Graco Inc. 245095 Paint Sprayer User Manual
Contents
1. Toxic fluids or fumes can cause serious injury or death if solashed in the eyes or on skin inhaled or swallowed e Read MSD9 s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection RECOIL HAZARD Brace yourself gun may recoil when triggered and cause you to fall which could cause serious injury 311046J Maintenance Maintenance Pressure Relief Procedure A WARNING 1 Lock gun trigger safety 2 Turn engine ON OFF switch to OFF 3 Move pump switch to OFF and turn pressure control knob fully counterclockwise 4 Unlock trigger safety Hold metal part of gun firmly to side of grounded metal pail and trigger gun to relieve pressure 5 Lock gun trigger safety 62. Pull drive shaft assembly FIG 5 19c out 10 311046J Installation 1 FIG 10 Install drive shaft assembly 19c Install retaining ring 19b 2 FIG 8 Lay two stacks of two dimes on smooth bench surface 3 Lay armature 25 on two stacks of dimes 4 Press center of hub 26 down to bench surface 25 26 0 12 01 in 3 0 25 mm oes ti6321a dimes FIG 8 5 FIG 9 Place spacer 19f and armature 26 25 on drive shaft assembly 19c i j 147 FIG 9 311046J 16 17 Pinion Housing Rotor Shaft Clutch Pulley Install three screws 35 through cart frame 1 and into clutch housing 19 Apply Loctite to screw 20 Install screw washer 61 key 18 and pulley 62 in end of drive shaft assembly 19c End of driveshaft 19c must be 0 090 in below flush with end of bushing Hold pulley 62 and install four screws 23 and washers 24 in hub 26 Torque to 125 in lb 14 Nm Install belt guard 146 belt guide bracket 148 and Vee belt 147 FIG 7 Tap pinion shaft 19c in with plastic mallet Install retaining ring 19b FIG 6 Place pinion housing on bench with rotor side up Apply locktite to screws Install four screws 28 and lockwashers 24 Alternately torque screws to 125 in lb until rotor is secure Push pinion housing 29 assembly onto clutch housing 19e Tap lightly on front of bearing housing 40 with a plastic mallet to push d
3. Open pressure drain valve Leave valve open until ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose CAUTION For detailed engine maintenance and specifications refer to separate Honda Engines Owner s Manual supplied DAILY Check engine oil level and fill as necessary DAILY Check hoses for wear and damage DAILY Check gun safety for proper operation 311046J DAILY Check pressure drain valve for proper operation DAILY Check and fill the gas tank DAILY Check that V belt 147 is centered on pulley and is not inverted Replace if worn or damaged AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscosity WEEKLY Remove engine air filter cover and clean ele ment Replace element if necessary If operating in an unusually dusty environment check filter daily and replace if necessary Replacement elements can be purchased from your local HONDA dealer WEEKLY Check level of TSL in displacement pump packing nut Fill nut if necessary Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion AFTER EACH 100 HO
4. POTENTIOMETER 1 59 15C972 PIN grooved 1 169e 198650 SPACER shaft 1 59 224807 BASE valve 1 169f 116752 SWITCH rocker 1 60 235014 VALVE drain 1 1699 119541 SWITCH toggle 1 64 15E925 GASKET transducer 1 169h 116167 KNOB potentiometer 1 65 164672 ADAPTER 1 169j 195428 BOOT toggle 1 162485 ADAPTER nipple 1 169k 15E857 LABEL identification 1 TexSpray 5900HD Convertible ee l 66 241732 TRANSDUCER pressure contl 1 169N 15E855 LABEL identification l 67 111457 O RING 1 169px 15E858 LABEL identification 1 71 116585 SCREW mach pnh sems 6 169r 119545 BUSHING strain relief 1 73 15E022 SEAT valve 175 287648 a complete 1 74 111699 GASKET seat valve 1 eA 91 287293 VALVE auto clean includes 91a 1 176 287649 CONTROL standard complete 1 9lax 115524 GASKET 1 includes 169b 169r 92 244346 KIT repair clamp trigger 1 l l 96 104813 PLUG pipe 1 Premium amp TexSpray 5900HD Convertible models only 122 248314 PLUG includes 123 1 Included in Filter Base Repair Kit 287510 123 15D541 O RING 1 Pressure Control Wiring Diagram TO GROUND DRIVE PUMP STROKE Parts C CONTROL O BOARD E E W 2 COUNTER TO ENGINE ON OFF SWITCH WATCHDOG DISPLAY BOARD 311046J 23 Parts Clutch Housing Parts Drawing and List Ref Part Description Qty Ref Part Description Qty 24 105510 WASHER lock spring hi collar 8 19 287519 HOUSING clu
