INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GMax 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
233709 A Sprayer, gas powered
233710 A Sprayer, gas powered, with RAC X tip,
gun and hose
233711 A Sprayer, gas powered, with electric
motor kit
233712 A Same as 233711 except with ETL
approval to CSA and UL standards
233713 A Sprayer, gas powered, with Lo-Boy
suction set kit
233714 A Sprayer, gas powered, with RAC X tip,
gun and hose and Lo-Boy suction set kit
233715 A Sprayer, gas powered, with Lo-Boy
suction set kit and electric motor kit
233709
ti1852a
Related Manuals
Operator 309410. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 309277. . . . . . . . . . . . . . . . .
Spray Gun 309639. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 309640. . . . . . . . . . . . . . . . . . . . . . . . . . .
AutoClean Kit 309450. . . . . . . . . . . . . . . . . . . . . . .
PC Board 309459. . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Kit 309469. . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 308961. . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2002, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Component Identification and Function 5. . . . . . . . . . . .
Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing and Connecting Rod 9. . . . . . . . . . .
Drive Housing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley 11.
ON/OFF Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 14. . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 16. . . . . . . . . . . . . . . . . . .
Parts
Basic Sprayer 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lo-Boy Suction Set Kit 25. . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Cautions
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
The wallet-sized warning card provided with this pole gun should be kept with the operator at all times. The card
contains important treatment information should a fluid injection injury occur. Additional cards are available at no
charge from Graco Inc.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
2 309411
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.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment!
Do not point the spray tip at anyone or any part of the body.
Do not put hand or fingers over the spray tip, and do not stop or deflect fluid 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 in-line valve when spraying.
Be sure the trigger safety lever operates before operating the in-line valve.
Lock the trigger safety lever when you stop spraying.
Follow the Pressure Relief Procedure on page 6 when you are instructed to relieve pressure;
stop spraying; check, clean, or service any system equipment; or install or change spray tips.
Tighten all fluid connections before each use.
Check the hoses, tubes and couplings daily. Replace worn or damaged parts immediately. Perma-
nently coupled hoses cannot be repaired.
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 150F (65C) or below –40F (–40C).
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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose hazardous fluid according to all local,
state and national guidelines.
Dress appropriately for your application. Wear protective eyewear, noise protection for the ears, a
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 balance and fall, resulting in serious injury.
3309411
INSTRUCTIONS
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.
Ground the equipment and the object being sprayed.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
sprayed.
Extinguish all the open flames or pilot lights in the spray area.
Electrically disconnect all the equipment in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about the usage, call your
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
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.
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 150F (65C) or below –40F (–40C).
Do not use the hoses to pull the equipment.
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.
Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or
bends near the couplings.
Comply with all applicable local, state and national fire, electrical and other safety regulations.
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 damage.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc
parts.
4 309411
Component Identification and Function
Engine On/Off Switch
Engine Controls
Pump On/Off Switch
Pressure Control
Prime/Drain Valve
Spray Gun Trigger Lock
Reference your Spray Gun Manual
ti1852a
Motor On/Off Switch
ti1854a
5309411
Maintenance
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 injection, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
Pressure Relief Procedure
1. Lock gun safety latch.
2. Turn engine or electric motor ON/OFF switch to
OFF.
3. Unplug power supply cord (electric motor).
4. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
CAUTION
For detailed engine maintenance and specifications,
refer to separate engine manual, supplied.
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.
DAILY: Check and fill gas tank.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
AFTER THE FIRST 20 HOURS OF OPERATION
AND EACH 100 HOURS THEREAFTER: Change
engine oil.
DAILY: Keep TSL in packing nut to help lubricate
pump packings. One full squirt of TSL is usually
enough.
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.
8. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
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.
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.
Repack connecting rod (22) top needle bearing after
every pump change.
Replacement elements can be purchased from your
local HONDA dealer.
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
Troubleshooting
Relieve pressure; page 6.
PROBLEM CAUSE SOLUTION
E=XX is displayed Fault condition exists Determine fault correction from table, page 14.
Engine won’t start Engine switch is OFF Turn engine switch on.
Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.
Engine oil level low Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
False tripping of WatchDog
system. EMPTY is displayed. Pump does not run.
