Graco 231-316 Series C, 231-330, 231-331, 236–379, 231-316 Instructions Manual

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Page 1

INSTRUCTIONS-PARTS LIST

308–327

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

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 C

Basic sprayer, without hose or gun

Model 231-330

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

First choice when

quality counts.

Rev. H

Supersedes Rev. G

Model 231-331

Complete sprayer, with hose and Contractor gun, RAC IVt DripLesst Tip Guard, and 517 size SwitchTipt

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

7340A

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

Page 2

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Function 5. . . . . . . . . . . .

Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fueling 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair

Bearing Housing and Connecting Rod 15. . . . . . . . . .

Drive Housing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pinion 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field and Wiring Harness 19. . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Alternator 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Replacement 22. . . . . . . . . . . . . . . .

Displacement Pump 24. . . . . . . . . . . . . . . . . . . . . . . . .

Parts

Basic Sprayer 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Housing Alternator 28. . . . . . . . . . . . . . . . . . . .

Complete Sprayer 29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Schematic 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number 31. . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to equipment if the you do not follow the instructions.

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

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

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.

2 308–327

Page 3

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 medi-

cal 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.

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Page 4

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

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.

SKIN INJECTION

HAZARD

READ AND UNDERST AND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

4 308–327

Page 5

Component Identification and Function

202

204

202Main hose 203Whip end hose 204Contractor gun with RAC IV

DripLess tip guard and 517 size SwitchTip

Fig. 1

203

53 15

7203A

A Pressure Control Switch ON/OFF, enables/disables clutch function B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner* Filters air entering the carburetor D Fuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline E Muffler* Reduces noise of internal combustion F Spark Plug Cable* Routes electrical current to spark plug G Fuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor H Choke* Enriches air/gasoline mixture for cold starting J Throttle* Adjusts engine speed for large or small orifice spray tips K Engine Switch* Enables/disables engine operation L Secondary Fluid Outlet Second hose and spray gun is connected here M Pressure Control Controls clutch cycling to maintain fluid pressure. N Primary Fluid Outlet Hose and spray gun is connected here 1 Engine* 5.5 HP gasoline engine 2 Clutch Housing Transfers power from engine to drive assembly

5 Drive Housing Transfers power from clutch to displacement pump

15 Displacement Pump Provides fluid to be sprayed through spray gun 18 Fluid Filter Filters fluid between source and spray gun 27 Grounding Clamp and Wire Grounds sprayer system 53 Pail Hanger Provides a hanger for paint pail 60 Pressure Drain Valve Relieves fluid pressure when open

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

5308–327

Page 6

Setup

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

mum Working Pressure

of serious injury caused by static sparking, fluid injection or over-pressurization and rupture of the hose or gun.

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

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.

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

3000 psi (210 bar, 21 MPa) Maxi-

. This is to reduce the risk

CAUTION

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.

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

Fill with TSL

Do not install any shutoff

device here. Do not use thread sealant

on swivels

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

4161

127

Fig. 2

6 308–327

126

7205A

Page 7

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 SERVICE 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.

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.

Fueling

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

 Always shut off the engine switch (A) before

refueling. See Fig 3.

 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.

 Do not overfill the tank. Close the gas fill cap

(B) securely after refueling. See Fig 3.

Fig. 3

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.

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.

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

7206A

 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.

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.

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

5. Shut off the engine before refueling.

6. After refueling, tighten the fuel tank cap firmly.

7308–327

Page 8

Startup

CAUTION

Trigger safety



latch shown engaged

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.

0137

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) counterclock- wise 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. 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).

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

Page 9

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.

WARNING

FIRE AND EXPLOSION HAZARD

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.

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.

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.

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.

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

7207A

9308–327

Page 10

WARNING

Maintenance

AFTER EACH 100 HOURS OF OPERATION:

Change the oil.

INJECTION HAZARD

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

Procedure on page 10.

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.

DAILY: Check hoses for wear and damage.