5. Turn pressure adjusting knob clockwise to increase pressure Fluid filter 29 is dirty lean filter Page 22 KETUT rs Tip or tip filter is clogged Clean tip or tip filter Manual 309639 Displacement pump piston rod is stuck Repair pump Manual 310894 due to dried paint Connecting rod is worn or damaged Replace connecting rod Page 8 Drive housing is worn or damaged Replace drive housing Page 9 Electrical power is not energizing clutch Check wiring connections Page 12 field Reference pressure control repair Page 14 Reference wiring diagram Page 23 With pump switch ON and pressure turned to MAXI MUM use a test light to check for power between clutch test points on control board Remove clutch wires from control board and measure resistance across clutch coil At 70 F the resistance must be between 1 2 0 20 if not replace pinion housing Have pressure control checked by authorized Graco dealer lutch is worn damaged or incorrectly Adjust or replace clutch Page 10 positioned pinion housing is worn or damaged Repair or replace pinion housing Page10 311046J Troubleshooting Pump output is low Strainer 82 is clogged Piston ball 206 is not seating V belt slipping Tighten V belt with tension bar 132 Adjust bracket until it takes 15 lb of force to lock tension bar down Clutch is worn or damaged Adjust or replace clutch Page 10 Pressure setting is too low Increase pressure Manu
6. side up 1 If pinion housing 29 is not removed from clutch housing r 19 do 2 through 5 Otherwise do 2 and then start at 6 6 Remove four screws 28 and lock washers 24 Install two screws in threaded holes E in rotor Alternately 1 WARNING tighten screws until rotor comes off Read Skin Injection Hazard page 3 Burn Hazard page 4 E 2 Do Pressure Relief Procedure page 5 3 FIG 4 Disconnect clutch cable connectors a Remove two screws 71 and swing down cover 130a b Remove strain relief 171 c Disconnect clutch cable connectors X a Jy _ N o g 4 Cee ti5987b ti5743a s FIG 6 7 FIG 7 Remove retaining ring 29e 8 Turn pinion housing over and tap pinion shaft 29d out with plastic mallet ti6293a Bottom View CLUTCH CLUTCH FIG 4 4 FIG 5 Remove four screws 36 lock washers 37 and pinion housing 29 FIG 7 ti5482a 9 FIG 9 Remove belt guide bracket 146 belt guard 148 and Vee belt 147 10 Hold pulley 62 and remove four screws 23 and washers 24 from hub 26 Remove armature 25 and spacer 19f 11 Engine Detail page 18 Remove screw 20 and washer 61 from engine drive shaft Remove pulley 62 and motor shaft sleeve 144 Remove pulley and key 18 12 Fig 9 Remove three screws 35 from beneath cart frame 1 13 Lift off clutch housing 19e ti5742a 14 Remove retaining ring 19b
7. 15E891 191084 183350 108068 108795 112827 245245 23 686 112798 2 6974 183401 287519 121727 114528 108803 105510 193510 101682 287465 114672 114699 287460 287700 116618 112395 102962 104008 150753 119562 289274 114666 106115 287472 287511 118444 287513 287579 112717 198688 114425 111457 243993 241920 15E284 189920 15E802 287543 15F110 248215 118494 311046J Description FRAME cart WASHER flat WHEEL pneumatic CLIP retaining SLEEVE cart WASHER PIN spring straight SCREW mach pnh BUTTON snap HANDLE cart WIRE ground assembly w clamp SCREW thread forming hex hd CAP leg KEY parallel HOUSING clutch SCREW cap hex hd SCREW mach phillips pnhd SCREW hex socket head see page 24 WASHER lock spring hi collar HUB armature see page 24 ROTOR clutch 5 in SCREW cap sch HOUSING pinion 5900 WASHER thrust WASHER thrust GEAR combination HOUSING drive convert MAGNET SCREW cap flnghd SCREW cap sch WASHER lock spring SCREW mach torx hex wash hd SWITCH reed w connector HOUSING bearing SCREW cap socket hd WASHER lock spring hi collar ROD connecting 5900 COVER front 5900 includes 45 SCREW machine hex washer head PUMP displacement 5900 includes 86 89 90 Manual 310894 PUMP displacement TexSpray 5900HD convertible includes 86 WASHER PULLEY engine BUSHING strain relief O RING HOSE coupled
