Graco GM 5000 Operation manual

’ INSTRUCTIONS-PARTS LIST
Thl8 manual contelnr IMPORTANT
WARNINGS and INFORMATION
REA0 AN0 RETAIN FOR REFERENCE
5 HORSEPOWER. GASOLINE-POWERED
GM 5000
AIRLESS PAINT SPRAYER
3000 PSI (210 bar) MAXIMUM WORKING PRESSURE
Model 220-006, Series B
Basic sprayer, without hose or gun
Model
231 -052
Complete sprayer, with hose or gun, RAC IVa
Dripiesss Tip Guard, and 517 size SwitchTipa
307-847
Rev D
Supersedes B
Hazard of Uslng Rulds Contahlng Halogenated Hydrocarbons
Never use 1.1 .l-trichioroethane. 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 explo-
sion, which could cause death,
serlous bodily injury and/or substantial properly damage.
Consult your fluid suppliers to ensure that the fluids being
used are compatible with aluminum and zinc parts.
Refer
to the Technical Data on page 39 for more information.
WARNING
GRACO
INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1444
nrnwmnm 4007 IIPAPA I~IP

' "CONTRACTOR" GUN
with RAC IV Dripless TIP GUARD
and 517 Size SwitchTip
Fig 3-1

Moving pam can pinch or amputate your fingers or other body
parts. KEEP CLEAR of moving parts when starting or operating
the sprayer. Follow the Pressure Rellet Procedure on page 4
before checking or sewicing any part of the sprayer, to prevent
it
from starting accidentally.
General Safety
Any misuse of the spy equipment or accessofles. such as
overpressurlzing. modifying parts. using incompatible chemi-
calsandfluids,orusingwomordamagedparts,cancausethem
toruptureandresultinfluidinjection,spiashingintheeyesoron
the skin, or other serious bodily injury, or fire, explosion or prop
eriy damage.
cause it to malfunction.
NEVERalterormodifyanypartofthisequipment;doingsocould
CHECKallsprayequipmentreguiarlyandrepairorreplacewom
or damaged parts immediately.
Always wear protective eyewear, gloves, clothing and respirator
as recommended by the fluid and solvent manufacturer.
System Pressure
This sprayer can develop 3OOO psi (210 bar) MAxlMUM WORK-
ING PRESSURE. Be sure all spray equipment and accessories
used
are rated to withstand the this pressure. DO NOT exceed
the maximum working pressure of any component or accessory
used in
the swtem.
Fluid and Solvent Compatibility
Allchemicaisusedinthesprayerarechemicallycompatiblewith
mewettedpartsshowninthe~~~~~1~~~~~~~onpage38.~1-
ways mad the chemical manufacturer's literature before using
them in this sprayer.
HOSE SAFETY ~~~~~~~~~~,~~~~~~~~~~~~~~~~~~~~~~~~ .....~
High pressure fluid in the hoses can be very dangerous. If the
hose develops
a leak, split or rupture due to any kind of wear,
damage or misuse, the high pressure spray emitted
from it can
causeafluid injection injury or otherserious bodily injury orprop
erty damage.
ALL FLUID HOSES
MUST HAVE STRAIN RELIEFS ON BOTH
ENDSlThestrainreiiehheipprotectthehosefromkinksorbends
at or close to the coupling which can result in hose rupture.
TIGHTEN
ail fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or aiiow high pres-
sure spray
to be emitted from the coupling.
NEVER use a damaged hose. Before each use. check the entire
hose for CUI?,,
leaks. abrasion, bulging cover, or damage or
movementofthehosecoupiings.Ifanyofthesewnditionsexist.
replacethe hose immediately. DO NOTtrytorecouple highpres-
sure hose or mend it with tape or any other device.
A repaired
hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULLY.
Do not pull on
hosestomoveequipment. Keephosesciearof moving parisand
hotsurfacesofthepumpandgasengine.Donotusefluidsormi-
vents which are not compatible with the inner tube and cover of
the tiose. DO NOT expose Graco hoses to temperatures above
180" F (82' C) or below -40' F (-40" C).
Hose Grounding Continuity
Proper hose grounding continuity
is essential to maintaining a
grounded spray system. Check the electrical resistance of your
fluid hoses at
least once a week. If your hose does not have a tag
on it which specifies the maximum electrical resistance. contact
the hose supplier or manufacturer for the maximum resistance
limits. Use
a resistance meter in the appropriate range for your
hose
to check the resistance. If the resistance exceeds the rec-
ommended limits. replace it immediately. An ungrounded or
poorly grounded hose can make your system hazardous.
Aim
read FIRE OR EXPLOSION HAZARD, below.
Static electricity is
created by the flow of fluid through the pump
and hose.
If every part of me spray equipment Is not properly
grounded,sparkingmayocwr.andthesystemmaybecomehar-
ardous.Sparkingmayalsooccurwhenpluggingin~unplugging
apowersuppiycordorusingagasoiineengine.Sparkscanignite
fumes from solvents and the fluid being sprayed. dust particles
and other flammable substances, whether you are spraying in-
dwrsorouIdoors,andcancauseafireorexplosionandserious
bodily injury and properiy damage.
usingthisequipment.STOPSPRAYlNG1MMEDIATELY.Check
Ifywexperlenceanystaticsparkingorevenasiightshockwhile
the entire system for proper grounding. Do not use the system
again until the problem has been identified and corrected.
Grounding
To reduce the risk of static spar(ting, ground the sprayer and ail
dhersprayequipmentusedorloca1edinthesprayarea.CHECK
your local electrical code for detailed grounding instructions for
your area and type
of equipment. BE SURE to ground all of this
spray equipment:
1. Spr6yer:connectagroundwireandclamp(supplied)toaIrue
earth ground.
spilled
on
a hot surface
can ignite and cause a fire.
NWER fill
the fuel tank
while
the engine is running or hot. Fuel
ALWAYS pour
fuel in slowly to avoid spilling. Also read FIRE OR
EXPLOSION HAZARD. above. and FUELING on page 6.
