Graco 231-316 Series C User manual

308–327
Rev. H
Supersedes Rev. G
First choice when
quality counts. t
7340A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
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
Model 231-331
Complete sprayer, with hose and Contractor gun,
RAC IVtDripLesstTip Guard,
and 517 size SwitchTipt
OptionalElectric 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
ECOPYRIGHT 1993, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2308–327
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing and Connecting Rod 15. . . . . . . . . .
Drive Housing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field and Wiring Harness 19. . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
equipment if the you do not follow the instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse 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.
DDo not use hoses to pull equipment.
DRoute 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DWear hearing protection when operating this equipment.
DDo 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.

3308–327
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate 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.

4308–327
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult 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.
Liquidscanbeinjectedintothebodybyhighpressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body.Drainallpressurebeforeremovingparts.Avoidaccidentaltrig-
geringof gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“SurgicalTreatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD SKIN INJECTION HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spraypainting,flushing orcleaning equipmentwith flammableliq-
uids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip-
ment,hoses,containers andobjects beingsprayed.
Avoidallignitionsourcessuchasstaticelectricityfromplasticdrop
cloths,open flames such as pilot lights, hot objects such as ciga-
rettes, arcsfromconnectingordisconnectingpowercordsorturn-
ing light switches on and off.
Failure to follow this warning can result in death or serious injury.
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.

5308–327
Component Identification and Function
Fig. 1 7203A
5
18
53
15
60
27
1
AB
C
D
E
F
G
HJ
K
202Mainhose
203Whipend hose
204Contractor gun with RAC IV
DripLess tip guard and 517 size SwitchTip
203
204
202
M
L
N
2
APressure Control Switch ON/OFF, enables/disables clutch function
BPressure Adjusting Knob Controls fluid outlet pressure
CAir Cleaner* Filters air entering the carburetor
DFuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline
EMuffler* Reduces noise of internal combustion
FSpark Plug Cable* Routes electrical current to spark plug
GFuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor
HChoke* Enriches air/gasoline mixture for cold starting
JThrottle* Adjusts engine speed for large or small orifice spray tips
KEngine Switch* Enables/disables engine operation
LSecondary Fluid Outlet Second hose and spray gun is connected here
MPressure Control Controls clutch cycling to maintain fluid pressure.
NPrimary Fluid Outlet Hose and spray gun is connected here
1Engine* 5.5 HP gasoline engine
2Clutch Housing Transfers power from engine to drive assembly
5Drive 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

6308–327
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 3000 psi (210 bar, 21 MPa) Maxi-
mum Working Pressure . This is to reduce the risk
of serious injury caused by static sparking, fluid
injection or over-pressurization and rupture of the
hose or gun.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and compo-
nent 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.
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.
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.
7205A
Do not install any shutoff
devicehere.
Fillwith TSL
Fig. 2
1
3
2
Do not use thread sealant
on swivels
56
126
128
127
4161
2
3
55

7308–327
Setup
5. Check the engine oil level. Refer to the Honda
engine manual, supplied. This is a summary of the
information: Remove one of the oil fill plugs (C);
the oil should be almost overflowing. See Fig 3.
Add oil as necessary.
Recommended lubrication oil: Use a high-quality,
detergent oil, SAE 10W-40, classified “FOR SER-
VICE SE or SF”, for regular use and for breaking-
in 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. Fig. 3 7206A
B
C
A
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.
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.
2. Gasolines containing alcohol (gasohol). Do not
use gasohol which contains methanol, if the gaso-
hol 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 infor-
mation.
3. General. Do not use oil and gasoline mixtures or
contaminated gasoline. Avoid getting dirt, dust or
water in the fuel tank.
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.

8308–327
Startup
Fig. 4
Triggersafety
latchshown
engaged
0137

NOTE: For the startup procedure, refer to Fig. 5
except where noted otherwise.
Before you start the sprayer
1. Become familiar with how to operate the gun’s
trigger safety latch. See Fig. 4 and refer to your
gun instruction manual.
2. Become familiar with the proper way to relieve
pressure. See the Pressure Relief Procedure on
page 10.
3. Determine if you should flush the sprayer. See
Flushing on page NO TAG.
4. Check the gas tank level. See page 7.
5. Check the oil level. See page 7.
NOTE: The engine stops automatically, or will not
start, if it is low on oil. If you try to start it again without
adding more oil, a red light near the engine on/off
switch glows as you pull the starter rope.
6. Push the spark plug cable (F) firmly onto the plug.
7. If starting a sprayer that IS NOT PRIMED, remove
the spray tip.
8. If a secondary hose and gun is not installed, be
sure the cap (L) is securely plugging the second-
ary 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).
CAUTION
Never try to start the engine unless fluid pressure is
relieved and the pressure control switch is OFF.
Trying to start the engine when it is pressurized
could damage the recoil system.
To start the engine
1. Turn the pressure adjusting knob (B) 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 mov-
ing the gray lever.
If the engine is warm, close the choke (H) by mov-
ing the gray lever half way or not at all.
4. Turn ON the engine switch (H).
WARNING
A rope which recoils too quickly may hit someone
and cause serious bodily injury. The rope could
also jam in recoil assembly.
5. Hold the frame of the sprayer with one hand and
pull the starter rope rapidly and firmly. Hold the
rope as you let it return. Pull and return the rope
until the engine starts.
6. Open the choke (G) as soon as the engine starts,
except in cold weather. In cold weather, leave the
choke closed for 10 to 30 seconds before opening
it to keep the engine running.
7. Disengage the gun safety latch.
To start and prime the pump
1. Open the filter’s pressure drain valve (60).
2. Turn ON the pressure control switch (A).
3. Turn the pressure control knob (B) about 1/4 turn
from minimum pressure. Run the pump until fluid is
flowing smoothly from the pressure drain valve,
indicating the pump is fully primed.