Engine operates, but displacement pump doesn’t
’
Spark plug cable disconnected or
spark plug damaged
Oil seepage into combustion
chamber
Operating conditions out of WatchDog
parameters
Low pump output; page 8.
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
Connecting rod worn or damaged Replace. See page 9.
Drive housing worn or damaged Replace. See page 10.
Electrical power is not energizing clutch field Check wiring connections. Page 23.
Connect spark plug cable or replace spark plug.
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.
Turn pressure down. Contact Graco Technical Service to adjust WatchDog parameters.
Operate without WatchDog active; Manual 309410.
Service pump. See page 16.
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 between 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
pinion housing.
Have pressure control checked by authorized Graco dealer.
±0.2Ω; if not, replace
Clutch is worn, damaged, or incorrectly
positioned
Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 11.
Replace clutch. Page 11.
7309411
PROBLEM CAUSE SOLUTION
load
Pump output low
Excessive paint leakage into
throat packing nut
Strainer (31) clogged Clean.
Piston ball (25) not seating Service piston ball check. Manual 309277.
Piston packings worn or damaged Replace packings. Manual 309277.
Displacement pump o-ring (227) is damaged Replace o-ring. Manual 309277.
Intake valve ball not seating properly Clean and service. Manual 309277.
Engine speed is too low 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 Replace. See page 11.
Pressure setting is too low Increase pressure. Manual 309410.
Fluid filter (318), tip filter or tip is clogged or
dirty
Large pressure drop in hose with heavy
materials
Throat packing nut is loose Remove throat packing nut spacer. Tighten
Clean filter. Manual 309410 or 309091.
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 performance (50 ft minimum).
throat packing nut just enough to stop leakage.
Throat packings worn or damaged Replace packings. Manual 309277.
Displacement rod worn or damaged 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 Repack pump. Manual 309277.
Fluid is too thick 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
High engine speed at no
Gallon counter not working Bad sensor, broken or disconnected wire Check connections. Replace sensor or wire.
No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.
8 309411
Clutch surfaces are not matched to each other
when new and may cause noise
Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load
Worn engine governor Replace or service engine governor
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time
Bearing Housing and Connecting Rod
Removal
1.
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.
3. Fig. 2. Remove front cover (38). Unclip drain hose
(74) from pump. Unscrew pump suction tube (73)
from pump. Disconnect pump hose (167).
4. Push up retaining spring (59). Push pin (58) out
rear.
Relieve pressure; page 6.
58
2. Assemble connecting rod (40) and bearing
housing (60).
3. Clean mating surfaces of bearing and drive housings (60, 3).
4. Align connecting rod (C) with crank (E) and drive
housing locating pins (3b) with bearing housing
(60) holes. Push bearing housing onto drive housing or tap into place with plastic mallet.
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.
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.
Fig. 1
5. Loosen locknut (57). Unscrew displacement
pump (48).
6. Remove four screws and lockwashers (20, 19).
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.
8. Remove pail hanger (105) and install it on new
bearing housing.
9. Inspect crank (E) for excessive wear and replace
parts as needed.
Installation
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.
59
7675B
1
B
E
3
3b
58
167
1
Oil
2
Pack with bearing grease 114819
Torque to 25 ft-lb (34 Nm)
3
Fig. 2
59
62
48
A
73
57
C
D
40
2
2
20, 19
60
74
3
38
107
72
105
8697B
9309411
Drive Housing
Removal
1.
2. Disconnect reed switch (A).
3. Fig. 3. Remove bearing housing. Do Removal of
Bearing Housing and Connecting Rod procedure on page 9.
4. Remove two screws (31) and lockwashers (37).
5. Remove four screws (35) and lockwashers (34)
from pinion housing (4).
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.
Relieve pressure; page 6.
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.
Installation
1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (36) and to
areas called out by note 2. Use full 0.68 pint (0.32
liter) of grease.
2. Place bronze colored washer (3g) on shaft protruding 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).
3. Install four screws (47) and lockwashers (37) to
pinion housing (4) and drive housing (3).
4. Install two screws (31) and lockwashers (37) to
drive housing (3).