NEVERoperatetheengineinaclosedbuildingunlesstheengine
exhaust is piped outside. The exhaust contains carbon monox-
ide,apoisonous,odoriessandinvisiblegaswhichcancausese-
rious illness and even death of inhaled.
2. Fluidhoses:useonlygroundedhoseswithamaximumof500
ft(150m)combinedhoselengthtoensuregroundingwntinu-
iIy. See Hose Groundlng Continuity on page 3.
3. Spraygun:obtaingroundingthroughconnectiontoaproperly
grounded fluid hose and sprayer.
4. Object being sprayed: according to imai code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to local code.
Use only metal
pails, which are conductive. Do not place the
pail on a non-conductive surface, such as paper or card-
board. which intempts the grounding continuity.
7. To maintain grounding continuity when flushing or relieving
pressure,aiwayshoidametalpartofthegunfirmlytotheside
of a grounded metal pail, then trigger the gun.
Flushha Safetv
Reduce~eriskoifiuidinjectioninjury,staticsparking,orspiash-
Ing by following the flushing procedure given on page 14 of this
manuai.FoliowthePRESSURERELIEFPR0CEDUREonpage
4. and remove the spray tip before flushing. Hold a metal pafl-of
the gun firmly
to the side of a grounded metal pail and use the
lowest possible fluid pressure during flushing.
United States Government safety standards have been adopted
under
the Occupational Safety and Health Act. mese standards
struction Standards. Part
1926 - should be wnsuited.
- particularly the General Standards, Part 1910, and the Con-

Consignes generales de securlte
toute utiiisation anormale de I'appareil du pulv6risation ou des
accessoirescomme. parexemple, la mlsesousune pressionex-
cessive.
lesmodificalionsdepieces, I'utilisationdeproduilschi-
miques el de malieres incompatibles el I'utilisation de pieces
usbes ou abimees
put Causer des dBgits a I'appareil ou des.
ruptures de pikes et entrainer une Injection de liquide ou d'au-
Ires blessures &rieuses, un incendie. une explosion ou d'autres
degils.
Toujours
porter une protection pour les yeux, de ganls, des vile-
ments prolecteur el
un disposilif pour la respiration correspon-
danlauxrecommandalionsdesfabricanlsdefluideselsolvanls.
Presslon
Ce puiverisaleur peut produire une PRESSION
MAXIMUM DE
TRAVAIL 210 bar (3000 1blpo.f) S'assurer que IOUS les Bibments
du puiverisateur el ses accBssoires sont conGus pour resister a
la pression maximum de travail de ce pulverisaleur. NE PAS dB
passer la pression maximumdelravail d'aucundes616menlsou
accBssoires utilisk avec cet appareil.
Compatlbllite chlmlque des corps
BlEN S'ASSURER que lous Ies corps des solvants utiliseS sonl
chimiquemenlcompallblesaveclesparliesmouill~esindiqubs
jours lire soigneusemenl les documents et brochures du fabri-
dans
ies 'Donnbs techniques", au dos de la couverlure. Tou-
can1 des fluides el soivanls utilisk avant de s'en sewir
dans ce
pulv6risateur.
dangereux. En cas de bile sur le luyau. de fissure, d6ChiNre ou
LefluideBhautepressioncirculantdanslestuyauxpeutBtret~s
Npture~lasuitedeI'usure,dedeg~lsoud'unemauvaiseutilisa-
tion, Ies projections de fluide haute pression qui en proviennenl
peuvent entrainer des blessures graves
par penetration sous la
peau ou par conlad.
ainsi que des d6g& materiels.
TOUS LES TUYAUX FLEXIBLES DOIVENT AVOIR DES RES-
SORTS SPIRALE DE PROTECTIONAUX2 BOUTS1 Lesspira-
Ies de protection contribuenl a eviler la formation de pliures. de
boucles ou de nmuds sur ies luyaux qui pourraienl entrainer la
Nplure
du luyau a I'endroit du raccord ou a son voisinage.
SERRER FERMEMENTIous
Ies raccords avant chaque ulilisa-
1ion.Lefluidesouspressionpeutfairesauterunraccorddesserre
ou produlre un jet A haute pression s'khappanl par le raccord.
NE JAMAlS.utiliser
un luyau endommage. NE PAS essayer de
refaireleraccordd'untuyauhautepressionnidereparerieluyau
avec du Nban adhesif ou par lout autre moyen. Un luyau repare
ne
peut pas rkisler au fiuide sous pression.
MANIPULER LES TUYAUX AVEC PRECAUTION
ET CHOlSlR
SOIGNEUSEMENTLEURCHEMIN. Nepasdepiacerlefluideen
liranl sur le luyau. Ne pas uliiiser de fiuides ou de soivants que
nesont DascomDaliblesavec I'enveioDoe inlgrieur ou exlerieure
deluyau.NEPASexposerleluyau~fluidesdeslemperaluressu-
perieures A 82% (18O'F) ou inferieures B -4O'C (-40°F).
Contlnulte
de la mise a la terre des tuyaux
Une bonne continuit6 de la mise A la Ierre des luyaux est essen-
Iiellepourmainlenirlamise~lalerredeI'ensembiedevaporisa-
lion. Verifiez la rkislance electrique de vos luyaux B fluides et a
air, au moines une fois par semaine. Si volre luyau ne comporle
pas d'Btiquene qui prkise la resistance electrique maximum,
prenezconlactaveciefoumisseurdeluyauxouiafabricanlpour
avoir les limiles de resistance maximum. Ulilisez un metre der&
sistance de la gamme approprib pour volre luyau el verifiez la
resistance. Si celle-ci depasse ies iimites remmmand6es. rem-
placez
le tuyau immkliatement. Un tuyau sans mise A la terre ou
avec une mise
A la lerre incorrecle put enlrainer des risques
pour volre sysldme. Lisez aussi LES RISQUES D'INCENDIE
OU D'EXPLOSION.
