INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GMaxt 5900 Convertible
Airless Paint Sprayers
309411E
–For Portable Airless Spraying of Architectural Coatings and Paints –
5.5 HORSEPOWER, GASOLINE POWERED
3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure
Model Series
Description
Sprayer, gas powered
233709
233710
A
A
R
Sprayer, gas powered, with RAC X tip,
gun and hose
233711
233712
233713
233714
233715
A
A
A
A
A
Sprayer, gas powered, with electric
motor kit
Same as 233711 except with ETL
approval to CSA and UL standards
Sprayer, gas powered, with Lo-Boy
suction set kit
233709
ti1852a
Sprayer, gas powered, with RAC X tip,
gun and hose and Lo-Boy suction set kit
Sprayer, gas powered, with Lo-Boy
suction set kit and electric motor kit
Related Manuals
AutoClean Kit . . . . . . . . . . . . . . . . . . . . . . . 309450
Electric Motor Kit . . . . . . . . . . . . . . . . . . . . 309469
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2002, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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WARNING
SKIN INJECTION HAZARD
Spray from the spray tip, hose leaks or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause can also cause serious injury.
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.
D Always have the tip guard and the trigger guard on the in-line valve when spraying.
D Be sure the trigger safety lever operates before operating the in-line valve.
D Lock the trigger safety lever when you stop spraying.
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;
stop spraying; check, clean, or service any system equipment; or install or change spray tips.
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nently coupled hoses cannot be repaired.
D Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and
hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures
above 150_ F (65_ C) or below –40_ F (–40_ C).
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if the fluid is swallowed or
splashed in the eyes or on the skin or if the fumes are inhaled.
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state and national guidelines.
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personal respirator, gloves, and clothing.
RECOIL HAZARD
Due to the high pressure fluid emitted, a strong recoil action may occur when you trigger the pole gun.
If you are unprepared, your hand could be forced back toward your body or you could lose your bal-
ance and fall, resulting in serious injury.
309411
3
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WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
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sprayed.
D Extinguish all the open flames or pilot lights in the spray area.
D Electrically disconnect all the equipment in the spray area.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not smoke in the spray area.
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correct the problem.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in serious injury.
INSTRUCTIONS
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distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check the equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 3600 psi (25 MPa, 248 bar) maximum working pressure.
D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 150_ F (65_ C) or below –40_ F (–40_ C).
D
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.
D Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
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bends near the couplings.
D Comply with all applicable local, state and national fire, electrical and other safety regulations.
D Wear hearing protection when operating this equipment.
HAZARD OF USING FLUIDS CONTAINING HALOGENATED HYDROCARBONS
Never use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in this equipment. Such use could result in a serious chemical reaction, with
the possibility of explosion, which could cause death, serious injury and/or substantial property dam-
age.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc
parts.
4
309411
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Component Identification and Function
Pump On/Off Switch
Pressure Control
Engine On/Off Switch
Engine Controls
Prime/Drain Valve
ti1852a
Motor On/Off Switch
Spray Gun Trigger Lock
Reference your Spray Gun Manual
ti1854a
309411
5
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Maintenance
CAUTION
For detailed engine maintenance and specifications,
refer to separate engine manual, supplied.
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
DAILY: Check engine oil level and fill as necessary.
Manual 309410.
DAILY: Check that V-belt (60) is centered on pulleys
and is not inverted. Replace if worn or damaged.
D are instructed to relieve pressure,
D stop spraying,
DAILY: Check and fill gas tank.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
D check or service any system equipment,
D or install or clean spray tip.
DAILY: Check pressure drain valve for proper opera-
tion.
Pressure Relief Procedure
AFTER THE FIRST 20 HOURS OF OPERATION
AND EACH 100 HOURS THEREAFTER: Change
engine oil.
1. Lock gun safety latch.
2. Turn engine or electric motor ON/OFF switch to
OFF.
DAILY: Keep TSL in packing nut to help lubricate
pump packings. One full squirt of TSL is usually
enough.
3. Unplug power supply cord (electric motor).
4. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
WEEKLY: Remove cover of air filter (C) and clean
element. Replace element, if necessary. If operating in
an unusually dusty environment, check filter daily and
replace it, if necessary.
5. Rotate RAC 5 tip, if used, to reverse position.
6. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
7. Lock gun safety latch.
Repack connecting rod (22) top needle bearing after
every pump change.
8. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
Replacement elements can be purchased from your
local HONDA dealer.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
SPARK PLUG: Use only an BPR6ES (NGK) or
W20EPR–U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing plug.