5. Fig. 3. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod procedure on page 9.
6. Connect reed switch (A).
1
35
34
A
4
2
B
62
36
61
62
1
Torque to 200 in-lb
2
Apply remaining grease to these areas
Fig. 3
3h
3g
3
37
1
31
A
Ti1889a
10 309411
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Removal
1. If pinion assembly (4) is not removed from clutch
housing (169), do 2. through 5. Otherwise, do 2.
and then start at 6.
2.
Relieve pressure; page 6.
3. Disconnect field cable (X) from pressure control
and reed switch (A).
A
6. Remove four screws (16) and lockwashers (37).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
16
37
E
Fig. 6
7. Fig. 7. Remove retaining ring (169b).
8. Tap pinion shaft (169c) out with plastic mallet.
169b
169c
8701B
Fig. 4
Bottom View
X
ti1842a
4. Fig. 5. Remove five screws (47) and lockwashers
(37) and pinion assembly (4).
47
37
4
47
Fig. 5
37
ti1888a
5. Fig. 6. Place pinion assembly (4) on bench with
rotor side up.
Fig. 7
8703B
9. Fig. 9. Remove belt guide bracket (171), belt guard
(117) and vee belt (103).
10. Hold pulley (53) and remove four screws (88) and
washers (37) from hub (94). Remove armature
(86) and spacer (169f).
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).
13. Lift off clutch housing (169).
14. Remove retaining ring (169b). Pull jack shaft assembly (169c) out.
11309411
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Installation
1. Fig. 9. Install jack shaft assembly (169c). Install
retaining ring (169b).
2. Fig. 8. Lay two stacks of two dimes on smooth
bench surface.
3. Lay armature (86) on two stacks of dimes.
4. Press hub (94) down on bench surface.
86
Fig. 8
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).
7. Apply Loctite
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.
94
0.12 ±.01 in. (3.0 ±.25 mm)
dimes
to screw (101). Install screw,
8705A
8. Hold pulley (53) and install four screws (88) and
washers (37) in hub (94). Torque to 125 in-lb
(14 Nm).
9. Install belt guard (117), belt guide bracket (171)
and vee belt (103).
10. Fig. 7. Tap pinion shaft (169c) in with plastic
mallet.
11. Install retaining ring (169b).
12. Fig. 6. Place pinion assembly on bench with rotor
side up.
13. Apply Loctite to screws. Install four screws (16)
and lockwashers (37). Alternately torque screws
to 125 in-lb until rotor is secure.
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.
15. Install pinion assembly with five screws (47) and
lockwashers (37).
16. Fig. 4. Connect field cable (X) to pressure control.
17. Page 10. Do Drive Housing, Installation.
Fig. 9
101 166
103
53
169b
169c
171
117
41
169e
169f
86
94
37
88
D
63
ti1853a
12 309411
On/Off Switch
Removal
1.
2. Fig. 10. Remove four screws (11) and
display/cover (12).
3. Pull display connector wings (A) open on PC board
and pull display connector out.
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.
12
11
Relieve pressure; page 6.
44
147
44
A
B
33
Installation
1. Install new ON/OFF switch (51) so tabs of switch
snap into place on inside of pressure control
housing.
2. Connect ON/OFF switch connector (B) to PC
board.
3. Push display connector into PC board close display connector wings (A) on PC board.
4. Install display/cover (12) with four screws (11).
8
Ref 4
147a
176
22
D
E
178
141
100a
95
100p
100q
Fig. 10
51
22
50
13
ti1849a
13309411
Pressure Control
Control Board
Removal
1.
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):
Lead (D) from potentiometer.
Lead (E) from transducer.
Remove ON/OFF switch (51) at connector (A).
4. Fig. 10. Remove six screws (44) from control board
(147) and green ground wire.
5. Remove connector (Ref 4) at backside of pressure
control. Remove jam nut (147a) and control board
(147).
Relieve pressure; page 6.
Pressure Control Transducer
Removal
1.
2. Fig. 10. Remove four screws (11) and
display/cover (12).
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).
Relieve pressure; page 6.
Installation
When installing replacement control board, follow
instructions with control board to set model type.
1. Fig. 10. Install control board (147) and jam nut
(147a). Install connector (Ref 4) at backside of
pressure control.
2. Install green ground wire and control board (147)
with six screws (44).
3. Fig. 17. Connect to control board (147):
Connect ON/OFF switch (51) connector (A).