De 1'6lectrlcitB slalique
est produile par le passage du flulde A
grande vitesse dans la pomp e1 dans Ies luyaux. SI loutes ies
pikesdel'appareildepuiverisalionnesontpasconvenabiement
duire,et I'appareil rlsques d'etre dangereux. Des Btincelles peu-
reliks ou
a la masse ou B la terre. des Blincelles peuvenl se pro-
vent Egalemenl
se produire B I'occasion du branchemenl ou du
d~branchemenlducordond'alimentationoudeI'utilisationd'un
vapeurs de solvanls el le fiulde pulvbrisb, les fines parlicules de
moteuraessence.
Les~tinceilessontsuffisaniespourallumeries
poussiereainsiqued'autressubstancesinfiammabies,quandon
pulvbri& B I'interieur ou B I'exterieur, et dies peuvent Causer un
dirgals materiels.
incendieou uneexplosion. ainsi quedes blessuresgraveseldes
S'il se pmduil des Btincelles d'electricil6 statique, ou si vous res-
,senIez la moindre dkharge. ARRETE2 IMMEDIATEMENT LA
PULVERISATION.V~rifiezquelesyst~meavan1queleprobl~me
soit Identifie et corrige.
Mise B la terre ou B la masse
statique. le pulverisateur et tous les Bquipement utili& ou se
Pour reduire les risques de production d'btincelles d'electricitb
lrouvanldanslazonedepulverisaliondoivenlBtrereli~Blalerre
ou A la ma%%. Pour connaitre le detail des instructions de mise
Blaterredanslaregionelletypepartlwlierd'~quipement.CON-
SULTER le code ou les r6glementalions Blectriques locales.
S'ASSURER que lous le Bquipemenls de pulverisalion sulvants
sonl bien relies B la lerre:
1. Pulv~risateur:Relierlefiiedemassesellecollier(foumi)Bune
bonne Ierre.
2. Pistolet.RBaliserlamise~laterreenleraccordanlBuneluyau
flexibleet aune puiverisaleurdejB convenablement reiiesaia
terre.
3. Tuyauxf1exibles:Afind'assurerlaconlinuiledeiamiseBlater-
re. n'utiiiser que des luyaux comportant une mise A la lerre el
ayant une longueur maximum combinw de
150 m (1500
pieds). Sereporter Bgalementau paragraphe. 'ContinultB du
circuit de mls B la terre des tuyaux".
4. Recipient dalimentation: ObseNer 1% code ou les rbglementa-
lions
locales.
5. Objets, materiel ou surfaces recevant la pulverlsation: obser-
ver le code ou les r&glementations locales.
6. Tous le seaux de solvant utilisk pour le rinpge: ObSeNer le
metallique conducteurs de I'electricile. Ne pas metlre le seau
codeou
lesr&~lementalionsiccales. N'utiliserquedesseaux
sur une surface non conductrice comme sur
du papier ou du
carloncarcela interromprait
la conlinuitede la mise a lalerre.
7. Pour conserver la continuit6 de la mise b la terre quand on
rime le materiel ou quand on libere la pression, loujours
mainlenir une partie metallique
du pistolel fermemenl ap
puyw contre le cbte d'un seau en metal puis appuyer sur la
detente
du pistolel.
Mesures de Securite concernant le Rincage
etlesrisquesdOsauxQtinwllesd'eiectrlcilestaliqueouauxecla-
Pour rkluire Ies risques de blessures par penelration de la peau
A la page 14 de ce manuei.
boussures.
observe la marche A suivre pour le rinpge donnee
IOUme Ou quand il est chaud. Le
cafburanl renverse sur une sur-
moins que
185 gaz d'echappemenl ne soient diriges au dehors.
NE JAMAIS remplir le rkewoir
de carburant quand
le moteur NE JAMAIS faire toumer un moteur dans
un
bitiment ferme B
face chaude put s'enflammer et causer un incendie. TOU-
Les gaz d'khappemenl contiennent de I'oxyde de carbone. un
JOURS verse
le carburant ientemenl pour eviler d'en renverser.
gaz loxique, inodore el invisible qui put entrainer des malaises
Lire RISQUES D'INCENDIE
OU D'EXPLOSION. graves ou mime la
molt se llon le respire.
"- -1- -,

PELlGRO POR MAL US0 DEL EQUIP0 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Seguridad general
Cualquier mal uso del equip pulverizadoro 10s accesorios, tal Esta pulverizadora puede desarroliar 210 barias (3000 psi) de
como sobre presurizaci6n, modiflcaci6n de piezas. uso de ma- PRESION DE TRABNO MANMA. Asegurar que iodo e1 equipo
ierlales y pmductos quimicos incornpaiibles.
0 utilizaci6n de pulverizadorysusaccesoriosiienenlacapacidadparaaguantar
piem daiiadas 0 desgastadas, puede hacen que se rompan y la presi6n mexima de irabajo de ningun wmponenie o acwsm
causen ia inyecci6n defluido
u oiras lesiones wrporalesgraves. rio de esie sisiema.
incendio, explosl6n
o darios a la propledad.
Siempreusargafas,guanies.veslimenrasprotectorasyunrespl-
Compatibilidad de fluid0
rad~r0,talcomorecomlendanlosfabricantesdelfiuidoydelsol-
SiempreleerlasinsiNccionesdeifabricaniedeifluldoysolvenie
vente. antes de
usarlos en esta pulverizadora.
Presion del sistema
SEGURlDAD EN EL US0 DE US MANGUERAS ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ .."*..I ,..*.,~~~,~~~.~~.,~~~.
w.mv
El fluido que escapa a alia presi6n por las mangueras puede ser
rotura 0 rajadura debido a cualquier iipo de desgaste. dario o
muy peligroso. SI en la manguera sa desarrola un escape, UM
maltraio, el chorro a ala presitm emiiido por alli puede causar
una Iesi6n pcr inyeccibn u oiras iesiones corporalesgraves oda-
~IOS ala propledad.
ITODAS
US MANGUERAS PARA FLUIDOS TIENEN QUE
TENER GUARDAS DE RESORTE EN AMBOS EXTREMOSI
Estas woteaen las manclueras contra dobleces o retorceduras
enlosawp~mieniosocijrcadeeilos,iosquepodriantraducirse
en mturas de la manguera.