6
309411
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Troubleshooting
Relieve pressure; page 6.
PROBLEM
CAUSE
SOLUTION
E=XX is displayed
Engine won’t start
Fault condition exists
Engine switch is OFF
Engine is out of gas
Engine oil level low
Determine fault correction from table, page 14.
Turn engine switch on.
Refill gas tank. Honda Engines Owner’s Manual.
Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable disconnected or
spark plug damaged
Connect spark plug cable or replace spark plug.
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or 4 times.
Clean or replace spark plug. Try to start engine.
Keep sprayer upright to avoid oil seepage.
False tripping of WatchDog
system. EMPTY is dis-
Operating conditions out of WatchDog
parameters
Turn pressure down. Contact Graco Technical Ser-
vice to adjust WatchDog parameters.
Operate without WatchDog active; Manual 309410.
played. Pump does not run.
Low pump output; page 8.
Pressure control switch turned OFF
Pressure setting too low
Turn on.
Engine operates, but dis-
placement pump doesn’t
Increase pressure.
Clean filter.
Displacement pump outlet filter dirty
Tip or tip filter clogged
Clean tip or tip filter.
Replace belt.
Broken drive belt
Displacement pump rod seized by
dry paint
Service pump. See page 16.
Connecting rod worn or damaged
Drive housing worn or damaged
Replace. See page 9.
Replace. See page 10.
Electrical power is not energizing clutch field Check wiring connections. Page 23.
Reference pressure control repair. Page 14.
Reference wiring diagram. Page 23.
With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power be-
tween clutch test points on control board.
Remove 7–pin connector from control board and
measure resistance across clutch coil. At 70_ F,
the resistance must be 1.7 0.2Ω; if not, replace
pinion housing.
Have pressure control checked by authorized Gra-
co dealer.
Clutch is worn, damaged, or incorrectly
positioned
Replace clutch. Page 11.
Pinion assembly is worn or damaged
Repair or replace pinion assembly. Page 11.
309411
7
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PROBLEM
CAUSE
SOLUTION
Strainer (31) clogged
Clean.
Pump output low
Piston ball (25) not seating
Piston packings worn or damaged
Displacement pump o-ring (227) is damaged
Intake valve ball not seating properly
Engine speed is too low
Service piston ball check. Manual 309277.
Replace packings. Manual 309277.
Replace o-ring. Manual 309277.
Clean and service. Manual 309277.
Increase throttle setting. See Manual 309410.
V–belt slipping
Tighten V–belt with tension bar (101). Adjust
bracket until it takes 15 lb of force to lock
tension bar down.
Clutch worn or damaged
Pressure setting is too low
Replace. See page 11.
Increase pressure. Manual 309410.
Clean filter. Manual 309410 or 309091.
Fluid filter (318), tip filter or tip is clogged or
dirty
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4
in. hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum perfor-
mance (50 ft minimum).
Excessive paint leakage into Throat packing nut is loose
throat packing nut
Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings worn or damaged
Displacement rod worn or damaged
Replace packings. Manual 309277.
Replace rod. Manual 309277.
Spitting from gun
Air in fluid pump or hose
Check and tighten all fluid connections.
Reprime pump. Manual 309410.
Tip partially clogged
Clear tip. Manual 309091.
Fluid supply is low or empty
Refill and prime pump. See Startup, Manual
309410. Check fluid supply often to prevent
running pump dry.
Pump is difficult to prime
Air leak
Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking
Shut off pump and relieve pressure. Disas-
semble and clean intake valve. Be sure ball
seat is not nicked or worn and that ball seats
well. Reassemble.
Worn packings
Fluid is too thick
Repack pump. Manual 309277.
Thin fluid according to supplier’s recommenda-
tions.
Engine speed is too high
Decrease throttle setting before priming pump.
Manual 309410.
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other.
when new and may cause noise
Noise will dissipate after a day of run time
Reset throttle to 3700 engine rpm at no load
Replace or service engine governor
Misadjusted throttle setting
High engine speed at no
load
Worn engine governor
Gallon counter not working
Bad sensor, broken or disconnected wire
Check connections. Replace sensor or wire.
Check connections. Replace display.
No display, sprayer operates Display damaged or has bad connection
8
309411
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Bearing Housing and Connecting Rod
Removal
2. Assemble connecting rod (40) and bearing
housing (60).
1.
Relieve pressure; page 6.
3. Clean mating surfaces of bearing and drive hous-
ings (60, 3).
2. Stop sprayer at bottom of stroke to get crank (E) in
lowest position. To lower crank manually, remove
spark plug and carefully rotate crank by pulling
starter rope.