Lead (E) to transducer.
Lead (D) to potentiometer.
4. Fig. 10. Push display connector into PC board
close display connector wings on PC board. Install
display/cover (12) with four screws (11).
5. Remove pressure control transducer (100q) and
o-ring (100p) from filter housing (100e).
Installation
1. Fig. 10. Install o-ring (100p) and pressure control
transducer (100q) in filter housing (100e). Torque
to 30–36 ft-lb.
2. Install transducer connector and rubber grommet
(176) in control housing (8) . Install transducer
guard (178) on control housing with two screws
(141).
3. Connect lead (E) to control board (147).
4. Install display/cover (12) with four screws (11).
Pressure Adjust Potentiometer
Removal
1.
2. Fig. 10. Remove four screws (11) and
display/cover (12).
3. Disconnect lead (D) from control board (147).
4. Loosen set screws on potentiometer knob (13) and
remove knob, shaft nut, lockwasher (22) and
pressure adjust potentiometer (22).
5. Remove seal (78) from potentiometer (22).
14 309411
Relieve pressure; page 6.
Installation
1. Install seal (33) on potentiometer (22).
2. Fig. 10. Install pressure adjust potentiometer (22),
shaft nut, lockwasher (22) and potentiometer knob
(13).
a. Turn potentiometer shaft (22) clockwise to
internal stop. Assemble potentiometer knob
(13) to strike pin on plate (50).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
3. Connect lead (D) to control board (147).
4. Install display/cover (12) with four screws (11).
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
No Display Sprayer may be pressurized. Loss of power or display
not connected
Sprayer may be pressurized. Pressure less than
200 psi (14 bar, 1.4 MPa)
psi
bar
MPa
Sprayer is pressurized. Power is applied. (Pressure varies with tip size and
pressure control setting.)
Sprayer stops. Engine is running. Exceeded pressure limit Remove any filter clogs or
Sprayer stops. Engine is running. Pressure transducer faulty,
Sprayer stops. Engine is running. High clutch current 1. Check clutch 7–pin bulk-
Normal operation Spray
bad connection or broken
wire.
INDICATION ACTION
Check power source. Relieve
pressure before repair or disassembly. Verify display is
connected.
Increase pressure as needed
flow obstructions. Make sure
gun trigger is locked open if
using AutoClean valve.
Check transducer connections
and wire. Replace transducer
or control board, if necessary.
head connector. Clean
contacts.
2. Measure 1.7 ±0.2Ω
across clutch field at 70F
3. Replace clutch field assembly
Sprayer stops. Engine is running.
Display alternates E=06.
Sprayer stops. Engine is running. Pressure greater than
High clutch temperature 1. If clutch is new, let spray-
2000 psi (138 bar, 14 MPa)
while in Flush Timer Mode
After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
er cool down and then restart
2. Inspect clutch. Replace
clutch if there is excessive
wear.
3. Remove pump pin, separate pinion housing from
clutch housing. Rotate
rotor clockwise to check
for excessive drag.
1. Flush paint from hose before operating Flush Timer
Mode
2. Verify AutoClean is activated and gun valve and
prime valve are open
15309411
Displacement Pump
Removal
1. Flush pump.
2.
3. Fig. 11. Cycle pump with piston rod (222) in its
lowest position.
4. Fig. 11. Remove suction tube (73) and hose (167).
167
Fig. 11
5. Fig. 12. Use screwdriver: push retaining spring up
and push out pin (58).
Relieve pressure; page 6.
222
73
7672B
Repair
58
Fig. 12
6. Fig. 13. Loosen jam nut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 13
7675B
7673B
See manual 309277 for pump repair instructions.
Installation
WARNING
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 property 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.
2. Fig. 12. Push pin (19) into hole. And push retaining
spring into groove all the way around connecting
rod.
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 (maximum) hammer to approximately 75" 5 ft–lb (102
Nm).
Fig. 15
4. Fig. 16. Fill packing nut with Graco TSL, through
one of the slits, until fluid flows onto the top of
seal.
7673B
Fig. 14
16 309411
1.5 in.