Antes de usarias. APRETAR bienfirmesiodas laswnexiones. El
fiuido a lata presi6n
puede desaiojar un acopiamienio suelio o
dejar que pro BI escape un chorro a alta presion.
enbuscadecortaduras,escapes,abrasl6n,cubieltaabultada,o
NUNCAusaruna mangueraqueestAdahda. Slemprerevisarla
acopiamlenios
suelios 0 daados. Si llegara a encontrarsecuai-
quleradeestascondiciones,reemplazardeinmediaiolamangue
darlaconcintaadhesivaudromaierialsimilar.Unamangueraque
ra.NOlnientarreacoplarunamangueradealtapresl6noenmerr
hasido remendada no aguanie ei fluidoal alta presibn.
MANEJAR
Y PASAR CUiDADOSAMENTE LAS MANGUERAS.
No tirarde
las mngueras para mover e1 equipo. No usarfluldos
0 solvenies oue sean incomcaiibles con el iubo iniemo v la cu-
bieltade la nianguera.
NO eiponer as mangueras atemberatu-
ras sobre 820 C (180'F) o baio -40% (-40" F).
Continuidad del circuit0 de puesta a tierra de la man-
guera
Lawniinuidaddelcircuitodepuesiaalierraapmpiadoesesen-
cia1 paramanienerconectadoaiierrael sisiema pulverizador. Es
indispensable revisar la resistencia eiectrica mexima de ias
Si
la rnanguera no iiene una eiiqueta en la cual sa especifica la
manguerasdeaireydefluidoporlomenosunavezalasemana.
veedorofabricaniedelamangueraparalainformacl6nsobrelos
resistencia electrica m&xImum, ponerse en coniacto con e1 pro-
apropiada
para wmprobar la resistencia; si excede ios lites re-
limiies de resistencia. Usar un metro de reskiencia en la gama
comendados,reemplazarladeinmedialo. Esmuyarriesgadoie
ner una manguera sin puesta a iierra
o con ia puesta a iierra en
mala condiciones. LeertambiBn la informacion sobre RIESGO
DE INCENDIO
0 EXPLOSION, m&s arriba.
Elfiujoaaliaveiccidaddelfluidoalpasarporlabombaymangue
racreaeiectricidadestatica.Siiodaslaspartesdelequipopulve
rizadornoiienenbuenaiierra,puedenocurrlrchispas.wnvirtiBn-
do al slstema en aigo peligroso. TambiBn, pueden producirse
chispas ai enchufar
0 desenchufar el wrd6n elktriw 0 ai usar
unmotordegasolina.Estaschispaspuedeninflamarlosvapores
de 10s solventes y Si chorro de fiuido pulverizado, panicuias de
polvoydrassustanciasinflamables,seaalairelibreobajoiecho,
lo que podria causar una expioslh o incendio y graves lesiones
corporales y daiios a la propiedad.
SI ocurre una chispa de electricidad eStatica o incluSo un ligem
choqueeiectrlcomienirasseusaelequipo.DEJARDEPULVERI-
ZAR DE INMEDIATO. Revisar tcdo el sistema en busca de una
tierraapropiado.Nousardenuevoeisisiemahasiahaberidentifi-
cad0 y solucionado e1 pmblema.
~~~~~ ~~.
Puesta a tierra
Para reduclr e1 riesgo de chispas eStaticas. conectar a iierra la
puiverizadoraytdoelotroequipodepulverizarqueseuseose
encuentre en el lugar que se va a miar. CONSULTAR el ckdlgo
eiktrico de la localidad para las insirucciones sobre las cone
xiones a iiena exlgidas
para la zona y tipa de equipo. ASEGU-
RAR de conectar a tiema iodo &e equipo pulverizador:
1. Pulverizadora: Conectar el aiambre de ilerra y la abrazadera
(suminlstrada) a una buena conexi6n a iierra.
2. Mangueras para fluldos: usar solamente mangueras con
puesta a tierra de una iongiiud wmbinada de 150 m (500
pies),paraasegurarbuenaconlinuidadaiierra.Referirsetam-
bien ai phafo sobre contlnuldad a tlerra de la manguera.
3. Pistola: hacer la puesia atierra wnectfindola a una maiguera
de fluido
y puiverizadora bien conecladas a tierra.
4. Suministrar un recipiente: de acuerdo al c6dlgo local. Usar
solamente baldes de metal,
que sean.conductivos. No wlo-
car el balde en una superficie no wnductiva, como papel o
wttm. que iniemmpe la wniinuidad a iierra.
5. Objeto que se est6 roclando: de conformidad con ei cixigo
local.
6. Todos 10s baldes de solvente usados durante el lavado, de
.
conformidad con si c6digo local.
7. Paramantenerla continuidada tierra durante ellavado o des-
carga de presidn, siempre apoyar una
pane mekilica de la
pistola bien firme wntra e1 costado de balde de metal. des-
pub apretar ei gatillo.
Seguridad durante el lavado
Para reducir ei riesgo de que se inyecte 0 salpique fiuido en la
piel,oqueocurraunadescargadeelectricidadesi~iica,siempre
seguir ias INSTRUCCiONES PARA EL LAVADO, dadas en la PA-
gina 14. Squire1 procedimlento de descarga de presl6n en
ia pasina
8. y quitar ia boquilla de metal y usar le presi6n mhs
baja posibie de fluido durante el lavado.

5. Be sure your system Is properly grounded before
operating it. Read and follow the warning section,
FIRE OR EXPLOSION HAZARD, On page 5.
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.
a. Before using water-base paint, flush with mineral
spirits, followed by soapy water, and then flush
with clean water.
b. Before using oil-base paint, flush with mineral
spirits, only.
the flushing procedure.
C. See FLUSHING GUIDELINES, On page 15, for
8. Prepare the palnt according to the manufacturer’s
recommendations.
a. Remove any skin that may have formed..
b. Stir the paint to mix plgrnents:
c. Strain the paint through a fine nylon mesh bag
ticles that could clog the filter or spray tip. This Is
(available at most paint dealers) to remove par-
probably the most important step toward trouble-
free spraying.