8. 3 Premium Standard STRAP retaining BUSHING strain relief SPRING retaining LABEL ProConnect CLIP retainer O RING LABEL warning 9 lt O N e ae WO W h a eS lt N VY S S i SN ee ee b h b b d A Replacement Danger and Warning labels tags and cards are availabel at no cost Included in Clutch Repair Kit 241113 t Not used on TexSpray 5900HD Convertible 19 Engine Detail 142 Ref 128 oS 129 ti5750a Engine Detail Parts List Ref 15 16 17 18 20 61 115 124 125 126 127 128 20 Part 114530 114653 110996 183401 121727 112717 194126 245272 116139 198689 112406 198997 Description ENGINE gas 5 5 Honda SCREW cap flange hd NUT flng hd hex KEY parallel SCREW cap hex hd WASHER LABEL warning BASE mounting GRIP handle BRACKET belt guard motor SCREW BRACKET tension Ra NE Wy 17 ee Qty lt M e N oO BR Ref 129 130 131 135 136 137 138 139 140 141 143 144 Part 198693 198695 110963 114816 116149 194414 114813 114678 194181 114805 15E896 15B314 Parts Description HANDLE slide engine BRACKET torsion bar SCREW cap hex hd flange NUT hex SPACER BRACKET J box SCREW mach hex washer hd BUSHING snap BOX junction engine JACK 1 4 engine PULLEY engine SLEEVE motor shaft 2 lt mek i a
9. 3 Replace clutch field assembly 1 Check for empty paint condition clogged inlet strainer failed pump or severe leak 2 Reduce pressure and turn pump switch OFF and ON to restart pump 3 Watch dog function can be deactivated by turning WatchDog switch OFF 1 Open prime valve and gun 2 Verify no flow obstructions or clogged filter After a fault follow these steps to restart sprayer red LED LED is an alternate to digital messages 1 Correct fault condition 1 Remove two screws 71 and swing down cover 130 2 Turn sprayer OFF 2 Start engine Blink count is the same as error code E 0X 3 Turn sprayer ON 14 311046J Displacement Pump Displacement Pump 6 Raise latch lock Push latch open Removal 1 Flush pump 2 FIG 19 Stop pump with piston rod in its lowest position A WARNING Aa Read Skin Injection Hazard page 3 Burn Hazard 3 Do Pressure Relief page 5 4 Separate drain hose from sprayer FIG 13 7 FIG 14 Ratchet open pump door a Ratchet pump door forward Fic 11 5 Disconnect material hose from pump Fic 14 b Twist latch u bolt out of pump door recess c Place u bolt on pump door outer edge d If pump door is stuck do steps e f and 8 otherwise go to step 9 FIG 12 FIG 15 311046J 15 e Twist latch u bolt back from pump door outer edge Place u bolt on pump door protrusion T FIG 16 8 Ratchet pump door
10. 6454 6205200 eau oes ee 3 Maintenance 0 00 c eee es 5 Troubleshooting 000 e eee eee 6 REDIN cette tes eet aes tee eee eee cee 8 Bearing Housing amp Connecting Rod 8 Driv HOUSING s lt ccscctectcdnceesew ted eae eee 9 Pinion Housing Rotor Shaft Clutch Pulley 10 Pressure Control 0 00 0c eee eeee 12 Displacement Pump 0000000 eee 15 PAS 616 x2 htecereeereseevessoreeueex teas 18 Manual Conventions A WARNING NO Hazard Symbol Dd WARNING a potentially hazardous situation which if not avoided could result in death or serious injury Warnings in the instructions usually include a symbol indicating the hazard Read the general Warnings section for additional safety information Manual Conventions Standard Sprayer 0000 c eee eee eee 18 Engine DGTAW s c sc0 sce ween od aoe eee eae oe 20 Pinion and Drive Housing 0 0000008 21 Pressure Control and Filter 5 22 Clutch HOUSING 620 56 esses Htaw ee cee e eee ee 24 Premium Sprayer 0000 e eee eee eee 25 Lo Boy Suction Set 020 ce ee eee 26 Technical Data 6 sic coset eed teeane see ew 27 Graco Standard Warranty 0020005 28 CAUTION CAUTION a potentially hazardous situation which if not avoided may result in property damage or destruction of equipment Note ee helpful information 311046J Warning Warning The following are general warning
11. DEFLECTOR threaded HOUSING filter STRAINER 1 11 1 2 npsm FITTING pump quick disconnect HOSE coupled PIN pump TUBE intake O RING Qty ANMHIFHHNHHK HA NANNNNNDNB BR BR BR om BRA QO HS SH VP A S C _ h ee ee h h b h h h a a Ref 91 93t 94T 98 99 100 101 102T 108T 104T 110 114 1164 117A 118A 119 132 133 134 142 145 146 147 148 151 164 169 172 173 174 185 190 191 1954 Part 287162 287253 118852 113161 15E918 15E736 119510 15E902 100270 102040 15F755 15E854 15E979 15E980 15F638 290228 804495 195098 245688 114808 198772 119584 100078 198996 193547 198691 116038 15F947 28 7648 287649 114271 119569 119677 15F584 114687 119790 195119 Parts Description VALVE auto clean TOOL BOX SCREW machine hex washer hd SCREW flange hex hd BRACKET holder manual BRACKET holder manual HOLDER manual PLATE SCREW cap hex hd NUT lock hex LABEL identification Premium amp TexSpray 5900HD Convertible Standard LABEL identification LABEL identification TexSpray 5900HD convertible LABEL warning LABEL caution LABEL warning LABEL instruction English BAR torsion includes 133 134 CAP vinyl COLLAR torsion bar CORD power convertible SCREW thd forming hex hd BRACKET belt guide BELT Vee 30 GUARD belt WASHER wave spring SHIELD magnetic BOX control see pages 22 2