9308–327
Startup
4. Close the pressure drain valve (60). See Fig. 5.
Squeeze the trigger until fluid flows from the gun.
This primes the hoses. Release the trigger. En-
gage 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. Re-
lease 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 sepa-
rate 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 chang-
ing 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 transport-
ing 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.
7207A
Fig. 5
B
A
50
P
L
F
HG
J
K
60
C

10 308–327
Maintenance
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.
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.
DAILY: Check pressure drain valve for proper opera-
tion.
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.
AFTER EACH 100 HOURS OF OPERATION:
Change the oil.
MONTHLY: Oil connecting rod.
SPARK PLUG: Use only an BPR6ES (NGK) or
W20EPR–U (NIPPONDENSO) plug. Gap the plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing the plug.
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.
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, VERY SLOWLY
loosen the tip guard retaining nut or hose end coupling
to relieve the pressure gradually, then loosen com-
pletely. Now clear the tip or hose.

11308–327
Flushing
When to Flush
1. New Sprayer. This sprayer was factory tested in
lightweight oil,which was left in to protect the pump
parts.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean water flush.
Before using oil–base paint, flush with mineral
spirits.
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.
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: flush with water, then mineral
spirits and leave the pump, hose and gun filled
with mineral spirits. Shut off the sprayer, remove
the spark plug cable, and open the pressure drain
valve to relieve the pressure. Leave the drain valve
open.
Oil base paint: flush with mineral spirits and leave
the pump, hose and gun filled with mineral spirits.
Shut off the sprayer, remove the spark plug cable,
and open the pressure drain valve to relieve the
pressure. Leave the drain valve open.
6. Startup after storage.
Before using water–base paint , flush out the
mineral spirits with soapy water, and then with
clean water.
When using oil–based paint, flush out the mineral
spirits with the paint to be sprayed.

12 308–327
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.
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 trig-
gered until clean solvent comes from the nozzle.
Release the trigger and engage the trigger safety
latch.
NOTE: For two guns, release the trigger safety latch
on the second gun and trigger that gun until clean
solvent comes from the nozzle. Flush the first gun and
then the second gun at least one more time.
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 damag-
ing the pump packings. Relieve pressure.
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.
Fig. 6
A
B
C
60 7208A

13308–327
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. Disconnect the spark plug!
Check everything in the chart before disassembling the sprayer.
PROBLEM CAUSE SOLUTION
Engine/sprayer won’t
start Engine switch not on Turn on.
Out of gas Replenish
Engine oil level low Try starting engine. If light on rear of engine glows,
replenish oil.
Spark plug cable disconnected or
spark plug damaged Connect cable on top of engine or replace spark plug.
Water frozen in pressure control Return pressure control to authorized Graco dealer
for repair.
Engine won’t “pull over” Oil seepage into combustion
chamber Remove spark plug. Pull starter rope 3 or 4 times. Clean or replace plug. Try to start. Keep sprayer
upright to avoid oil seepage.
Engine operates, but
dis
p
lacement
p
um
pPressure control switch turned OFF Turn on. displacement pump
doesn’t 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 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.
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.
Clutch worn or damaged Service. See page 18.
Pinion assembly worn or damaged Service. See page 17.

14 308–327
Troubleshooting
PROBLEM CAUSE SOLUTION
Displacement pump
output low on upstroke
Pump inlet screen clogged Clean.
output low on upstroke 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 Replace. See page 24.
Displacement pump
out
p
ut low on down
Pump inlet screen clogged Clean.
output low on down-
stroke or both strokes 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.
Paint leaks into wet-cup Loose wet-cup Tighten just enough to stop leakage.
Throat packings worn or damaged Replace packings. See page 24.
Displacement rod worn or damaged Replace rod. See page 24.
Low fluid delivery Pump inlet screen clogged. Clean.
Pressure setting too low Increase pressure. See Step 1, page 9.
Engine RPM too low Increase throttle setting. See Step 1, page 9.
Dirty outletfilter, 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.