9. Keep the sprayer uprlght and level during operatlon
TlON on page 12.
and whenever
it is being moved. See the last CAU-
OIL LIGHT
ENGINE
Fig 11-1
, WARNING I 2. Gasollnes contalnlna alcohol laasohol). Do not use
Gasoline
Is extremelyflarnmableand explosiveun-
der certaln conditions.
Always shut
off the engine before refueling.
Refuel in a well-ventilated area.
where
the engine Is refueled or where the gasoline
Do not smoke or allow flames or sparks In the area
Is stored.
Do not overfill the tank. Make sure the filler cap is
securely closed after refueling.
or spilledfuel
can ignite. If any fuel is spilled, make
Be careful not to spill fuel when fueling. Fuel vapor
sure
the area is dry before starting the engine.
1. Fuel speciflcatlons. Use automotive gasoline with a
pump octane number of 86 or higher, or a
research octane number of 91 or higher. Unleaded fuel
minimizes combustion chamber deposits.
(y)
gasohol khich contaiis methan;, if the gasohol does
not contain cosolvents and corrosion inhibitors for
methanol.Evenifitdoescontainsuchadditives,donot
use the gasohol If it contains more than 5% methanol.
NOTE:
The HONDA engine warranty does not cover
tainlng alcohol. See the HONDA engine manual
damage resulting from the use of gasollnes con-
for more information.
~ ~ ~~
3. General. Do not use oil and gasoline mixtures or con-
taminated gasoline. Avoid getting dirt, dust
or Water in
the fuel tank.
4. Tank CapacRy. 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 refuellng.
6. Afler refueling, tighten the fuel tank cap flrmly.

ONlOFF SWITCH
PRESSURECONTROL
'TIP
GUARD
307-847 13

WARNING
Toreducetheriskofseriousbcdilyinjury,includingfluidinjec-
lion, splashing fluid or solvent in the eyes or on the skin, or in-
jury from moving parts or eleCtric shock. always follow this
or servicing any pati of the spray system, when installing,
procedure whenever
you shut off the sprayer, when checking
cleaning or changing spray tips, and whenever you stop
spraying.
2. Turn the ON/OFF switch to OFF.
1. Engage the gun safety latch.
3. Flip the pressure control switch to OFF.
4. Disengagethegunsafetylatch.Holdametalpartofthegun
firmly to the side of a grounded metal pail, and triggerthe
gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container ready to
catch the drainage. 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 fol-
lowingthestepsabove,wraparagaroundthetipguardretain-
ing nul or hose end coupling and VERY SLOWLY loosen the
part to relieve pressure gradually, then loosen completely,
Now clear
the tip or hose.
When To Flush
1. New Sprayer. Your new GM.5000 sprayer was factory
tested
in lightweight oil.which was leil in to protect the
pump parts.
Before
using water-base palm, flushwithmineral spir-
water flush.
its, followed by a soapy water flush, and then a clean
Before using oil-base paint, flush with mlneral spirits,
only.
2. Changlng Colors. Flush with a compatible solvent
such as mineral spirits
or water.
3. Changlng from water-base to oil-base paint. Flush
with warm, soapy water, then mineral spirits.
4. Changing from oil-base to water-base paht.Flush
with mineral spirits, followed by warm. soapy water,
and then a clean water flush.
5. Storage.
and leave the pump, hose and gun filled with mineral
Water base
paint: flush with watw'then mineral spirits
spirit. Shut off the sprayer, remove the spark plug
cable, and open the pressure drain valve
to relieve
pressure. Leave the drain valve open.
CAUTION
slightest change it could freeze. Push the water out
NEVER leave water In the sprayer if there is the
with mineralspirits. Water left to freeze in the pres-
sure control tube prevents the sprayer from being
started, and causes serious damage
to the pres-
sure control.
6. Startup after storage.
Before using wafer-base paint, flush out the mineral
spirits with soapy water. and then with clean water.
When usingoil-basedpaint, flush outthe mineral spir-
its with the paint
to be sprayed.
Continued on page 16

Check everything in the chart before disassembling the sprayer.
hgine won't
"pull over"
rngine operates, but displace
nent pump doesn't
PROBLEM
Enginekprayer won't start
-
E
-
E
n
-
PROBLEM
Enginekprayer won't start
-
E
-
E
n
-
ZAUSE
.
)ut of aas
Zngine oil level low
;park plug cable disconnected or
spark plug damaged
Nater frozen in pressure control
311 seepage Into combustion
:hamber
?ressure control switch turned OFF
Pressure setting loo low
Displacement pump outlet filter dirty
np or tip filter clogged
Displacement pump rod seized by
dry paint
Connecting rod worn or damaged
Drive housing worn or damaged
Electrical power not energizing field
Clutch worn or damaged
Pinion assembly worn or damaged
iOLUTlON
I
urn on.
~~
I
leplenish
iy starting engine. If light on rear of engine
~lows, replenish oil.
:onnecl cable on top of engine or replace
;park plug.
Wum pressure control to authorized Graco
haler for repair. I
?emove spark plug. Pull starter rope 3 or 4
<eep sprayer upright to avoid oil seepage.
imes. Clean and replace plug. Try to start.
Increase pressure.
Service pump. See
307-806.
Check wiring connections. See page 20.
With pressure control switch ON and pres-
sure tumed
lo MAXIMUM, use a test light to
check continuity across black and white
wires from pressure control.
Have pressure control check by authorized
Graco dealer.
Service. See page
28.
Service. See page 25.
-

WARNING
To reduce the risk of serious bodily injury, Including
fluid injecfon
or splashing in the eyes or on the skin,
or injury from moving parts, always follow the Pres-
sure Relief Procedure Warning on page
17 before
checking, adjusting, cleaning
or shutting.off the
sprayer. Disconnect the
spark plug!
1. Disconnect both hoses at the pressure control (63).
holding the hex of the nipple (31 1) firmly with a wench
to prevent turning the elbow. Take note of the original
location of each hose to be sure you reassemble them
correctly at the end
of this procedure. See Fig 19-1. 31 1
CAUTION
DO NOT ailow the elbow (312)
to turn when remov-
ing
or connecting the hoses. Turning the elbows can
damage the sensitive bourdon tube.