DAILY: Check gun safety for proper operation.

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.

WARNING

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. 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.

Pressure Relief Procedure

1. Lock the gun trigger safety.

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.

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.

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.

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,

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

VERY SLOWLY

10 308–327

Page 11

When to Flush

Flushing

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

Before using water–base paint,

spirits, followed by a soapy water flush, and then a clean water flush.

Before using oil–base paint,

spirits.

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.

4. Changing from oil–base to water–base paint. Flush with mineral spirits, followed by warm, soapy water, and then a clean water flush.

flush with mineral

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.

5. Storage.

Water base paint:

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.

Oil base paint:

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.

6. Startup after storage.

Before using water–base paint

mineral spirits with soapy water, and then with clean water.

When using oil–based paint,

spirits with the paint to be sprayed.

flush with water, then mineral

flush with mineral spirits and leave

, flush out the

flush out the mineral

11308–327

Page 12

Flushing

How to Flush

WARNING

INJECTION HAZARD

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

Procedure on page 10.

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

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.

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).

WARNING

FIRE AND EXPLOSION HAZARD

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.

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.

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.

12 308–327

Fig. 6

7208A

Page 13

Troubleshooting

WARNING

INJECTION HAZARD

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.

Check everything in the chart before disassembling the sprayer.

PROBLEM CAUSE SOLUTION

Disconnect the spark plug!

Engine/sprayer won’t start

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

Engine operates, but

displacement pump doesn’t

Engine switch not on Turn on.

Out of gas Replenish Engine oil level low Try starting engine. If light on rear of engine glows,

Spark plug cable disconnected or spark plug damaged

Water frozen in pressure control Return pressure control to authorized Graco dealer

chamber

Pressure control switch turned OFF Turn on. Pressure setting too low Increase pressure. Displacement pump outlet filter dirty Clean filter. Tip or tip filter clogged Clean tip or tip filter. Broken drive belt Replace belt. Displacement pump rod seized by

dry paint

replenish oil. Connect cable on top of engine or replace spark

plug.

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.

Service pump. See page 24.

Connecting rod worn or damaged Replace. See page 15. Drive housing worn or damaged Replace. See page 16. Electrical power not energizing field Check wiring connections. See page 19.

Clutch worn or damaged Service. See page 18. Pinion assembly worn or damaged Service. See page 17.

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.

13308–327

Page 14

Troubleshooting

PROBLEM CAUSE SOLUTION

Displacement pump output low on upstroke

Displacement pump

output low on downstroke or both strokes

Paint leaks into wet-cup Loose wet-cup Tighten just enough to stop leakage.

Low fluid delivery Pump inlet screen clogged. Clean.

Pump inlet screen clogged Clean. Piston ball check not seating Service piston ball check. See page 24. Piston packings worn or damaged Replace packings. See page 24. Sleeve gasket in displacement pump is

damaged Pump inlet screen clogged Clean.

Piston packings worn or damaged Replace packings. See page 24. 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 Replace. See page 18.

Throat packings worn or damaged Replace packings. See page 24. Displacement rod worn or damaged Replace rod. See page 24.

Pressure setting too low Increase pressure. See Step 1, page 9.

Replace. See page 24.

Engine RPM too low Increase throttle setting. See Step 1, page 9. Dirty outlet filter , tip filter or tip Clean. Large pressure drop in hose Use larger diameter hose.

Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake and

tighten. Then prime pump. See Startup, page 8. Tip partially clogged Clear. Fluid supply is low or empty Refill and prime the pump. See Startup, page 8.

Check fluid supply often to prevent running the

pump dry .

Pump is difficult to prime Air leak Check all hose connections and tighten as

needed.

Reduce RPM and cycle pump as slowly as possi-

ble during priming. Intake valve is leaking 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. Reas-

semble. Worn packings Repack the pump. See page 24. Fluid is too thick Thin fluid according to supplier’s recommenda-

tions.