15308–327
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 hous-
ing (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 con-
necting rod assembly (8,11) off the drive housing.
8. Inspect the crank (D); replace the drive housing if
the crank is worn excessively.
9. Evenly lubricate the inside of the bronze bearing
(A) in the bearing housing (11) and the inside of
the connecting rod link (B) with high-quality motor
oil. Liberally pack the roller bearing (C) in the con-
necting rod (8) with bearing grease.
10. Assemble the connecting rod (8) and bearing
housing (11).
11. Clean the mating surfaces of the bearing housing
(11) and drive housing (5).
12. Align the connecting rod (8) with the crank (D) and
carefully align the locating pins (E) in the drive
housing (5) with the holes in the bearing housing
(11). Push the bearing housing onto the drive
housing or tap it into place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screw (73) to align
or seat the bearing housing with the drive housing.
These parts must be aligned using the locating pins
(F), to help avoid premature bearing wear.
13. Install the screws (72) and lockwashers (73) on the
bearing housing. Tighten evenly to 300 in-lb (34
N.m).
14. Refer to Installing the Pump on page 24 to install
the pump.
02693
Fig. 7
52
51
49
50
423
14
12
78 7
72 73 ABC410 D5
11
13
63
8
E
Torqueto 300 in-lb (34 N.m)
1
1
Lubricatewithhigh-qualitymotoroil
2
Packwithbearinggrease
3
3
2
2

16 308–327
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 hous-
ing and connecting rod away from the drive hous-
ing as one assembly (C).
5. Remove the two drive housing screws (10) and
lockwashers (4). Remove the four pinion housing
screws (215) and lockwashers (214).
6. Lightly tap around the drive housing (5) to loosen
it. Pull the drive housing straight off the pinion
housing (219). Be prepared to support the gear
cluster (16) which may also come out.
CAUTION
Do not drop the gear cluster (16) when removing the
drive housing (5). The gear cluster is easily dam-
aged. 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 re-
cesses, but could be dislodged. If the balls are
caught between the gears and not removed, they will
damage the drive housing. If the balls are not in
place, the bearings will wear prematurely.
7. Apply the full 6 oz. (160 grams) of bearing grease,
which is supplied with a replacement gear, to the
gear cluster (16). Be sure the thrust balls (5c and
219d) are in place.
8. Place the bronze colored washer (5a) and then the
silver–colored washer (5b) on the shaft protruding
from the big gear of the drive housing (5). Align the
gears and push the new drive housing straight
onto the pinion housing and locating pins (A).
9. Starting at Step 4, work backwards to reassemble
the sprayer. Or, move ahead to the next section in
this manual if further service is needed.
Fig. 8 02694
78 772 73 C10 4
5
16 215,214
219
52
51
49
Torqueto 300 in-lb (34 N.m)

Apply a full 6 oz. (160 grams) of
bearinggrease (supplied with
replacementgear –16)



5a5b
5c
A
219d

17308–327
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 arma-
ture 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.
Fig. 9 02695
219 212b 222
SeeFig. 10


43
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 re-
cess 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.
Fig. 10
219 218
217
02787


Drivehousing shown
removedfor visual
purposesonly
218e

18 308–327
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 sepa-
rated 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 lock-
washers (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). Re-
place 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.
Fig. 11 02699
52
51
49
5
212b213
212a 222 43
63
215
11
219
DETAIL
222
A
B
C

19308–327
Field and Wiring Harness
Fig. 12 02702
A
22
64
211
210
SeeFig 13 for a detail of
where64connects


NOTE: Refer to Fig. 12.
1. Pull the plastic caps (A) off the wire screws (22) in
both places on the field. Loosen the screws and
release the wires (64).
2. Loosen the four setscrews (211). Pull off the field
(210).
3. Skip ahead to Reassembly, page 21, Step 1 or
continue on page 19.
Fig. 13
Ref 64
Ref 206
7210A
Alternator
Fig. 14
B
A
95
7209
A
Disassembly
1. Remove the engine. Loosen the knob (95). Grasp
the engine as shown in Fig. 14 and raise side A.
Slide the engine out of the channel (B).
2. Remove the screws (43) and belt guard (35).
Remove the belt (40). See Fig. 15.
Fig. 15
100
222
40
43
35
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.

20 308–327
Alternator
Fig. 16
202200 201 A
209
207208
206205
204 203
222
02728
202
204
201
205
206
207
209
B
222
CUTAWAY VIEW
B
D, 203
C
220
221
See Fig. 13 for a detail of
where206 connects


NOTE: Refer to Fig. 16 which also shows the
assembly in a cutaway view.
4. Remove the screws (A) from the bushing (201)
and screw them into the threaded holes of the
bushing. Tighten the screws until the sheave (202)
separates from the bushing. Remove these parts
and the key (200).
NOTE: If necessary, use a steering wheel puller as
described in Step 6.b on page 18.
5. Remove the retaining ring (203).
6. Press the shaft (B) of the alternator shaft rotor
(209) to free it from the clutch housing.
NOTE: The bearing (204) must be replaced if you
remove the alternator rotor shaft (209).
7. Remove the cable clamp (220) and screw (221).
8. Remove the screws (207) and lockwashers (208)
and the stator (206).
9. Remove the retaining ring (205).
10. Remove the bearing (204) from inside the clutch
housing (222).
Reassembly
1. Clean all parts.
2. Reassemble in the reverse order of disassembly.
Route the wires of the stator (206) through the
clutch housing (222) and through the hole (C) in
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.
Fig. 17 02747
202
41
1
E
222