2. Working under the engine mounting plate of the cart,
move the three nuts (61) and lockwashers (9) from the
disconnect the red, black and white wires. Then re
capscrews (62), which hold the pressure control
bracket (67) to the cart. Remove the pressure control.
See Flg 19-2.
ng 19-1
3. Remove the pressure control cover and screws (76,
64). Remove the four screws (65) holding the bracket
(67) to the pressure control. See Fig 19-1.
4. Remove the wire clamp (97) from the pressure control
wires.
[See Step 2, page 21)
5. Disconnect the wlres from the rectlfler (307). Remove
the screw (314), nut (306) and lockwasher (305). See
Fig 20-1.
6. Unscrew the connector (315) from the control box,
pulling the wires out with
it.
7. Use a wrench to hold the hexof the adapters (A) while
removing the elbows (312).
8. Remove the screw (310) and lockwashers (305) from
the ground wire (308).
9. Reassemble In the reverse order. Be sure to reinstall
ten both clamps to the cart with the same screws,
the wire clamp on the new pressure control wires. Fas-
bracket
(67) to the caR.
lockwashers, and nuts (62, 9, 61) which hold the
10. Pelform the Pressure Control Callbratlon procedure
on pages
20 and 21 before regular operation of the
sprayer. Flg 19-2
VIEW FROM UNDER ENGINE MOUNTING

1. Follow the Pressure Relief Procedure Warning on
page
17.
2. Connect the new 50 foot (1 5.2 m) spray hose to the
sprayer outlet.
On the other end of the hose, install the
gun. Install the new spray tip
(0.025 to 0.029 size) and
tip guard on the gun. Install the fluid-fllled pressure
ter. Remove
the pressure
control cover.
gauge in the top port
(6 -
See Fig
19-1) of the fluid
fll-
3. With the gun safety latch engaged, start the engine
(only). Use
of 3/8” Ignition wrench to turn the pressure
adjusting nul
(E) clockwlse two full turns. See Fig
21 -1. Turn the pressure control knob (D) to the rnini-
mum setting. Tum the sprayer switch
ON.
THE DISPLACEMENT PUMP SHOULD NOT CYCLE.
M it does cyde, shut the sprayer switch OFF, disen-
gage the gun safety latch, trigger
the gun into a
grounded metal waste container until pressure is r6-
5.
the soraver on aaain to be sure THEPUMP
DOESNOT
iieved, and engage the gun safety iaich again.
Turn
CYCLE. ’
.,
4. Increase the throttle setting and then the pressure con-
trol setting to the maximum while triggering the gun.
at which the pump stalls, which should, be approxi-
Keep the gun triggered while observing the pressure
mately 3000 psi (210 bar).
NOTE When the gun trigger is released, It Is normal for
the stall pressure to be 3100 to 3400 psi (217
to
238 bar) during this procedure.
If the pressure is not 3000psi (210 bar), turn the adjust-
ing nut
(E) clockwlse to reduce pressure and coun-
ferclockwlse to Increase pressure, to obtaln exactly
3000 psi (210 bar) pressure.
Then note the pressure to which the gauge drops be
fore the pressure begins to rise again.
if the pressure drops to below
2600 psi (182 bar), turn
the differential wheel
(A) clockwise to raise the pres-
sure to 2800 psi (182 bar).
If the pressure stops dropping before
2600 psi (182
bar), turn the differentlal wheel (A) counferclockwlse
to decrease the pressure.
Follow the Pressure Rellef Procedure Warning on
water out with mineral spirits, relieve pressure again,
page 17. Install the pressure control cover. Flush the
and then remove ail the test equipment.
ng 21 -i

BEARING HOUSING & CONNECTING ROD
NOTE: Refer to Fig 23-1 for Step 14.
14.
Screw the displacement pump about 3/4 of the way
into the bearing housing
(21). Hold the pin (25) up the
tinue screwing in the pump until the pin slides easily
pin hole in the connecting rod assembly
(22) and con-
into the hole. Back off the pump until the top threads
of the pump cylinder
are flush with the face of the bear-
ing housing and the outlet nipple (92) faces. back.
way around the connecting rod. Tighten the locknut
Push the retaining spring (26) into the groove all the
(27) to 65 to 75 ft-lb (90 to 100 N.m), using a 2-1/4 in.
open end wrench and a light hammer.
WARNING
Be sure the retaining spring (26) Is firmly In the
from working loose due to vibration.
groove, ail the way around, to prevent the pin
(25)
If the pin works loose, it or other parts could break
off due to the force of the pump action. These parts
could be projected through the air and result in seri-
ous bodily injury or propelty damage, including
damage to the pump connecting
rod and bearing
housing.
15. install the front cover and screws (23,68). Connect the
suction tube (30) and pump outlet hose
(59). See Fig
22-1.

Disassembling these parts can stalt from the pinion hous-
ing, or from
the clutch if no pinion service is needed.
If starting from the plnion housing, first follow Steps 1
to 6 of DRIVE HOUSING, on page 24, and then continue
with
the procedure below.
If startlng from the clutch, see page 28.
Pinion Housing
WARNING
To reduce the risk of serious bodily injury, including
fluid injection or splashing
in the eyes or on the skin,
or Injury from moving parts, always follow the Pres-
sure Relief Procedure Warnlng on page 17 before
checking, adjusting, cleaning or shutting
off the
sprayer.
Disconnect the spark plug!
NOTE Refer lo Fig 25-1 for Steps 1 to 3.
1. Remove the two bottom screws (29) and lockwashers
(1 1) first. and then remove the three screws (12) and
the clutch housing
(2).
lockwashers (1 1) holding the pinion housing (19) to
2. Pull the pinion housing away from the clutch housing.
The armature (4a) will come with it.
3. Pull the armature (4a) off the hub (19j -see Fig 27-7)
of the pinion housing.
NOTE To disassemble the pinion, go to page 26. To dis-
assemble more of the sprayer, go
to page 28. To
reassemble the sprayer from this point, skip
ahead to Reassembly, Step
7.