14 308–327

Page 15

Bearing Housing and Connecting Rod

WARNING

INJECTION HAZARD

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

Procedure on page 10.

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.

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.

T orque to 300 in-lb (34 N.m) Lubricate with high-quality motor oil

Pack with bearing grease

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 (1 1).

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.

Fig. 7

12 14

423

02693

15308–327

Page 16

Drive Housing

WARNING

INJECTION HAZARD

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

Procedure on page 10.

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).

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).

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.



T orque to 300 in-lb (34 N.m) Apply a full 6 oz. (160 grams) of



bearing grease (supplied with replacement gear – 16)



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.



219d

215,214

219

Fig. 8

16 308–327

02694

Page 17

Pinion

Remove the Pinion Housing

WARNING

INJECTION HAZARD

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

Procedure on page 10.

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

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.

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.

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.



See Fig. 10

222

212b

219

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. 10 except where noted.

1. Remove the retaining ring (218e).

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

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

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).

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

217

Fig. 9

219



02695

Fig. 10

218

218e

Drive housing shown removed for visual



purposes only

02787

17308–327

Page 18

Clutch

NOTE: The clutch assembly (212) includes the arma-

ture (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.

WARNING

INJECTION HAZARD

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 10.

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.

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).

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.

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.

 Skip ahead to Reassembly, page 21, Step 2, or

continue on page 19.

222

212a

215

213

212b

219

63 11

DETAIL

222

A B

Fig. 11

18 308–327

02699

Page 19

210

See Fig 13 for a detail of



where 64 connects

Fig. 12

Field and Wiring Harness

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

211



02702

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.

Ref 64

Ref 206

Fig. 13

7210A

Alternator

2. Remove the screws (43) and belt guard (35). Remove the belt (40). See Fig. 15.

35 43

40 222

100

Fig. 14

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).

7209 A

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.

19308–327

Page 20

Alternator

201

200

222

202

220

221

203

204

208

207

205

206



See Fig. 13 for a detail of where 206 connects

Fig. 16

209

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).

205

207

204

202

201

209

206

CUTAWAY VIEW

D, 203

222

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.

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

222

E 202

02747

Page 21

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.

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



210

211

Fig. 18

02702

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.

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



(4). See Fig. 19.



213

215

212a

222

212b

219

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 re-

coil 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).

Fig. 19

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



02699

21308–327

Page 22

Pressure Control Replacement

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

WARNING

See Fig. 22.

INJECTION HAZARD

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 10.

T o the pump.

T o the filter .

Fig. 20

1. Relieve pressure.

Front view

318

CAUTION

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

06873

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).

Fig. 22

317

110

111

7211A

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.

Fig. 21

7210A

22 308–327

Page 23

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.

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

10. Disconnect the potentiometer cable assembly (310) from the pressure control cover.

301

304

302

Fig. 23

303

310

317

314

304

06872A

11. Disconnect the red power lead (B) from the ON/OFF switch.

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

13. Pull off the pressure control cover.

WARNING

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

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).

23308–327

Page 24

Displacement Pump

WARNING

INJECTION HAZARD

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

Procedure on page 10.

Removing the pump. (See Fig. 24.)

1. Relieve pressure.

2. Flush the pump. See page NO TAG.

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.

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

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. 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. 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.

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

Fig. 24

25 27

80, 74 76

7179A

Fig. 25

22 26

The face of the bearing housing.





T orque to 90 ±5 ft-lb (122 ±6.8 Nm)



0031



24 308–327

Page 25

Notes

25308–327

Page 26

Model 231–316, Series A

See alternate view of 74 below

See exploded view on page 28

See parts in manual 307–806

See engine detail on page 27

See parts on page 30

Parts – Basic Sprayer

6

Ref 219d

Ref 63

14 12

15 52

51 50

49 89

40 102

43 35

100

71, 112

Ref 63

119

54 60

118

111 Ref 51

26 308–327

67 110 120

7213A

Page 27

Model 231–316, Series A

Parts – Basic Sprayer

Ref. No. Part No. Description Qty.