7676B
Fig. 16
7677B
Notes
17309411
Model 233709, Series A
103
101
166
53
188
82
3
124
Parts – Basic Sprayer
1
See exploded view on page 21
2
See parts in manual 309277
171
87
5
117
189
47
37
169
63
39
3
See Engine Detail on page 20
4
See parts on page 22
5
See parts on page 24
Label
6
5
37
35
34
16
5
1
4
3h
3g
36
DETAIL A
5 Ref
175
123
102
61
97
99
64
37
6
31
120
40
60
19
20
38
100
49
110
127
128
32
141
142
151
DETAIL A
21
121
162
115
62
102
54
6
6
1
3
6
137
106
59
58
72
57
167
105
107
95
2
23
73
48
74 Ref
71
70
140
139
18 309411
4
10
18
74(Ref)
81
141
179
152
ti1845b
Parts – Basic Sprayer
Ref.
No. Part No. Description Qty.
3 245443 HOUSING, drive (5900) 1
4 245399 HOUSING, pinion (5900) 1
parts, page 21
5 245245 HANDLE, cart 1
6 116806 SWITCH, reed 1
10 196670 LABEL, crtl box cover, Ultra 1
16 101682 SCREW, cap, sch 4
18 193682 PLUG, tube 2
19 106115 WASHER, lock spring (hi–collar) 4
20 114666 SCREW, cap, socket hd 4
21 112798 SCREW, thread forming, hex hd 1
23 237686 CLAMP, grounding assy 1
31 114686 SCREW, cap, socket hd 2
32 114794 CORD, power, convertible 1
34 104008 WASHER, lock, spring 4
35 101864 SCREW, cap sch 4
36 241440 GEAR, combination 1
37 105510 WASHER, lock, spring hi-collar 15
38 241308 COVER, drive 1
39 ROTOR, clutch, 5 in.; parts, page 24 1
40 241279 ROD, connecting 1
47 100644 SCREW, cap, sch 4
48 244224 PUMP, displacement 1
49 104811 CAP, hub 2
53 198688 PULLEY, engine 1
54 194125 LABEL, danger, English 1
57 193031 NUT, retaining 1
58 183210 PIN, str, hdls 1
59 183169 SPRING, retaining 1
60 241015 HOUSING, bearing 1
61 114699 WASHER, thrust 1
62 114672 WASHER, thrust 2
63 112395 SCREW, cap, flnghd 3
64 290228 LABEL, CAUTION 1
66 109099 BUSHING, snap 1
70 181072 STRAINER, inlet 1
71 241920 DEFLECTOR, threaded 1
72 197124 CLIP, spring 1
73 193097 TUBE, suction 1
74 244240 HOSE, coupled 1
Ref.
No. Part No. Description Qty.
76 206994 FLUID, TSL 8 oz bottle 1
81 195119 LABEL, warning 1
82 195098 LABEL, instruction (English) 1
87 114271 STRAP, retaining 1
88 108803 SCREW, hex, socket head 4
95 162485 NIPPLE, adapter 1
97 183350 WASHER 2
99 108068 PIN, spring straight 2
100 198723 CLIP, axle 2
101 112406 SCREW, cap, hex hd 1
102 245269 FRAME, cart, convert. 1
103 193547 BELT, vee, 30 in. 1
105 192719 HANGER, pail 1
106 112746 NUT, hex 2
107 114818 SCREW, self–tap, filhd 4
110 198720 WHEEL, semi pneumatic, 12 in. 2
115 114687 CLIP, retainer 2
117 198691 GUARD, belt 1
120 108795 SCREW, mach, pnh 4
121 114809 BUSHING, strain relief 1
123 191084 SLEEVE, cart 2
127 116891 WASHER 4
128 198772 COLLAR, torsion bar 2
137 198882 LABEL, ident, GMax 5900C 1
139 112774 SCREW, MACH 9
140 198904 SCREW, PLASTITE #8 2
141 109575 SCREW, threadforming, hex hd 3
142 245688 BAR, torsion, includes 128 1
151 198697 BRACKET, shelf belt guard 1
152 110997 SCREW, flange, hex 3
162 109032 SCREW, mach, pnh 2
166 112717 WASHER 2
167 243814 HOSE, coupled 1
169 245689 HOUSING, clutch 1
171 198996 BRACKET, belt guide 1
175 111590 BUTTON, snap 2
179 155699 ELBOW, street 1
188 100078 SCREW, mach, slt hex wash hd 4
189 245406 SHAFT, input; part of Kit 169 1
19309411
Engine Detail 118 111
93
N
M
32 Ref
146
125
L
112
P
92
156
165
J
124
41
42
C
170
166
101
101
53
108
52
C
C
Ref.