12. M st st et NS N 311046J Parts Pinion and Drive Housing Parts Drawing and List Ref No 29 Pinion Housing 287465 Ref 29 29a 29b 29C 29d Part 287476 241114 112770 105489 114683 AN Pinion Housing 29 includes Clutch Field 311046J Description PINION HOUSING amp COIL PINION SHAFT RETAINING RING large PIN O RING Qty N e a Ref No 33 Drive Housing 287700 Ref Part Description Qty 33 HOUSING drive 1 33a 194173 WASHER 1 33b 116192 WASHER 1 Premium models and TexSpray 5900HD convertible 21 Parts Pressure Control and Filter Parts Drawing Control Premium TexSpray 5900HD Convertible Complete 175 Part Number 287648 Premium i models 60 73 74 123 122 Sania mand as oni 7 Standard Premium a a a Models Models Control Standard Complete 176 TexSpray 5900HD Part Number 287649 Convertible Part Number 287510 22 311046J Pressure Control and Filter Parts List REF PART DESCRIPTION QTY REF PART DESCRIPTION QTY 154 116756 FITTING elbow 45 degrees 1 53 15C765 CAP filter 1 169ax 249583 BOX control premium 1 54 117285 O RING 1 169a 249584 BOX control standard 1 55 15C766 TUBE diffusion 1 169b 287516 CONTROL board 1 56 243984 FILTER fluid 1 169c 117317 SCREW plastite pan hd 7 57 15C780 HANDLE 1 169d 240925
13. Remove two screws 71 and swing down cover 169a 2 Disconnect potentiometer 169d lead from control board 169b 3 Loosen set screws on potentiometer knob 169h and remove knob shaft nut lock washer and potentiometer 169d 4 Remove shaft spacer 169e from potentiometer 311046J Installation 1 Install shaft spacer 169e on potentiometer 169d 2 FIG 10 Install potentiometer shaft nut lock washer and potentiometer knob 169h a Turn potentiometer shaft clockwise to internal stop Assemble potentiometer knob 169h to strike pin on cover 169a b After adjustment of step a tighten both set screws in knob 1 4 to 3 8 turn after contact with shaft Connect potentiometer lead to control board 169b 4 Swing up cover 169a and secure with two screws 71 Digital Display Messages 13 Pressure Control Digital Display Messages A WARNING Relieve pressure before repair page 5 DISPLAY SPRAYER OPERATION INDICATION 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 ti6314a annn Sprayer is pressurized Power is applied Normal operation UU psi Pressure varies with tip size and au bar pressure control setting cit MPa ti6315a oo a a Sprayer stops Engine is running Exceeded pressure limit List l ti6316a Sprayer stops Engine is running Pressure transducer faulty bad L n
14. Repair G GRACO GMAX 115900 Convertible TexSpray 5900 HD Airless Sprayers 311046J 5 pe i P is Spat ue ue z For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi 22 8 MPa 228 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 248691 Standard 248693 Standard with electric motor kit 248694 Same as 248693 except with ETL approval to CSA and UL standards 248695 A Standard with Lo Boy suction set kit 248696 A Premium same as 248890 except with ETL approval to CSA and UL standards 248697 A Standard with Lo Boy suction set kit and electric motor kit 248889 A Premium same as 248692 except with electric motor kit 248890 Premium with Lo Boy suction set kit eo Gei 255630 A TexSpray 5900HD convertible with texture S A SoA gun and hose Pi a a Aa 1 ix n 255631 Same as 255630 with electric motor kit J 255954 A Same as 255630 except with electric 114178 motor kit that is ETL approved to CSA and G UL standards 245096 KIT electric motor CSA 245095 KIT electric motor Non CSA ar y Related Manuals x 311861 Eel 310892 RI ee KA 309469 Ti 310894 E 309640 PROVEN QUALITY LEADING TECHNOLOGY Graco Inc P O Box 1441 Minneapolis MN 55440 1441 Pe Copyright 2005 Graco Inc is registered to l S EN ISO 9001 daos Contents WARNING 23520
15. SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and Cause serious injury e Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply Warning WARNING EQUIPMENT MISUSE HA
16. URS OF OPERATION Change engine oil Reference Honda Engines Owner s Manual for correct oil viscosity SPARK PLUG Use only BPR6ES NGK or W20EPR U NIPPONDENSO plug Gap plug to 0 028 to 0 031 in 0 7 to 0 8 mm Use spark plug wrench when installing and removing plug Troubleshooting Troubleshooting Solution Determine fault correction trom table page Engine switch is OFF Turn engine switch ON Engine is out of gasoline Refill gas tank Honda Engines Owner s Man ual Engine will not start False tripping of WatchDog system EMPTY is displayed Pump does not run Engine operates but displacement pump does not operate Engine oil level is low Try to start engine Replenish oil if necessary Honda Engines Owner s Manual Spark plug is disconnected of damaged Connect spark plug cable or replace spark plug Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position ROVE ENEO ON PORON a a Oil is seeping into combustion chamber Remove spark plug Pull starter 3 to 4 times Clean or replace spark plug Start engine Keep sprayer upright to avoid oil seepage Operating conditions out of WatchDog Turn pressure down Contact Graco Technical parameters Assistance to adjust WatchDog parameters Pump output is low page 7 Operate without WatchDog active Manual 310892 Error code displayed Reference Pressure Control repair page 14 Pump switch is OFF Turn pump switch ON Pressure setting too low
17. ZARD Misuse can cause death or serious injury e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage SUCTION HAZARD Never place hands near the pump fluid inlet when pump is operating or pressurized Powerful suction could cause serious injury CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon mon oxide can cause death Do not operate in an enclosed area TOXIC FLUID OR FUMES HAZARD
18. al 310892 Fluid filter 56 tip filter or tip is clogged or Clean filter Manual 310892 or 309639 dirty Large pressure drop in hose with heavy __ Use larger diameter hose and or reduce materials 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 Excessive paint leakage into throat Throat packing nut is loose Remove throat packing nut spacer Tighten packing nut throat packing nut just enough to stop leak age Throat packings are worn or damaged Replace packings Manual 310894 Displacement rod is worn or damaged Replace rod Manual 310894 Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Rep rime pump Manual 310892 Tip is partially clogged Clear tip Manual 309639 Fluid supply is low or empty Refill fluid supply Prime pump Manual 310892 Check fluid supply often to prevent running pump dry Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming Intake valve is leaking Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve Pump packings are worn Replace pump packings Manual 310894 Paint is too thick Thin the paint according to the supplier s recommendations Engine speed is too high Decreas
19. e throttle setting before priming pump Manual 310892 Clutch squeaks each time clutch Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other engages when new and may cause noise Noise will dissipate after a day of run time High engine speed at no load Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load Gallon counter not working Bad sensor broken or disconnected wire Check connections Replace sensor or Displaced or missing magnet wire Reposition or replace magnet No display sprayer operates Display damaged or has bad connection Check connections Replace display 311046J 7 Bearing Housing and Connecting Rod Bearing Housing and Connecting Rod Removal CAUTION DO NOT use bearing housing screws 41 to align or 44 WARNING seat bearing housing with drive housing Align these tS o parts with locating pins to avoid premature bearing N wear Dd Read Skin Injection Hazard page 3 Burn Hazard page 4 5 Install screws 41 and washers 42 in bearing housing Torque evenly to note 3 value in Fig 1 1 Relieve pressure page 5 6 Install pump Refer to Displacement Pump Installation page 14 2 FIG 1 Remove four screws 45 and front cover 44 3 Remove pump Refer to Displacement Pump Removal page 14 4 Remove four screws 41 and washers 42 from bearing housing 40 5 Pull connecting rod 43 and lightly tap lower rear of bearing