4. Align connecting rod (C) with crank (E) and drive
housing locating pins (3b) with bearing housing
(60) holes. Push bearing housing onto drive hous-
ing or tap into place with plastic mallet.
3. Fig. 2. Remove front cover (38). Unclip drain hose
(74) from pump. Unscrew pump suction tube (73)
from pump. Disconnect pump hose (167).
CAUTION
Do not use bearing housing screws (19) to align or
seat bearing housing; this may cause bearing and
drive housing misalignment and result in premature
bearing wear.
4. Push up retaining spring (59). Push pin (58) out
rear.
58
5. Install screws and lockwashers (20, 19). Tighten
screws evenly to 25 ft-lb (34 Nꢀm).
6. Install pump; page 16.
7. Fig. 2. Install remaining parts.
2
C
1
B
59
2
7675B
Fig. 1
D
40
5. Loosen locknut (57). Unscrew displacement
pump (48).
3
20, 19
38
6. Remove four screws and lockwashers (20, 19).
E
7. Tap lower rear of bearing housing (60) with a
plastic mallet to loosen from drive housing (3). Pull
bearing housing and connecting rod assembly (40)
straight off drive housing.
3
107
3b
59
72
58
8. Remove pail hanger (105) and install it on new
bearing housing.
167
62
48
57
60
74
9. Inspect crank (E) for excessive wear and replace
parts as needed.
A
105
Installation
73
1
2
3
Oil
1. Evenly lubricate inside of bronze bearing (B) in
bearing housing (60) with high-quality motor oil.
Liberally pack top roller bearing (C), lower bearing
(D) inside connecting rod assembly (40) with
bearing grease 114819.
Pack with bearing grease 114819
8697B
Torque to 25 ft-lb (34 Nꢀm)
Fig. 2
309411
9
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Drive Housing
Removal
3. Install four screws (47) and lockwashers (37) to
pinion housing (4) and drive housing (3).
1.
Relieve pressure; page 6.
4. Install two screws (31) and lockwashers (37) to
drive housing (3).
2. Disconnect reed switch (A).
3. Fig. 3. Remove bearing housing. Do Removal of
Bearing Housing and Connecting Rod proce-
dure on page 9.
5. Fig. 3. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod proce-
dure on page 9.
4. Remove two screws (31) and lockwashers (37).
5. Remove four screws (35) and lockwashers (34)
from pinion housing (4).
6. Connect reed switch (A).
6. Lightly tap around drive housing (3) to loosen drive
housing. Pull drive housing straight off pinion
housing (4). Be prepared to support gear cluster
(36) which may also come out.
1
35
34
A
4
CAUTION
Do not drop gear cluster (36) when removing drive
housing (3). Gear cluster is easily damaged. Gear
may stay engaged in drive housing or pinion housing.
2
3h
3g
3
37
Installation
B
1. Liberally apply bearing grease (supplied with re-
placement gear cluster) to gear cluster (36) and to
areas called out by note 2. Use full 0.68 pint (0.32
liter) of grease.
1
31
62
36
61
62
2. Place bronze colored washer (3g) on shaft protrud-
ing from large shaft of drive housing (3). Note: If
replacing a washer with pin holes with a washer
without pin holes, remove guide pins from housing.
Place silver colored washer (3h) on pinion housing.
Assemble washers (61) and (62) onto gear (36).
Align gears and push new drive housing straight
onto pinion housing and locating pins (B).
A
1
Torque to 200 in-lb
2
Apply remaining grease to these areas
Ti1889a
Fig. 3
10
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Removal
6. Remove four screws (16) and lockwashers (37).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
1. If pinion assembly (4) is not removed from clutch
housing (169), do 2. through 5. Otherwise, do 2.
and then start at 6.
16
37
2.
Relieve pressure; page 6.
E
3. Disconnect field cable (X) from pressure control
and reed switch (A).
8701B
Fig. 6
7. Fig. 7. Remove retaining ring (169b).
8. Tap pinion shaft (169c) out with plastic mallet.
169b
169c
A
8703B
Bottom View
Fig. 7
ti1842a
X
Fig. 4
9. Fig. 9. Remove belt guide bracket (171), belt guard
(117) and vee belt (103).
4. Fig. 5. Remove five screws (47) and lockwashers
(37) and pinion assembly (4).
10. Hold pulley (53) and remove four screws (88) and
washers (37) from hub (94). Remove armature
(86) and spacer (169f).
47
37
4
11. Engine Detail, page 20. Remove screw (101) and
washer (166) from engine drive shaft. Remove
pulley (53) and motor shaft sleeve (170). Remove
pulley and key (41).