1 802–264 ENGINE, 5.5 HP 1 2 241–299 CLUTCH HOUSING ALTERNATOR

See separate parts list on page 28 1

3 100–644 CAPSCREW, socket head,

1/4–20 x 3/4” 9 4 105–510 LOCKW ASHER, spring, 1/4” 11 5 241–291 DRIVE HOUSING KIT

Includes replaceable items 5a to 5d 1 5a 106–227 . WASHER, bronze colored 1 5b 183–209 . WASHER, silver colored 1 5c 100–069 . BALL 1 5d 1 10–293 . TUBE OF GREASE 1 6 185–953 LABEL, Danger 1 7 188–423 COVER, housing 1 8 220–640 CONNECTING ROD KIT 1 10 108–849 CAPSCREW, sckt hd, 1/4–20 x 3” 2 1 1 220–639 BEARING HOUSING 1 12 183–210 PIN, straight, 3/8 x1/8” 1 13 183–169 SPRING, retaining 1 14 189–969 NUT, hex, 1 13/16–16 1 15 220–872 PUMP See parts in manual 307–806 1 16 220–919 GEAR REDUCER 1 17 109–099 BUSHING, snap 2 18 239–286 FLUID FILTER;

See manual 307–273 for other parts 1 21 1 12–583 PLUG 4 22 108–860 SCREW, No. 8–32 x 1/4”

Shown on page 28 2 25 1 12–798 SCREW , thread forming 1 27 237–686 GROUNDING CLAMP & WIRE 1 28 102–556 RIVET, blind (not shown) 2 29 187–112 PLATE, designation (not shown) 1 30 179–811 WHEEL, semi–pneumatic 2 31 154–636 W ASHER, 5/8” 2 32 101–242 RING, retaining 2 33 104–811 HUBCAP 2 34 1 10–837 FLANGE SCREW, hex hd,

5/16–18 x 1–1/2” 4 35 236–378 BELT GUARD 1 37 108–859 SCREW, 5/16–18 x 3/8” shld, 1/2” thd 2 38 183–401 KEY, parallel, 3/16” sq x 7/8” 1 39 109–581 BUSHING 1 40 109–582 BELT, 3V 1 41 109–580 SHEAVE 1 43 1 12–161 FLANGE SCREW, 1/4–20 x 1/2” 4 44 1 10–963 FLANGE SCREW, hex hd,

5/16–18 x 3/4” 3 46 1 12–746 NUT , retainer 2 47 183–461 NIPPLE, 3/8–18 npsm x 1/4–18 npt 1 49 181–102 CLIP, spring 1 50 183–423 TUBE, intake 1 51 186–495 TUBE, bypass 1 52 186–490 CLIP, spring 1 53 189–918 HANGER, pail 1 54 1 10–997 SCREW, flange hex hd, 1/4–20 x 5/8” 2 60 237–677 PRESSURE DRAIN VALVE 1 63 222–516 FLUID HOSE, 3/8” ID, 3/8” npt

couplings, 2.5 ft. long, spring guards 1

Ref. No. Part No. Description Qty .

64 220–980 HARNESS, wiring, Shown on page 28 1 65 108–842 SCREW, cap, flange, 5/16–24 x 3/4” 4 66 1 12–386 PIN 1 67 101–344 SCREW, cap, 10–24 x 1/2” 3 71 290–375 LABEL, identification, control, top 1 72 1 10–141 CAPSCREW, 3/8–16 x 1–1/2” 4 73 106–115 LOCKWASHER, spring, 3/8 74 239–662 PRESSURE CONTROL

See parts on page 30 1 76 192–225 PRESSURE CONTROL BRACKET 1 77 290–436 IDENTIFICATION LABEL, front cover 1 78 108–850 SCREW, No. 8–32 x 1–1/4” 4 88 181–867 LABEL, W arning 1 89 187–147 STRAINER 1 90 239–521 CART 1 91 206–994 THROAT SEAL LIQUID,