20. ecting Rod Removal page 8 CAUTION Gallon counter sensor is connected to control board in pres sure control Pulling on the sensor wires could cause damage 3 Premium sprayers Remove two screws 108 and gallon counter sensor 39 ti5740a CAUTION Thrust washers may stick to grease inside of drive housing Do not lose or misplace 4 Remove six screws 38 5 Lightly tap around drive housing 33 to loosen drive housing Pull drive housing straight off pinion housing Be prepared to support combination gear 32 which may also come out A Torque to 25 ft lb 34 N m y 22 A Gallon counter sensor Installation AA Pack with grease 114819 1 FIG 2 Apply all grease supplied with replacement gear SUA C RNCNCSCNN cluster to gear cluster 32 and to areas called out by note 3 2 FIG 3 Ensure thrust washers are on combination gear 32 as shown na 30 30a A 3 Clean mating surfaces of pinion and drive housings 4 Align gears and push new drive housing straight onto pinion housing 29 and locating pins B 5 Install six screws 38 6 Install gallon counter sensor 39 with two screws 108 N Steel 7 Install bearing housing Refer to Bearing Housing and tases A Cc eee opper Connecting Rod Installation page 8 FIG 3 311046J 9 Pinion Housing Rotor Shatt Clutch Pulley PinionHousing Rotor Shaft Clutch Pulley Removal 5 FIG 6 Place pinion housing 29 on bench with rotor
21. ene fluoroelastomer acetal leather aluminum tungsten carbide nickel and zinc plated carbon steel stainless steel chrome plating Dimensions Height in Width in Sprayer Weight Ib Length in cm without hose and gun kg in cm in cm 248691 Hi Boy 168 76 34 5 87 6 24 5 62 2 33 5 85 1 255630 HD 248695 Lo Boy 173 78 34 5 87 6 24 5 62 2 33 5 85 1 311046J 27 Graco Standard Warranty Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures acce
22. es 4 Remove four screws 169c and control board 169b Installation 1 FIG 10 Install control board 169b with four screws 169c 2 Connect engine wires to control board 169b 3 Install control box 169a with four screws 71 4 Connect at control board 169b e Ground and clutch wires e Display connector e Lead from gallon counter sensor pump stroke e Lead from ON OFF switch 169f e Lead from WatchDog switch 169g e Lead from transducer 66 e Lead from potentiometer 169d 5 Install new strain relief bushings 123a and 123b 6 Swing up cover 169a and secure with two screws 71 Pressure Control Transducer Removal WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 1 FIG 10 Remove two screws 71 and swing down cover 169a 2 Disconnect transducer 66 lead from control board 169b 3 Pull transducer connector through rubber grommet 113 4 Remove pressure control transducer 66 and o ring 67 from filter housing 72 Installation 1 FIG 10 Install o ring 67 and pressure control transducer 66 in filter housing 72 Torque to 35 45 ft lb 2 Install transducer connector and rubber grommet in control housing 3 Connect transducer 66 lead to control board 169b 4 Swing up cover 169a and secure with two screws 71 Pressure Adjust Potentiometer Removal A WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 1 Fig 13
23. forward FIG 17 9 Open pump door FIG 18 16 Displacement Pump Installation 1 FIG 20 Adjust piston rod with pin holder to pull out piston rod Tap piston rod on hard surface to push in piston rod 2 Push pump collar flush with bearing housing ledge to be able to close pump door ti6325a FIG 20 3 FIG 21 Slide pump into connecting rod Push pump pin until it is fully retained Note Pin will snap into position 4 FIG 22 Close pump door and rotate latch into position Do not tighten latch 311046J Displacement Pump FIG 24 Attach drain hose to sprayer 5 FIG 22 Rotate pump to align with material hose Connect 7 material hose and hand tighten to 70 in lb FIG 24 8 FIG 25 Fill pump with Graco TSL until fluid flows onto top FIG 22 of seal 6 FIG 23 Tighten latch and rotate latch lock into locked position FIG 25 FIG 23 311046 17 Parts Parts Standard Sprayer Parts Drawing AN See exploded view on page 21 20 A N Label DETAIL A r ane ol AA See Engine Detail on page 20 See parts on page 22 See parts on page 24 A See parts on page 25 5 6 aah Ref 1 33a Ref 33b Ref ti5737b ae TexSprayer 5900HD Convertible Only 101 el 100 145 18 311046J Standard Sprayer Parts List Ref OONDOaBRWNDY 61 62 63 67 68 69 72 82 86 87 88 89T 90T Part 287423 156306 119509