19d
n

PINION HOUSING 5
\ '19e
19d
Lubricate exterior
EAR TO PUSH ON
ROUND STEEL
SHAFT
(I9g)
,STEEL
BAR
STOCK
PRESS PLATFORM
PLACEMENT
OF STEEL BLOCKS WHEN
PRESSING OFF LARGE BEARING
(Ish)
Fig 27-2

LW& ,~~,,~~.~~~~~~~~~~~~~~ ENGlNE~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
NOTE The engine must be removed before the Field,
Clamp or Clutch Housing can be removed.
1. Working under the mounting plate (A)
of the Cart, re-
move the screw (1
3, lockwasher (80) and washer (99)
which hold the clutch housing (2) to the cart. See Fig
2. Stillworkingunderthemounting plate, removethetwo
nuts (61) and lockwashers (9), and then puli the
screws (14) out
of the base of the engine. Disconnect
the red wire from the engine lead
(e). Dlsconnect the
black and white wires from the field. Pull the wires
carefully through the grommets (66) before removing
the engine. See Fig
29-1 and 29-2.
3. Lifl the engine carefully and place it on a work bench.
4. Remove the Fleld and Wlrlng Harness, Clamp and
Clutch Housing, as instructed on pages 30 and
31.
5. Skip ahead to Reassembly, page 32, Step 1.
NOTE All selvice to the engine must be performed by an
29-1.
Flg
29-2
authorized HONDA dealer.

CLAMP CLUTCH HOUSING &@@#$&@
NOTE A standard steering wheel puller is required to re NOTE Refer to Fig 31-1.
move the clamp. Two 1/4-28 x 3 or 4 in. long
screws are
also needed. 1. Remove the four capscrews (8) and lockwashers (9)
NOTE Refer to Fig 31 -1.
which hold the clutch housing (2) to the engine.
1. Loosen the two screws (16) on the clamp (3), working
2. Remove the capscrew (15), lockwasher (801 and
through the slot at the bottom
of the clutch housing (2).
washer (99) from beneath the mounting plate (D).
2. Install two smews (6) of the tool (A) in two of the
3. Remove the engine key (13).
threaded holes in the clamp (3). Tighten the screws (C) 4. pull off the clutch housing (2).
until the clamp comes off.
tinue to the right.
3. Skip ahead to Reassembly, page 32, Step 3, or con- the on page
32.
5. Skip ahead to Reassembly, page 32, Step 1, or con-
B
C
15
Flg 31-1 Flg 31 -2

5. Place the engine (1) assembly on the cart. Align the
mounting holes. Carefully guide the engine wire
(D)
and wiring hamess (96) from the field, through the ap-
propriate grommets
(66) in the mounting plate (E). In-
stall the capscrews
(14), lockwashers (9) and nuts
(61). Install the capscrews (15), lockwashers (80) and
washer
(99) from under the engine mounting plate to
the clutch
(2). Connect the engine wire (A) to the red
wire, and connect the black and white wires as shown
in the Detail drawing
in Fig 33-1.
7. Be sure the face of the armature (4a) is clean. As-
semble the armature to the shafl in the pinion housing
(19). A retaining ring located within the armature
makes it difficult to assemble these parts. Follow this
procedure for the best results. First, engage a few
splines
of both parts. While they are engaged, use a
screwdriver to gently push the retaining ring into the ar-
mature, and finish engaging the splines. Push the ar-
mature onto the shafl until it contacts the ring (19m).
See Fig
33-1.
6.
Be Sure the face Of the rotor (4b) and the field is free 8. Assemble the pinion housing (1 9) to the clutch t
of all oil and contaminants. InStalLthe rotor, lockwash-
ers
(1 1) and capscrews (16). Torque the capscrews to
6.5 to 7.5 fl-lb (8.8 to 10 Nm). See Fig 33-1.
ing, using the capscrews (10) and lockwashers
See Fig
33-1.
I.
FiB 33-1
VIEW UNDER ENGINE MOUNTING PLATE

REF
NO. PART NO.
1 108-802
2 183-397
3 183-398
4 221-031
4a
4b
6 183-400
7 108-800
8 108-842
9 100-214
10 100-644
11 105-510
12 108-801
13 183-401
14 102-547
15 100-469
16 108-803
18 220-919
19 220-920
20 220-879
20a 106-227
20b 183-209
2od 107-329
2oc 100-069
21 220-639
22 220-640
24 108-849'
23 183-168
25 183-210
26 183-169
27 183-170
28 220-872
30 183-423
35 220-917
31 181-072
36 220-918
37 183-350
38 108-794
39 108-795
40 183-391
41 179-811
42 101-242
43 104-811
44 154-636
45 179-777
46 108-068
47 222-011
49 100-078
DESCRIPTION QTY
ENGINE, gasoline 1
HOUSING, clutch 1
CLAMR
mounting. rotor 1
CLUTCH ASSEMBLY
Includes items 4a and 4b
.ARMATURE
1
1
.ROTOR- 1
FIELD 1
PIN,
dowel; 5/16 x 1" 1
CAPSCREW.
hex hd: 5/16-24 UNF-2a
x 0.75" 4
LOCKWASHER, 5/16" 9
x 0.75'
CAPSCREW,
SCh; 1/4-20 UNC-3a
LOCKWASHER.
spring, 114'
5
SmCREW, 114"
17
KEY
parallel, 3/16" sq x 718"
4
CAPSCREW, hex hd; 5/16-18 UNC-2a
1
x 0.875" 2
CAPSCREW,
hex hd; 3/8-16 UNC-2a
x 0.75"
CAPSCREW.
hex sch; 1/4-26 x 1.0"
GEAR REDUCER
PINION
.~
See parts on page 36
DRIVE HOUSING
Includes Items 20a to 2W
.WASHER, bronze
.WASHER, silver
.BALL. sst
.TUBE. grease
BEARING HOUSING
CONNECTING ROD
COVER.
housing
CAPSCREW, sch; 1/4-20 UNC-3a
x 3"
PIN,
straight. 318 x 1.125"
SPRING,
retaining
NUT. hex: 3\8-16 UNC-2b
DIsPL~CEMENT PUMP
See 307-806 for mrts
SCREk!; maEh. pnh: 10-24 X 318'
SLEEVE
WHEEL,
semi-pneumatic
RING, retaining
HUBCAP
WASHER, 518"
size. 16 ga
BUTTON. snaD
PIN, spring, &igW 3/16" x 1.25'
GROUNDING CLAMP
& WIRE
1
6
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
2
4
2
2
2
2
2
2
2
1
SCREW,
ma& sldted pan hd; No. 8
x 5/16" 1
REF
NO. PART NO.