No. Part No. Description Qty.
41 183401 KEY, parallel 1
42 198689 BRACKET, belt guard (motor) 2
52 245272 BASE, mounting 1
53 198688 PULLEY, engine 1
84 194925 BRACKET, tension 1
92 194414 BRACKET, J–box 13
93 114805 JACK, 1/4 engine 1
101 112406 SCREW, cap, hex hd 3
108 114653 SCREW, cap, flange hd 4
111 192014 PLATE, indicator 1
112 116149 SPACER 1
118 113084 RIVET, blind 2
124 114530 ENGINE, gas, 5.5HP, Honda 1
ti1846a
84
Ref.
No. Part No. Description Qty.
125 198693 HANDLE, slide, engine 2
146 116139 GRIP, handle 2
156 198695 BRACKET, torsion bar 1
165 111800 SCREW, cap, hex hd, flange 2
166 112717 WASHER 2
170 198995 SLEEVE, motor shaft 1
C 110996 NUT, flng hd, hex 6
J 194126 LABEL, warning 1
L 194181 BOX, junction, engine 1
M 114816 NUT, hex 1
N 114813 SCREW, mach, hex washer hd 1
P 109099 BUSHING, snap 1
20 309411
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
No. Part No. Description Qty
4a 245267 PINION HOUSING & COIL 1
4b 105489 PIN 2
4d* PINION SHAFT 1
4e* 112770 RETAINING RING, large 1
*Must be ordered separately
4d
4e
4b
47 (Ref.)
37 (Ref.)
4
3h
Ref
No. Part No. Description Qty
3 HOUSING, drive 1
3g* 194173 WASHER 1
3h* 116192 WASHER 1
3k 116806 SWITCH, reed 1
3m 116838 PIN, spring 2
3n 116618 MAGNET 1
3p 15A622 LABEL, WatchDog 1
*Must be ordered separately
3g
15 (Ref)
3
3p
10 (Ref.)
7(Ref)
1
16 (Ref)
3m
3k
1 Pinion housing assembly (4) includes clutch field and connector
3n
9 (Ref.)
TI0177B
21309411
Parts Drawing – Sprayer
Ref No 24
Pressure Control Assembly
100a
100b
139
51
50
11
181
12
33
44
22
30
8
147
182
44
147a
7
139
178
141
100n 100m
176
100h
Ref 19
100g
100k
100c
100d
100e
100f
100j 100p
104
100r
174
95 Ref
100s100q
2213
22 309411
ti1848a
Parts List – Sprayer
REF
NO. PART NO. DESCRIPTION QTY
7 198534 PLATE, control 1
8 198548 HOUSING, control 1
11 116252 SCREW, #8 taptite, phil 4
12 245393 COVER, digital display 1
13 116167 KNOB, potentiometer 1
22 241443 POTENTIOMETER, pressure control 1
30 198648 LABEL, GMax, LCD 1
33 198650 SPACER, shaft 1
44 114331 SCREW, pnhd 6–32 6
50 198553 PANEL, control 1
51 116752 SWITCH, rocker, (spst) 1
95 162485 NIPPLE, adapter 1
104 164672 ADAPTER 2
139 112774 SCREW, mach 4
141 109575 SCREW, threadforming, hex hd 4
147 245394 BOARD, PC 1
147a NUT, nylon 1
174 245474 PLUG, packless 1
176 114296 BUSHING, step 1
178 198994 GUARD, transducer 1
181 198884 LABEL, instruction, GMax 1
189246 LABEL, warning 1
182
Includes 11, 30, 181,
Includes 147a
REF
NO. PART NO. DESCRIPTION QTY
FILTER, fluid 1
100 245396 KIT, repair, filter 1
100a 196675 BOWL, filter 1
100b 104361 O-RING 1
100c 244067 STRAINER, mesh, 60 1
100d 196786 TUBE, diffuser 1
100e 245401 KIT, repair, filter base 1
100f 193710 SEAL, valve 1
100g 193709 SEAT, valve 1
100h 114797 GASKET 1
100j 245103* VALVE 1
100k 114708 SPRING, compression 1
100m 194102 HANDLE, valve 1
100n 114688 NUT, cap, hex hd 1
100p 111457 O-RING 1
100q 243222 TRANSDUCER, pressure control 1
includes 100p
100r 197055 GASKET, plug 1
100s 196781 PLUG, AutoClean 1
* Drain valve repair kit 245103 includes 100f, g, h, k, m, n
Replacement warning labels may be ordered free of charge
VIEW A
Engine Power
Gallon