24. housing with plastic mallet to loosen from drive housing 33 Pull bearing housing and connecting rod assembly off drive housing 6 Inspect crank B and connecting rod 43 for excessive wear and replace parts as needed Installation 1 Evenly lubricate inside of bronze bearing C in bearing housing 40 with high quality motor oil Liberally pack top roller bearing E lower bearing D inside connecting rod 43 with bearing grease 2 Assemble connecting rod 43 to bearing housing 40 Rotate connecting rod to lowest position ti5739b 3 Clean mating surfaces of bearing and drive housings 4 Align connecting rod with crank B and carefully align locating pins in drive housing 33 with holes in bearing A oil housing 40 Push bearing housing onto drive housing or A Pack with bearing grease 114819 tap into place with plastic mallet A Torque to 25 ft lb 34 N m FIG 1 8 311046J Drive Housing Drive Housing Removal CAUTION DO NOT use drive housing screws 18 to align or seat WARNING bearing housing with drive housing Align these parts with locating pins to avoid premature bearing wear 8 Install screws 18 in drive housing Torque evenly to note Read Skin Injection Hazard page 3 Burn Hazard page 4 3 value in Fig 1 9 Install pump Refer to Displacement Pump Installation page14 1 Relieve pressure page 5 2 Remove bearing housing Refer to Bearing Housing and Conn
25. ion Graco reserves the right to make changes at any time without notice This manual contains English MM 311046 Graco Headquarters Minneapolis International Offices Belgium Korea China Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com 2 2005 Revised 05 2009 28 311046J
26. n l connection or broken wire LU J ti6317a 2 ee Sprayer stops Engine is running High clutch current Loft Lud ti6318a Sprayer stops Engine is running Loss of paint to pump or severe _LmwmiutV pressure loss Lettie with constant green LED Sprayer stops Engine is running Pressure greater than 2000 psi 138 bar 14 MPa while in Flush Timer Mode Error codes also appear on control board as a blinking Digital messages are not available on all sprayers e Blinking LED total count equals digital error code i e two blinks is the same as E 02 ACTION Check power source Relieve pressure before repair or disassembly Verify display is connected Increase pressure as needed Spray 1 Check fluid path for clogs such as clogged filter 2 Open prime valve and gun if running AutoClean 3 Use Graco paint hose 1 4 in x 50 ft minimum Smaller hose or metal braid hose may result in pressure spikes 4 Replace transducer if fluid path is not clogged and proper hose is used 1 Check transducer connection 2 Disconnect and reconnect transducer plug to ensure good connection with control board socket 3 Open prime valve Replace sprayer transducer with known good transducer and run sprayer Replace transducer if sprayer runs or control board if sprayer does not run 1 Check wiring connections 2 Measure 1 2 0 2Q GMAX II 3900 1 7 0 2Q GMAX II 5900 7900 across clutch field at 70 F
27. ng LATCH housing bearing NUT lock hex CLIP spring SCREW adjustment SCREW set socket hd LATCH RECEIVER clamp SCREW shoulder socket head Parts Qty m et kt i DS st eh 25 Lo Boy Suction Set Parts Drawing and List Models 248695 248697 248890 Ref Part Description Qty 287631 KIT repair tube suction 401 287537 HOSE suction GMAX II 3900 5900 402 287536 HOSE drain GMAX II 3900 5900 403 189920 STRAINER 1 11 1 2 nosm 404 241920 DEFLECTOR threaded 405 15D000 CLIP drain line 406 15C980 NUT jam 407 15C981 WASHER suction swivel 408 118505 RING retaining external 409 117559 O RING 410 115099 WASHER garden hose lt N S 1 1 26 ti5756a 403 Parts 311046J Technical Data Technical Data Honda GX160 Engine ANSI Power Rating 3600 5 5 Horsepower 4 1 kW rpm measured at 3 1 feet 1 m Cycles gallon liter 93 25 Maximum delivery Gas Engine 1 6 gpm 6 0 liter min Electric Motor 1 1 gpm 4 2 liter min 1 gun with 0 043 in tip 2 gun with 0 029 in tip 3 gun with 0 023 in tip 4 gun with 0 019 in tip 1 gun with 0 031 in tip 2 gun with 0 017 in tip Inlet paint strainer 16 mesh 1190 micron stainless steel screen reusable Gas Engine Electric Motor Outlet paint filter 60 mesh 250 micron Pump inlet size 1 5 16 12 UN 2A Fluid outlet size Y npsm from fluid filter zinc plated carbon steel PTFE Nylon polyurethane UHMW polyethyl
