6
245245  
116806  
196670  
101682  
193682  
106115  
114666  
112798  
237686  
114686  
114794  
104008  
101864  
241440  
105510  
241308  
1
1
1
4
2
4
4
1
1
2
1
4
4
1
15  
1
1
1
4
1
2
1
1
1
1
1
1
1
2
3
1
1
1
1
1
1
1
10  
16  
18  
19  
20  
21  
23  
31  
32  
34  
35  
36  
37  
38  
39  
40  
47  
48  
49  
53  
54  
57  
58  
59  
60  
61  
62  
63  
64  
66  
70  
71  
72  
73  
74  
100  
101  
102  
103  
105  
106  
107  
110  
115  
117  
120  
121  
123  
127  
128  
137  
139  
140  
141  
142  
151  
152  
162  
166  
167  
169  
171  
175  
179  
188  
189  
GUARD, belt  
SCREW, mach, pnh  
BUSHING, strain relief  
SLEEVE, cart  
241279  
100644  
244224  
104811  
198688  
WASHER  
COLLAR, torsion bar  
LABEL, ident, GMax 5900C  
SCREW, MACH  
SCREW, PLASTITE #8  
SCREW, threadforming, hex hd  
BAR, torsion, includes 128  
BRACKET, shelf belt guard  
SCREW, flange, hex  
SCREW, mach, pnh  
WASHER  
HOSE, coupled  
HOUSING, clutch  
BRACKET, belt guide  
BUTTON, snap  
ELBOW, street  
194125  
193031  
183210  
183169  
241015  
114699  
114672  
112395  
290228  
109099  
181072  
241920  
197124  
193097  
244240  
Y
PIN, str, hdls  
SPRING, retaining  
HOUSING, bearing  
WASHER, thrust  
WASHER, thrust  
SCREW, cap, flnghd  
LABEL, CAUTION  
BUSHING, snap  
STRAINER, inlet  
DEFLECTOR, threaded  
CLIP, spring  
SCREW, mach, slt hex wash hd  
SHAFT, input; part of Kit 169  
TUBE, suction  
HOSE, coupled  
309411  
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Engine Detail  
118 111  
L
93  
J
124  
P
41  
112  
92  
N
M
42  
C
170  
166  
32 Ref  
101  
146  
125  
101  
52  
53  
156 108  
165  
C
ti1846a  
84  
C
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
KEY, parallel  
BRACKET, belt guard (motor)  
BASE, mounting  
Qty.  
Part No.  
Description  
Qty.  
41  
42  
52  
53  
84  
92  
93  
101  
108  
111  
112  
118  
124  
183401  
198689  
245272  
198688  
194925  
194414  
114805  
112406  
114653  
192014  
116149  
113084  
114530  
1
2
1
1
1
13  
1
3
4
1
1
2
1
125  
146  
156  
165  
166  
170  
198693  
116139  
198695  
111800  
112717  
198995  
110996  
HANDLE, slide, engine  
GRIP, handle  
BRACKET, torsion bar  
SCREW, cap, hex hd, flange  
WASHER  
SLEEVE, motor shaft  
NUT, flng hd, hex  
LABEL, warning  
BOX, junction, engine  
NUT, hex  
SCREW, mach, hex washer hd  
BUSHING, snap  
2
2
1
2
2
1
6
1
1
1
1
1
PULLEY, engine  
BRACKET, tension  
BRACKET, J–box  
JACK, 1/4 engine  
SCREW, cap, hex hd  
SCREW, cap, flange hd  
PLATE, indicator  
SPACER  
RIVET, blind  
ENGINE, gas, 5.5HP, Honda  
C
J
L
M
N
P
Y
1
9
4
1
2
6
194181  
114816  
114813  
109099  
20  
309411  
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Parts List & Drawing – Pinion Assembly  
Ref No. 4 and 3  
Ref No. 4: Pinion Housing Assembly 245399  
Ref No. 3: Drive Housing Assembly 245443  
Ref  
Ref  
No.  
Part No.  
Description  
Qty  
No.  
Part No.  
Description  
Qty  
4a  
4b  
4d*  
4e*  
245267  
105489  
PINION HOUSING & COIL  
PIN  
PINION SHAFT  
1
2
1
1
3
HOUSING, drive  
WASHER  
WASHER  
SWITCH, reed  
PIN, spring  
MAGNET  
1
1
1
1
2
1
1
3g*  
3h*  
3k  
3m  
3n  
3p  
194173  
116192  
116806  
116838  
116618  
15A622  
112770  
RETAINING RING, large  
*Must be ordered separately  
LABEL, WatchDog  
*Must be ordered separately  
4d  
4b  
4e  
47 (Ref.)  
37 (Ref.)  
4
3h  
3g  
3
15 (Ref)  
3p  
10 (Ref.)  