8 oz (0.27 liter) 1 93 236–529 MOUNTING BASE 1 94 236–388 EYE BOLT 1 95 1 12–392 KNOB 1 96 236–402 CART HANDLE 1 97 236–376 ENGINE GUARD 1 100 112–395 SCREW , 3/8–16 x 3/4” 3 102 177–144 LABEL, W arning 1 104 189–679 LABEL, caution (not shown) 1 105 112–756 SCREW, cap, socket hd 3 106 110–838 LOCKNUT, w/nylon insert, 5/16–18 4 1 10 100–214 WASHER, lock 3 1 1 1 237–831 BRACKET, filter 1 1 18 1 13–983 RING, retaining, external 1 1 12 290–437 LABEL, identification, control, bottom 1 1 19 112–818 SCREW, cap, hex, hd, flange 1



Replacement Danger and Warning labels, tags and

”

cards are available at no cost.



02708

27308–327

Page 28

219a 219e

219b 219c

219d

02697

218

215

214

Parts – Clutch Housing Alternator

217

215

212b

213

219

214

212a

218b

218c

210

218e

218a

209

207

218d

208

218f

206

205

204

203

221

214

220

Lubricate exterior

Lubricate inner and outer diameters

Lubricate teeth

Press fit before 218f

Press fit after 218d

202

201

200

211

222

02737

Ref No. 2 Part No. 241–299 CLUTCH HOUSING ALTERNATOR KIT

Includes items 200 to 222

Ref. No. Part No. Description Qty.

200 183–401 KEY 1 201 109–581 BUSHING 1 202 109–580 SHEA VE 1 203 112–132 RET AINING RING, 0.693” 1 204 112–126 BALL BEARING 1 205 112–128 RET AINING RING, 2.054” 1 206 236–396 GENERATOR STATOR 1 207 112–143 SCREW, pan head, 10–24 x 1” 4 208 100–020 LOCKWASHER 4 209 236–395 AL TERNATOR SHAFT ROTOR 1 210 188–425 FIELD 1 211 108–801 SETSCREW , 1/4–20 x .31” 4 212 221–031 CLUTCH, includes 212a and 212b 1 212a . ROTOR 1 212b . ARMATURE 1 213 112–142 CAPSCREW , 1/4–28 x 3/4” 4 214 105–510 LOCKWASHER, spring, 1/4” 9 215 100–644 CAPSCREW , 1/4–20 x 3/4” 5 217 108–799 RET AINING RING 1

Ref. No. Part No. Description Qty .

218 236–394 PINION OUTPUT SHAFT KIT

Includes replaceable items

218a to 218f 1 218a 188–812 . PINION OUTPUT SHAFT 1 218b 1 12–141 . RETAINING RING 1 218c 108–798 . BALL BEARING 1 218d 1 12–139 . NEEDLE BEARING, small 1 218e 108–796 . RET AINING RING 1 218f 112–140 . NEEDLE BEARING, large 1 219 241–290 PINION HOUSING KIT

Includes replaceable items

219a to 219e 1 219a 194–313 . PINION HOUSING 1 219b 108–692 . NEEDLE BEARING, large 1 219c 107–088 . NEEDLE BEARING, small 1 219d 100–069 . BALL 1 219e 105–489 . PIN 1 220 112–145 CABLE CLAMP 1 221 112–144 SCREW , pan head, 8–32 x 1/4” 1 222 188–791 CLUTCH HOUSING 1

28 308–327

Page 29

Parts – Complete Sprayer

Model 231–331

Includes items 125 to 128

Ref. No. Part No. Description Qty.