12. Fig. 9. Remove three screws (63) from beneath
mounting plate (D).
47
37
ti1888a
13. Lift off clutch housing (169).
Fig. 5
5. Fig. 6. Place pinion assembly (4) on bench with
rotor side up.
14. Remove retaining ring (169b). Pull jack shaft as-
sembly (169c) out.
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Installation
8. Hold pulley (53) and install four screws (88) and
washers (37) in hub (94). Torque to 125 in-lb
(14 Nꢀm).
1. Fig. 9. Install jack shaft assembly (169c). Install
retaining ring (169b).
9. Install belt guard (117), belt guide bracket (171)
and vee belt (103).
2. Fig. 8. Lay two stacks of two dimes on smooth
bench surface.
10. Fig. 7. Tap pinion shaft (169c) in with plastic
mallet.
3. Lay armature (86) on two stacks of dimes.
4. Press hub (94) down on bench surface.
11. Install retaining ring (169b).
86
94
12. Fig. 6. Place pinion assembly on bench with rotor
side up.
0.12 .01 in. (3.0 .25 mm)
13. Apply Loctite to screws. Install four screws (16)
and lockwashers (37). Alternately torque screws
to 125 in-lb until rotor is secure.
dimes
8705A
Fig. 8
14. Push pinion housing (4) assembly onto clutch
housing (169e). Tap lightly on front of bearing
housing (17) with a plastic mallet to push drive
housing and pinion housing assembly onto clutch
housing.
5. Fig. 9. Place spacer (169f) and armature (94, 86)
on jack shaft assembly (169c).
6. Install three screws (63) through mounting plate
(D) and into clutch housing (169).
15. Install pinion assembly with five screws (47) and
lockwashers (37).
R
7. Apply Loctite to screw (101). Install screw,
washer (166), key (41) and pulley (53) in end of
jack shaft assembly (169c). End of jackshaft
(169c) must be 0.090 in. below flush with end of
bushing.
16. Fig. 4. Connect field cable (X) to pressure control.
17. Page 10. Do Drive Housing, Installation.
41
169e
169f
101
166 53
169b
169c
86
94
171
117
37
88
D
63
103
ti1853a
Fig. 9
12
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On/Off Switch
Removal
Installation
1. Install new ON/OFF switch (51) so tabs of switch
1.
Relieve pressure; page 6.
snap into place on inside of pressure control
housing.
2. Fig. 10. Remove four screws (11) and
display/cover (12).
2. Connect ON/OFF switch connector (B) to PC
board.
3. Pull display connector wings (A) open on PC board
and pull display connector out.
3. Push display connector into PC board close dis-
play connector wings (A) on PC board.
4. Disconnect ON/OFF switch connector (B) from PC
board.
5. Press in on two retaining tabs on each side of
ON/OFF switch (51) and remove switch.
4. Install display/cover (12) with four screws (11).
100a
8
Ref 4
44
147
44
95
A
147a
100p
100q
12
11
B
176
D
178
E
141
22
33
50
51
22
13
ti1849a
Fig. 10
309411
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Pressure Control
Control Board
Removal
Installation
When installing replacement control board, follow
instructions with control board to set model type.
1.
Relieve pressure; page 6.
1. Fig. 10. Install control board (147) and jam nut
(147a). Install connector (Ref 4) at backside of
pressure control.
2. Fig. 10. Remove four screws (11) and
display/cover (12). Pull display connector wings
open on PC board and pull display connector out.
3. Fig. 17. Disconnect at control board (147):
D Lead (D) from potentiometer.
2. Install green ground wire and control board (147)
with six screws (44).
D
L
e
a
d
(
E
)
f
r
o
m
t
r
a
n
s
d
u
c
e
r
.
3. Fig. 17. Connect to control board (147):
D
R
e
m
o
v
e
O
N
/
O
F
F
s
w
i
t
c
h
(
5
1
)
a
t
c
o
n
n
e
c
t
o
r
(
A
)
.
D Connect ON/OFF switch (51) connector (A).
D Lead (E) to transducer.
4. Fig. 10. Remove six screws (44) from control board
(147) and green ground wire.
D
L
e
a
d
(
D
)
t
o
p
o
t
e
n
t
i
o
m
e
t
e
r
.
5. Remove connector (Ref 4) at backside of pressure
control. Remove jam nut (147a) and control board
(147).
4. Fig. 10. Push display connector into PC board
close display connector wings on PC board. Install
display/cover (12) with four screws (11).