3n  
9 (Ref.)  
7(Ref)  
1
16 (Ref)  
3m  
3k  
TI0177B  
1
Pinion housing assembly (4) includes clutch field and connector  
309411  
21  
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Parts Drawing – Sprayer  
Ref No 24  
Pressure Control Assembly  
100a  
100b  
139 147a  
Ref 19  
7
44  
182  
8
12  
44  
100c  
181  
100d  
100e  
176  
104  
174  
11  
100f  
178  
141  
147  
100g  
50  
139  
100h  
95 Ref  
30  
100q100r 100s  
100k 100j 100p  
100n 100m  
22  
33  
51  
13  
22  
ti1848a  
22  
309411  
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Parts List – Sprayer  
REF  
REF  
NO. PART NO.  
DESCRIPTION  
QTY  
NO. PART NO.  
DESCRIPTION  
QTY  
7
8
11  
12  
198534  
198548  
116252  
245393  
PLATE, control  
1
1
4
1
FILTER, fluid  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HOUSING, control  
SCREW, #8 taptite, phil  
COVER, digital display  
Includes 11, 30, 181,  
KNOB, potentiometer  
POTENTIOMETER, pressure control  
LABEL, GMax, LCD  
SPACER, shaft  
SCREW, pnhd 6–32  
PANEL, control  
SWITCH, rocker, (spst)  
NIPPLE, adapter  
ADAPTER  
SCREW, mach  
SCREW, threadforming, hex hd  
BOARD, PC  
Includes 147a  
100 245396  
100a 196675  
100b 104361  
100c 244067  
100d 196786  
100e 245401  
100f 193710  
100g 193709  
100h 114797  
100j 245103*  
100k 114708  
100m 194102  
100n 114688  
100p 111457  
100q 243222  
KIT, repair, filter  
BOWL, filter  
O-RING  
STRAINER, mesh, 60  
TUBE, diffuser  
KIT, repair, filter base  
SEAL, valve  
SEAT, valve  
GASKET  
VALVE  
SPRING, compression  
HANDLE, valve  
NUT, cap, hex hd  
O-RING  
TRANSDUCER, pressure control  
includes 100p  
GASKET, plug  
PLUG, AutoClean  
13  
22  
30  
33  
44  
50  
51  
95  
116167  
241443  
198648  
198650  
114331  
198553  
116752  
162485  
1
1
1
1
6
1
1
1
2
4
4
1
104 164672  
139 112774  
141 109575  
147 245394  
100r 197055  
100s 196781  
1
1
147a  
NUT, nylon  
PLUG, packless  
BUSHING, step  
GUARD, transducer  
LABEL, instruction, GMax  
LABEL, warning  
1
1
1
1
1
1
174 245474  
176 114296  
178 198994  
181 198884  
182Y 189246  
* Drain valve repair kit 245103 includes 100f, g, h, k, m, n  
Y Replacement warning labels may be ordered free of charge  
Pressure Control  
Wiring Diagram  
Clutch Coil  
VIEW A  
Engine Power  
DISPLAY BOARD  
Gallon  
Counting  
Sensor  
Thermistor  
ON/OFF SWITCH  
DRIVE  
HOUSING PINION  
HOUSING  
CONTROL BOARD  
TRANSDUCER  
VIEW A  
CLUTCH TEST POINTS  
TO CORD, 32  
POTENTIOMETER  
ti1843a  
Fig. 17  
309411  
23  
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Parts List & Drawing –Clutch Assembly  
Ref  
No.  
Ref  
Part No.  
Description  
Qty  
No.  
Part No.  
Description  
Qty  
16*  
37*  
39*  
86*  
88*  
94*  
169  
101682  
105510  
SCREW, cap, sch  
WASHER, lock, spring  
ROTOR, clutch, 5 in.  
ARMATURE, clutch  
SCREW, hex, sch  
HUB, armature  
4
8
1
1
4
1
1
169b 114962  
169c 245406  
169e 193493  
RING, retaining, internal  
SHAFT, drive, input  
HOUSING, clutch  
STOP, armature  
O-RING  
1
1
1
1
1
1
169f  
194059  
108803  
245689  
169j  
115078  
169k 115079  
O-RING  
HOUSING, clutch  
Includes 169b, 169c, 169e, 169j & 169k  
* Clutch replacement kit 241113 includes 16, 37, 39, 86, 88,  
and 94  
169b  
169c  
169e  
169k  
169j  
169f  
86*  
94*  
16*  
37*  
39*  
37* 88*  
8745A  
Parts – Complete Sprayer  
Model 233710, 233714  
Includes:  
D
233709 Convertible GMax 5900C Sprayer, parts  
list page 18,  
226a  
D
245507 (233714) Lo-Boy Suction Set Kit, parts list  
page 25  
D
287036 Contractor Gun Kit below:  
Ref.  