Counting
Sensor
Clutch Coil
Thermistor
DRIVE
HOUSING PINION
HOUSING
DISPLAY BOARD
CONTROL BOARD
VIEW A
Pressure Control
Wiring Diagram
ON/OFF SWITCH
TRANSDUCER
Fig. 17
TO CORD, 32
CLUTCH TEST POINTS
POTENTIOMETER
ti1843a
23309411
Parts List & Drawing –Clutch Assembly
Ref
No. Part No. Description Qty
16* 101682 SCREW, cap, sch 4
37* 105510 WASHER, lock, spring 8
39* ROTOR, clutch, 5 in. 1
86* ARMATURE, clutch 1
88* 108803 SCREW, hex, sch 4
94* HUB, armature 1
169 245689 HOUSING, clutch 1
Includes 169b, 169c, 169e, 169j & 169k
169b
169c
169e
Ref
No. Part No. Description Qty
169b 114962 RING, retaining, internal 1
169c 245406 SHAFT, drive, input 1
169e 193493 HOUSING, clutch 1
169f 194059 STOP, armature 1
169j 115078 O-RING 1
169k 115079 O-RING 1
* Clutch replacement kit 241113 includes 16, 37, 39, 86, 88,
and 94
169k
169j
169f
86*
94*
16*
37*
39*
Parts – Complete Sprayer
Model 233710, 233714
Includes:
233709 Convertible GMax 5900C Sprayer, parts
list page 18,
245507 (233714) Lo-Boy Suction Set Kit, parts list
page 25
287036 Contractor Gun Kit below:
Ref.
No. Part No. Description Qty.
226 287036 Contractor II Gun Kit 1
Includes 226a – 226c
226a 240794 HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(fbe); 50 ft (15 m);’
spring guards both ends 1
226b 238358 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
226c 246220 CONTRACTOR II SPRAY GUN
Includes RAC
and 517 SwitchTip
See 309639 for parts 1
X HandTite Tip Guard
88*37*
8745A
226a
226c
226b
0160
24 309411
Parts – Lo-Boy Suction Set Kit
Model 245507
Includes items 401 to 407
Ref.
No. Part No. Description Qty.
401 241124 .TUBE, suction, 5 gallon (20 liter) 1
includes 401a through 401e
401a 240513 ..SWIVEL, tube, inlet 1
401b 176450 ..GUARD, hose 1
401c 194306 ..HOSE, fluid 1
401d 101818 ..CLAMP, hose 2
401e 170957 ..TUBE, suction 1
402 245611 .HOSE, drain, includes 406 1
403 194194 .CLIP, spring 1
405 181072 .STRAINER 1
406 241920 .DEFLECTOR 1
407 144958 .STRAP, tie 1
Technical Data
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
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 zinc-plated carbon steel,. . . . . . . . . . . . . .
PTFE, Nylon, polyurethane, UHMW polyethylene,
FKM, POM, leather, aluminum, tungsten carbide,nickle-plated carbon steel, stainless steel,
chrome plating
401
402(REF)
406
405
403
401a
401e
402
401d
407
401b
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). . . . . . . . . . . . . . . . . . . . . . . . . . . .
DANGER LABELS
The English language DANGER label is 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 your Graco distributor.
French 194931
Spanish 194932
German 194933
Greek 194934
Korean 194935
English 194125
Apply other
language here
401c
ti1851a
03497A
25309411
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 accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les 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 INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
International Offices: Belgium, China, Japan, Korea
Graco Headquarters: Minneapolis
www.graco.com
Printed in USA 309411
1/2002 Rev. 5/2008
26 309411
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