Pressure Control Transducer
Removal
5. Remove pressure control transducer (100q) and
o-ring (100p) from filter housing (100e).
Installation
1.
Relieve pressure; page 6.
1. Fig. 10. Install o-ring (100p) and pressure control
transducer (100q) in filter housing (100e). Torque
to 30–36 ft-lb.
2. Fig. 10. Remove four screws (11) and
display/cover (12).
2. Install transducer connector and rubber grommet
(176) in control housing (8) . Install transducer
guard (178) on control housing with two screws
(141).
3. Disconnect lead (E) from control board (147).
4. Remove two screws (141) and transducer guard
(178) from control housing (8). Pull transducer
connector through rubber grommet (176).
3. Connect lead (E) to control board (147).
4. Install display/cover (12) with four screws (11).
Pressure Adjust Potentiometer
Removal
Installation
1. Install seal (33) on potentiometer (22).
1.
2. Fig. 10. Install pressure adjust potentiometer (22),
shaft nut, lockwasher (22) and potentiometer knob
(13).
Relieve pressure; page 6.
a. Turn potentiometer shaft (22) clockwise to
internal stop. Assemble potentiometer knob
(13) to strike pin on plate (50).
2. Fig. 10. Remove four screws (11) and
display/cover (12).
3. Disconnect lead (D) from control board (147).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
4. Loosen set screws on potentiometer knob (13) and
remove knob, shaft nut, lockwasher (22) and
pressure adjust potentiometer (22).
3. Connect lead (D) to control board (147).
5. Remove seal (78) from potentiometer (22).
4. Install display/cover (12) with four screws (11).
14
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Pressure Control Repair
Digital Display Messages
Relieve pressure before repair; page 6. No display does not mean that sprayer is not pressurized.
DISPLAY
SPRAYER
OPERATION
INDICATION
ACTION
No Display Sprayer may be pressurized.
Loss of power or display
not connected
Check power source. Relieve
pressure before repair or dis-
assembly. Verify display is
connected.
Sprayer may be pressurized.
Pressure less than
200 psi (14 bar, 1.4 MPa)
Increase pressure as needed
Sprayer is pressurized. Power is ap-
plied. (Pressure varies with tip size and
pressure control setting.)
Normal operation
Spray
psi
bar
MPa
Sprayer stops. Engine is running.
Exceeded pressure limit
Remove any filter clogs or
flow obstructions. Make sure
gun trigger is locked open if
using AutoClean valve.
Sprayer stops. Engine is running.
Sprayer stops. Engine is running.
Pressure transducer faulty, Check transducer connections
bad connection or broken
wire.
and wire. Replace transducer
or control board, if necessary.
High clutch current
1. Check clutch 7–pin bulk-
head connector. Clean
contacts.
2. Measure 1.7 0.2Ω
across clutch field at 70_ F
3. Replace clutch field as-
sembly
Sprayer stops. Engine is running.
Display alternates E=06.
High clutch temperature
1. If clutch is new, let spray-
er cool down and then re-
start
2. Inspect clutch. Replace
clutch if there is excessive
wear.
3. Remove pump pin, sepa-
rate pinion housing from
clutch housing. Rotate
rotor clockwise to check
for excessive drag.
Sprayer stops. Engine is running.
Pressure greater than
2000 psi (138 bar, 14 MPa)
while in Flush Timer Mode
1. Flush paint from hose be-
fore operating Flush Timer
Mode
2. Verify AutoClean is acti-
vated and gun valve and
prime valve are open
After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
309411
15
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Displacement Pump
Removal
58
1. Flush pump.
2.
Relieve pressure; page 6.
3. Fig. 11. Cycle pump with piston rod (222) in its
lowest position.
7675B
Fig. 12
4. Fig. 11. Remove suction tube (73) and hose (167).
6. Fig. 13. Loosen jam nut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
222
167
73
7672B
Fig. 11
5. Fig. 12. Use screwdriver: push retaining spring up
7673B
Fig. 13
and push out pin (58).
Repair
See manual 309277 for pump repair instructions.
Installation
2. Fig. 12. Push pin (19) into hole. And push retaining
spring into groove all the way around connecting
rod.
WARNING
3. Fig. 15. Screw jam nut down onto pump until
stops. Screw pump up into bearing housing until it
is stopped by jam nut. Back off pump and jam nut
to align pump outlet to back. Tighten jam nut by
hand, then tap 1/8 to 1/4 turn with a 20 oz (maxi-
mum) hammer to approximately 75" 5 ft–lb (102
Nꢀm).