No.  
226c  
Part No.  
Description  
Qty.  
226  
287036  
Contractor II Gun Kit  
1
Includes 226a – 226c  
226b  
226a 240794  
226b 238358  
226c 246220  
HOSE, grounded, nylon; 1/4” ID;  
cpld 1/4 npsm(fbe); 50 ft (15 m);’  
spring guards both ends  
1
HOSE, grounded, nylon; 3/16” ID;  
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;  
3 ft (0.9 m); spring guards both ends  
CONTRACTOR II SPRAY GUN  
1
1
Includes RAC X HandTitet Tip Guard  
0160  
and 517 SwitchTip  
t
See 309639 for parts  
24  
309411  
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Parts – Lo-Boy Suction Set Kit  
Model 245507  
Includes items 401 to 407  
Ref.  
No.  
401  
Part No.  
Description  
Qty.  
401  
241124  
.TUBE, suction, 5 gallon (20 liter)  
includes 401a through 401e  
..SWIVEL, tube, inlet  
..GUARD, hose  
..HOSE, fluid  
..CLAMP, hose  
..TUBE, suction  
.HOSE, drain, includes 406  
.CLIP, spring  
.STRAINER  
1
402(REF)  
406  
401a 240513  
401b 176450  
401c 194306  
401d 101818  
401e 170957  
402  
403  
405  
406  
407  
1
1
1
2
1
1
1
1
1
1
405  
403  
407  
245611  
194194  
181072  
241920  
144958  
401a  
401e  
.DEFLECTOR  
.STRAP, tie  
402  
401c  
401b  
401d  
ti1851a  
Technical Data  
Dimensions  
Model 233709  
Weight (dry, without packaging) . . . . . . . 170 lb (77 kg)  
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)  
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 in. (99.1 cm)  
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)  
Honda GX160 Engine  
Power Rating @ 3700 rpm  
ANSI . . . . . . . . . . . . . . . . . . . . . . . 5.5 Horsepower  
DIN 6270B/DIN 6271  
NA . . . . . . . . . . . . . . . . . . . . . . 2.9 Kw – 4.0 Ps  
NB . . . . . . . . . . . . . . . . . . . . . . 3.6 Kw – 4.9 Ps  
Maximum Working Pressure . . . . . . . . . . . . . . 3300 psi  
(227 bar, 22.7 MPa)  
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . 93 (25)  
Maximum Delivery . . . . . . . . . . 1.25 gpm (4.7 liter/min)  
Fuel Tank Capacity . . . . . . . . . . . 0.95 gallons (3.6 liter)  
Maximum Tip Size . . . . . . . . . . . . . . 1 gun with 0.041 tip  
2 guns with 0.028 tip  
DANGER LABELS  
The English language DANGER label is on your  
sprayer. If you have painters who do not read En-  
glish, order one of the following labels to apply to  
your sprayer. The drawing below shows the best  
placement of these labels for good visibility.  
Inlet Paint Strainer . . . . . . . . . . . 16 mesh (1190 micron)  
Stainless steel screen, reusable  
Outlet Paint Filter . . . . . . . . . . . . . 60 mesh (250 micron)  
Stainless steel screen, reusable  
Order the labels directly from your Graco distributor.  
Pump inlet Size . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)  
Fluid Outlet Size . . . . . . . . . . . 1/4 npsm from fluid filter  
Wetted parts . . . . . . . . . . . . . . zinc-plated carbon steel,  
PTFE, Nylon, polyurethane, UHMW polyethylene,  
FKM, POM, leather, aluminum, tungsten car-  
bide,nickle-plated carbon steel, stainless steel,  
chrome plating  
French  
Spanish 194932  
German 194933  
Greek  
Korean  
194931  
194934  
194935  
Apply other  
language here  
English 194125  
03497A  
309411  
25  
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Graco Standard Warranty  
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the  
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited  
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment  
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-  
dance with Graco’s written recommendations.  
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by  
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-  
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of  
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,  
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.  
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for  
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The  
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect  
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and  
transportation.  
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT  
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.  
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other  
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any  
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the  
date of sale.  
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection  
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured  
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide  
purchaser with reasonable assistance in making any claim for breach of these warranties.  
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment  
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,  
breach of warranty, the negligence of Graco, or otherwise.  
FOR GRACO CANADA CUSTOMERS  
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings  
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-  
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires  
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.  
TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call this number to identify the  
distributor near you:1–800–690–2894 Toll Free  
All written and visual data contained in this document reflects latest product information available at time of publication. Graco  
reserves right to make changes at any time without notice.  
MM 309411  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
Printed in USA 309411  
1/2002 Rev. 5/2008  
26  
309411  
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