28. rive housing and pinion housing assembly onto clutch housing Install pinion housing with five screws 36 and lockwashers 37 FIG 4 Connect clutch cable connectors X to board Page 9 Do Drive Housing Installation ti5745a 11 Pressure Control Pressure Control On Off Switch Removal Installation A WARNING 1 Install new ON OFF switch 169f so tabs of switch snap into place on inside of cover amp 2 Connect ON OFF switch connector to control board ed 3 Swing up cover 169a and secure with two screws 71 Read Skin Injection Hazard page 3 Burn Hazard page 4 FIG 10 Remove two screws 71 and swing down cover 169a 2 Disconnect ON OFF switch 169f connector from control board 3 Press in on two retaining tabs on each side of ON OFF switch 169f and remove switch from cover TO ENGINE 15 CLUTCH oe 171 Gee CLUTCH op GALLON COUNTER 39 169f 169j Fic 10 12 311046 Pressure Control Control Board Removal A WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 1 FIG 10 Remove two screws 71 and swing down cover 169a 2 Remove strain relief bushings 123a and 123b 3 Disconnect at control board 169b Lead from potentiometer 169d Lead from transducer 66 Lead from WatchDog switch 169g Lead from ON OFF switch 169f Lead from gallon counter sensor pump stroke e Display connector e Engine ground and clutch wir
29. s related to the setup use maintenance and repair of this equipment Additional more specific warnings may be found throughout the text of this manual where applicable 311046J Ay WARNING FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Do not fill fuel tank while engine is running or hot shut off engine and let it cool Fuel is flammable and can ignite or explode if spilled on hot surface Do not fill fuel tank while engine is running or hot shut off engine and let it cool Fuel is flammable and can ignite or explode if spilled on hot surface When flammable liquid is sprayed or used for flushing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground equipment and conductive objects in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem
30. ssories 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 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 FORA 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 mo
31. tch 1 25 ARMATURE clutch 5 in 1 Includes 19b 19c 19e 19j amp 19k 26 193510 HUB armature 1 19b 114962 RING retaining internal 27 ROTOR clutch 5 in 1 19c 287422 SHAFT drive input 28 101682 SCREW cap sch 4 i i i 4 19e 15E887 HOUSING clutch Included in Clutch Repair Kit 241113 19j 115078 O RING 19k 115079 O RING 21 15E894 STOP armature 23 108803 SCREW hex socket head f 5 J Pace ti5754a BAI 24 311046J Premium Sprayers Parts Drawing and List Ref Part 201 202 240794 240797 204 288420 241705 205 241735 311046J Description Hi Boy Sprayers See parts page 18 Lo Boy Sprayers See parts page 18 Includes Lo Boy Suction Set Kit See parts page 26 HOSE grounded nylon 1 4 in ID cpld 1 4 npsm fbe 50 foot 15 m spring guards both ends 3300 psi 227 bar 27 7 MPa HOSE grounded 3 8 in x 50 ft TexSpray 5900HD Convertible CONTRACTOR II SPRAY GUN Includes RAC X 517 size SwitchTip and HandTite Guard See 311861 for parts TEXTURE SPRAY GUN see 308491 for parts TexSpray 5900HD Convertible HOSE whip 1 4 in x 3 ft TexSpray 5900HD Convertible Qty Ref 40 Bearing Housing Ref 40 45 50 51 52 150 180 181 182 196 197 181 Part 289274 118444 15E625 15G890 111040 15E975 15F498 15F503 15F116 15G584 116942 Description HOUSING bearing complete SCREW mach hex wash hd PIN housing beari
32. tors 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 r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor All written and visual data contained in this document reflects the latest product information available at the time of publicat
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