50 157-021
51 214-570
53 221-077
54 178-034
55 100-040
56 220-285
57 162-453
58 100-840
59 220-849
61 100-188
.~
62 101-344
63 222-369
.. ..
64 106-075
€6 108-805
67 183-392
M) 108-850
69 183-414
71 183-037
72 108-662
73 107-210
74 106-115
76 179-959
77 183-415
78 100-270
79 104-123
86 206-994
87 162-485
92 183-461
96 220-980
97 108-868
98 108-860
99 106-851
100 177-762*
101 181-867.
102 179-885.
DESCRIPTION QN
LOCKWASHER. Internal. No. 8 1
FLUID FILTER
See 307-253 for &
1
TAG,
warning
VALVE, pressure.drain 1
1
PLUG, pipe, sq hd; 318 npt 1
ct3 P 1
NIPPLE. hex. 114 nasm x 114 nom x
114 nps,'l-3/16" Ions
ELBOW. street. 1/4-18 (m x R
2
1
HOSE,
318" ID, cpld 318 npsm (b);
29" (737 mm); spring guard both ends 2
NUT,
heavy hex; 5/16-18 UNC-2a 5
CAPSCREW,
hex hd; 5/16-18 UNC-2a 3
PRESSURE CONTROL ASSEMBLY
See page 37 for parts
SCREW, mach. ovhd, thd frmg;
No. 6-24 x 112" Type 'C"
BUSHING, Snap
BRACKET, mounting
SCREW, mach. filh; 8-32 UNC-2a
x 1.25"
LABEL,
identification
HANGER, pail
CAPSCREW. sch; 3/8-16 UNC-3a
NUT, retainer
x 1-112"
LOCKWASHER.
spring, 318"
COVER,
prsssure control
LABEL, identification. outside cover
CAPSCREW. hex hd: 1/4-20 x 518'
LOCKWASHER.
sprik. 114"
THROAT SEAL LIQUID,
8 oz (0.27 liter)
318 npsm(m)
NIPPLE, pipe; 318 npt(m)
NIPPLE, 3/8-18 npsm x 1/4-18 npt
HARNESS, wiring
CLAMR wire
SCREW, mach, Wgh, 8-32 x 0.25"
WASHER,
plain, type B, 318"
LABEL,
warning
LABEL, warning
LABEL. warning
*Extra warning labels are avallable free.
1
4
2
1
4
1
2
1
4
4
1
2
1
2
1
1
1
1
2
2
1
1
1
1

BARE PRESSURE CONTROL ASSSEMBLY 222-369
All other items are available forpurchase separately.
Includes items
300,301,305,306,307,314,316-319
REF
NO. PART NO. DESCRlPTlON
Q.m NO. PARTNO. DESCRIPTION
REF
QTY
300 222-380 PRESSURE CONTROL 310 100-035 SCREW, mach. slotted pan head
301 183-466" LABEL, warning
Includes items
302 to 304 1 No. 8 x 5/16' 1
1 31 1
183-461 NIPPLE, hex; 3/8-18 npsm X 1/4-18 2
302 105-679
ON/OFF SWITCH 1 312 100-840 ELBOW, str, 1/4-18 npt (rn x r)
303 105-659 BOOT, switch
2
304 107-255
GUARD, locking 1 x 0.812"
305 157-021
LOCKWASHER. No. 8. internal 2 315 108-852 CONNECTOR.45'
1
306
100-284 NUT, hex, msc 8-32 UNC-2a 1 316 222-352 TRIACASSEMBLY
1
307 108-219
RECTIFIER, bridge 1 317 107-070 SCREW, fiat had csk hd
1
308 220-979
CONDUCTOR, red 2 318 100-072 NUT,hex
2
309 220-978
CONDUCTOR, red, white, black 3 319 103-181 LOCKWASHER
2
2
1 314 108-783
SCREW, mach, fmd 8-32 UNC-2a
'Extra warning labels are available free.
ENGINE
CLUTCH
FIEW
CLUTCH
FIEW
L 1
3n7-847 37

Engine ..................... .5 Horsepower, Honda
Maximum Working Pressure.
....... 3000 psi (210 bar)
CycledGallon (liter)
...................... 200 (53)
Maximum Delivery .......... 1.25 GPM (4.7 liter/min)
Fuel Tank Capacitv
............ 0.95 gallons (3.6 liter)
Maximum Tip Size
.............
. .I gin with 0.031 tip
2 guns with 0.021 tip
-
Inlet Paint Strainer ............ 16 mesh (1 190 micron)
Stainless Steel screen, reusable
Outlet Paint Filter ............. 60 mesh (250 micron)
Stainless Steel screen, reusable
Pump lniet Size
........................ 3/4 npt (m)
DIMENSIONS
Model 220-040
Upright cart without hose or gun
Weight (dry, withoul packaging) .......
135 Ib (61 Kg)
Height
.........................
31.6 in. (803 mm)
Length
.........................
30.5 in. (775 mm)
Width
..........................
22.5 in.' (572 mm)
SERVICE INFORMATION
Fluid Outlet Size ............ 1/4 npsm from fluid filter
Wetted Parts
Dlsplacement Pump.
... Carbon Steel, Polyurethane
Filter Aluminum, Carbon Steel, Stainless Steel
UHMW polyethylene, Delrinm. Leather
NOTE For information on converting your sprayer to one
that can safely pump fluids containing haloge
vice, at 1-800-543-0339.
nated hydrocarbons, contact Graco Product
Ser-
.....
NOTE Delrinm
me pressure control has been changed. me new number
is 222-369. See the parts list and drawing on page 37.