If pin works loose, parts could break off due to
force of pumping action. Parts could project
through the air and result in serious injury or prop-
erty damage. Make sure pin and retaining spring
are properly installed.
CAUTION
If the pump jam nut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure jam nut is properly tightened.
1. Fig. 14. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
7673B
Fig. 15
4. Fig. 16. Fill packing nut with Graco TSL, through
one of the slits, until fluid flows onto the top of
seal.
1.5 in.
7677B
7676B
Fig. 14
Fig. 16
16
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Notes
309411
17
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Parts – Basic Sprayer
1
See exploded view on page 21
Model 233709, Series A
101 166 53 103
DETAIL A
2
See parts in manual 309277
171
5 Ref
3
4
5
See Engine Detail on page 20
See parts on page 22
117
175
189
See parts on page 24
47
37
169
123
Label
6
97
99
5
35
188
16
102
34
37
1
4
120
20
82
3h
3g
36
6
61 64
3
124
40
31
37
87
5
60
19
39
5
63
38
72
54
6
1
62
6
137
3
6
106
59
DETAIL A
58
141
151
21
121
57 105
167
95
107
48 2
23
32
115
128
102
73
74 Ref
127
71
70
100
49
140
142
139
162
110
179
18
4
10
81
141
152
ti1845b
74(Ref)
18
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Parts – Basic Sprayer
Ref.
No.
Ref.
Part No.
Description
Qty.
No.
Part No.
Description
Qty.
3
4
245443
245399
HOUSING, drive (5900)
HOUSING, pinion (5900)
parts, page 21
HANDLE, cart
SWITCH, reed
LABEL, crtl box cover, Ultra
SCREW, cap, sch
PLUG, tube
WASHER, lock spring (hi–collar)
SCREW, cap, socket hd
SCREW, thread forming, hex hd
CLAMP, grounding assy
SCREW, cap, socket hd
CORD, power, convertible
WASHER, lock, spring
SCREW, cap sch
GEAR, combination
WASHER, lock, spring hi-collar
COVER, drive
ROTOR, clutch, 5 in.; parts, page 24
ROD, connecting
SCREW, cap, sch
PUMP, displacement
CAP, hub
PULLEY, engine
LABEL, danger, English
NUT, retaining
1
1
76
81
82
87
88
95
97
99
206994
FLUID, TSL 8 oz bottle
LABEL, warning
LABEL, instruction (English)
STRAP, retaining
SCREW, hex, socket head
NIPPLE, adapter
WASHER
PIN, spring straight
CLIP, axle
SCREW, cap, hex hd
FRAME, cart, convert.
BELT, vee, 30 in.
HANGER, pail
NUT, hex
SCREW, self–tap, filhd
WHEEL, semi pneumatic, 12 in.
CLIP, retainer
1
1
1
1
4
1
2
2
2
1
1
1
1
2
4
2
2
1
4
1
2
4
2
1
9
2
3
1
1
3
2
2
1
1
1
2
1
4
1
195119
195098
114271
108803
162485
183350
108068
198723
112406
245269
193547
192719
112746
114818
198720
114687
198691
108795
114809
191084
116891
198772
198882
112774
198904
109575
245688
198697
110997
109032
112717
243814
245689
198996
111590
155699
100078
245406
Y
5
6
245245
116806
196670
101682
193682
106115
114666
112798
237686
114686
114794
104008
101864
241440
105510
241308
1
1
1
4
2
4
4
1
1
2
1
4
4
1
15
1
1
1
4
1
2
1
1
1
1
1
1
1
2
3
1
1
1
1
1
1
1
10
16
18
19
20
21
23
31
32
34
35
36
37
38
39
40
47
48
49
53
54
57
58
59
60
61
62
63
64
66
70
71
72
73
74
100
101
102
103
105
106
107
110
115
117
120
121
123
127
128
137
139
140
141
142
151
152
162
166
167
169
171
175
179
188
189
GUARD, belt
SCREW, mach, pnh
BUSHING, strain relief
SLEEVE, cart
241279
100644
244224
104811
198688
WASHER
COLLAR, torsion bar
LABEL, ident, GMax 5900C
SCREW, MACH
SCREW, PLASTITE #8
SCREW, threadforming, hex hd
BAR, torsion, includes 128
BRACKET, shelf belt guard
SCREW, flange, hex
SCREW, mach, pnh
WASHER
HOSE, coupled
HOUSING, clutch
BRACKET, belt guide
BUTTON, snap
ELBOW, street
194125
193031
183210
183169
241015
114699
114672
112395
290228
109099
181072
241920
197124
193097
244240
Y
PIN, str, hdls
SPRING, retaining
HOUSING, bearing
WASHER, thrust
WASHER, thrust
SCREW, cap, flnghd
LABEL, CAUTION
BUSHING, snap
STRAINER, inlet
DEFLECTOR, threaded
CLIP, spring
SCREW, mach, slt hex wash hd
SHAFT, input; part of Kit 169
TUBE, suction
HOSE, coupled
309411
19
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Engine Detail
118 111
L
93
J
124
P
41
112
92
N
M
42
C
170
166
32 Ref
101
146
125
101
52
53
156 108
165
C
ti1846a
84
C
Ref.