125 231–316 CONVERTIBLE GM5000 Basic Sprayer

See parts list on page 27 1

126 238–361 HOSE, grounded, nylon; 1/4” ID;

cpld 1/4 npsm(fbe); 50 ft (15 m);’ spring guards both ends 1

127 238–358 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 1

128 220–955 “CONTRACTOR” SPRAY GUN

Includes RAC IV and 517–size SwitchTip See 307–614 for parts 1

 DripLess Tip Guard

126

128

127

0160

29308–327

Page 30

Parts – Pressure Control

Basic Pressure Control for the GM5000 Convertible Sprayer

Ref No. Part No. Description Qty

301 239–519 ENGINE CONTROL BOARD 1 302 107–251 SCREW, panhead, 10–24 x 1 in. 2 303 112–610 SCREW, panhead, 10–24 x 2 in. 2 304 100–020 LOCKWASHER, No. 10 4 305 189–095 HOUSING, 1 306 112–614 PLUG 1 307 11 1–930 TOGGLE SWITCH 1 308 107–255 GUARD 1 309 105–659 BOOT 1 310 236–352 POTENTIOMETER, pressure

adjustment 1

311 112–382 NUT, shaft, sealing 1

Parts Drawing –

Pressure Control

309

313

308

312

311

305

310 314

316

306

05799C

302

301

304

303

319

307

317

318

315

Ref No. Part No. Description Qty

312 112–373 KNOB 1 313 185–565 LABEL 1 314 237–674 CONDUCTOR 1 315 109–078 CONNECTOR 1 316 112–376 LOCKNUT 1 317 100–078 SCREW , hex head, 8–24 x .375 in. 1 318 189–286 LABEL, warning 1 319 189–246 LABEL, warning 1



Replacement Danger and Warning labels, tags, and

cards are available free.

Wiring Schematic –

Pressure Control

310

307

RED

314

03496

GROUND

T o engine

T o clutch field

301

WHITE

GREEN

BLACK

30 308–327

Page 31

Manual Change

Graco Phone

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 5.5 Horsepower, Honda. . . . . . . . . . . . . . . . . . . .

Maximum Working Pressure 3000 psi (210 bar). . . . . .

Cycles/Gallon (liter) 104 (28). . . . . . . . . . . . . . . . . . . . . . .

Maximum Delivery 1.25 gpm (4.7 liter/min). . . . . . . . . .

Fuel Tank Capacity 0.95 gallons (3.6 liter). . . . . . . . . . .

Maximum Tip Size 1 gun with 0.035 tip. . . . . . . . . . . . . .

2 guns with 0.025 tip

Inlet Paint Strainer 16 mesh (1190 micron). . . . . . . . . . .

Stainless steel screen, reusable

Outlet Paint Filter 60 mesh (250 micron). . . . . . . . . . . . .

Stainless steel screen, reusable

Pump inlet Size 3/4 npt (m). . . . . . . . . . . . . . . . . . . . . . .

Fluid Outlet Size 1/4 npsm from fluid filter. . . . . . . . . . .

Wetted Parts

Displacement Pump

Polyurethane, UHMW polyethylene,

Filter

. . . . . .

NOTE: Delrin is a trademark of the DuPont Company.

Aluminum, Carbon steel, Stainless steel

Stainless steel, Carbon steel,

Delrin, Leather

Dimensions

Weight (dry, without packaging) 145 lb (66 kg). . . . . . .

Height 31.6 in. (803 mm). . . . . . . . . . . . . . . . . . . . . . . . .

Length 30.5 in. (775 mm). . . . . . . . . . . . . . . . . . . . . . . . .

Width 22.5 in. (572 mm). . . . . . . . . . . . . . . . . . . . . . . . . .

Number

TO PLACE AN ORDER

tor, or call this number to identify the distributor closest to you: 1–800–367–4023 T oll Free

, contact your Graco distribu-

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

31308–327

Page 32

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 MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT , MA TERIALS 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 Warranty 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.

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 USA 308–327 October 1993, Revised November 1998

32 308–327

http://www.graco.com