No.
Ref.
No.
Part No.
Description
KEY, parallel
BRACKET, belt guard (motor)
BASE, mounting
Qty.
Part No.
Description
Qty.
41
42
52
53
84
92
93
101
108
111
112
118
124
183401
198689
245272
198688
194925
194414
114805
112406
114653
192014
116149
113084
114530
1
2
1
1
1
13
1
3
4
1
1
2
1
125
146
156
165
166
170
198693
116139
198695
111800
112717
198995
110996
HANDLE, slide, engine
GRIP, handle
BRACKET, torsion bar
SCREW, cap, hex hd, flange
WASHER
SLEEVE, motor shaft
NUT, flng hd, hex
LABEL, warning
BOX, junction, engine
NUT, hex
SCREW, mach, hex washer hd
BUSHING, snap
2
2
1
2
2
1
6
1
1
1
1
1
PULLEY, engine
BRACKET, tension
BRACKET, J–box
JACK, 1/4 engine
SCREW, cap, hex hd
SCREW, cap, flange hd
PLATE, indicator
SPACER
RIVET, blind
ENGINE, gas, 5.5HP, Honda
C
J
L
M
N
P
Y
1
9
4
1
2
6
194181
114816
114813
109099
20
309411
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Parts List & Drawing – Pinion Assembly
Ref No. 4 and 3
Ref No. 4: Pinion Housing Assembly 245399
Ref No. 3: Drive Housing Assembly 245443
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
4a
4b
4d*
4e*
245267
105489
PINION HOUSING & COIL
PIN
PINION SHAFT
1
2
1
1
3
HOUSING, drive
WASHER
WASHER
SWITCH, reed
PIN, spring
MAGNET
1
1
1
1
2
1
1
3g*
3h*
3k
3m
3n
3p
194173
116192
116806
116838
116618
15A622
112770
RETAINING RING, large
*Must be ordered separately
LABEL, WatchDog
*Must be ordered separately
4d
4b
4e
47 (Ref.)
37 (Ref.)
4
3h
3g
3
15 (Ref)
3p
10 (Ref.)
3n
9 (Ref.)
7(Ref)
1
16 (Ref)
3m
3k
TI0177B
1
Pinion housing assembly (4) includes clutch field and connector
309411
21
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Parts Drawing – Sprayer
Ref No 24
Pressure Control Assembly
100a
100b
139 147a
Ref 19
7
44
182
8
12
44
100c
181
100d
100e
176
104
174
11
100f
178
141
147
100g
50
139
100h
95 Ref
30
100q100r 100s
100k 100j 100p
100n 100m
22
33
51
13
22
ti1848a
22
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Parts List – Sprayer
REF
REF
NO. PART NO.
DESCRIPTION
QTY
NO. PART NO.
DESCRIPTION
QTY
7
8
11
12
198534
198548
116252
245393
PLATE, control
1
1
4
1
FILTER, fluid
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HOUSING, control
SCREW, #8 taptite, phil
COVER, digital display
Includes 11, 30, 181,
KNOB, potentiometer
POTENTIOMETER, pressure control
LABEL, GMax, LCD
SPACER, shaft
SCREW, pnhd 6–32
PANEL, control
SWITCH, rocker, (spst)
NIPPLE, adapter
ADAPTER
SCREW, mach
SCREW, threadforming, hex hd
BOARD, PC
Includes 147a
100 245396
100a 196675
100b 104361
100c 244067
100d 196786
100e 245401
100f 193710
100g 193709
100h 114797
100j 245103*
100k 114708
100m 194102
100n 114688
100p 111457
100q 243222
KIT, repair, filter
BOWL, filter
O-RING
STRAINER, mesh, 60
TUBE, diffuser
KIT, repair, filter base
SEAL, valve
SEAT, valve
GASKET
VALVE
SPRING, compression
HANDLE, valve
NUT, cap, hex hd
O-RING
TRANSDUCER, pressure control
includes 100p
GASKET, plug
PLUG, AutoClean
13
22
30
33
44
50
51
95
116167
241443
198648
198650
114331
198553
116752
162485
1
1
1
1
6
1
1
1
2
4
4
1
104 164672
139 112774
141 109575
147 245394
100r 197055
100s 196781
1
1
147a
NUT, nylon
PLUG, packless
BUSHING, step
GUARD, transducer
LABEL, instruction, GMax
LABEL, warning
1
1
1
1
1
1
174 245474
176 114296
178 198994
181 198884
182Y 189246
* Drain valve repair kit 245103 includes 100f, g, h, k, m, n
Y Replacement warning labels may be ordered free of charge
Pressure Control
Wiring Diagram
Clutch Coil
VIEW A
Engine Power
DISPLAY BOARD
Gallon
Counting
Sensor
Thermistor
ON/OFF SWITCH
DRIVE
HOUSING PINION
HOUSING
CONTROL BOARD
TRANSDUCER
VIEW A
CLUTCH TEST POINTS
TO CORD, 32
POTENTIOMETER
ti1843a
Fig. 17
309411
23
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Parts List & Drawing –Clutch Assembly
Ref
No.
Ref
Part No.
Description
Qty
No.
Part No.
Description
Qty
16*
37*
39*
86*
88*
94*
169
101682
105510
SCREW, cap, sch
WASHER, lock, spring
ROTOR, clutch, 5 in.
ARMATURE, clutch
SCREW, hex, sch
HUB, armature
4
8
1
1
4
1
1
169b 114962
169c 245406
169e 193493
RING, retaining, internal
SHAFT, drive, input
HOUSING, clutch
STOP, armature
O-RING
1
1
1
1
1
1
169f
194059
108803
245689
169j
115078
169k 115079
O-RING
HOUSING, clutch
Includes 169b, 169c, 169e, 169j & 169k
* Clutch replacement kit 241113 includes 16, 37, 39, 86, 88,
and 94
169b
169c
169e
169k
169j
169f
86*
94*
16*
37*
39*
37* 88*
8745A
Parts – Complete Sprayer
Model 233710, 233714
Includes:
D
233709 Convertible GMax 5900C Sprayer, parts
list page 18,
226a
D
245507 (233714) Lo-Boy Suction Set Kit, parts list
page 25
D
287036 Contractor Gun Kit below:
Ref.
No.
226c
Part No.
Description
Qty.
226
287036
Contractor II Gun Kit
1
Includes 226a – 226c
226b
226a 240794
226b 238358
226c 246220
HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(fbe); 50 ft (15 m);’
spring guards both ends
1
HOSE, grounded, nylon; 3/16” ID;
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;
3 ft (0.9 m); spring guards both ends
CONTRACTOR II SPRAY GUN
1
1
Includes RAC X HandTitet Tip Guard
0160
and 517 SwitchTip
t
See 309639 for parts
24
309411
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Parts – Lo-Boy Suction Set Kit
Model 245507
Includes items 401 to 407
Ref.
No.
401
Part No.
Description
Qty.
401
241124
.TUBE, suction, 5 gallon (20 liter)
includes 401a through 401e
..SWIVEL, tube, inlet
..GUARD, hose
..HOSE, fluid
..CLAMP, hose
..TUBE, suction
.HOSE, drain, includes 406
.CLIP, spring
.STRAINER
1
402(REF)
406
401a 240513
401b 176450
401c 194306
401d 101818
401e 170957
402
403
405
406
407
1
1
1
2
1
1
1
1
1
1
405
403
407
245611
194194
181072
241920
144958
401a
401e
.DEFLECTOR
.STRAP, tie
402
401c
401b
401d
ti1851a
Technical Data
Dimensions
Model 233709
Weight (dry, without packaging) . . . . . . . 170 lb (77 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 in. (99.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)
Honda GX160 Engine
Power Rating @ 3700 rpm
ANSI . . . . . . . . . . . . . . . . . . . . . . . 5.5 Horsepower
DIN 6270B/DIN 6271
NA . . . . . . . . . . . . . . . . . . . . . . 2.9 Kw – 4.0 Ps
NB . . . . . . . . . . . . . . . . . . . . . . 3.6 Kw – 4.9 Ps
Maximum Working Pressure . . . . . . . . . . . . . . 3300 psi
(227 bar, 22.7 MPa)
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . 93 (25)
Maximum Delivery . . . . . . . . . . 1.25 gpm (4.7 liter/min)
Fuel Tank Capacity . . . . . . . . . . . 0.95 gallons (3.6 liter)
Maximum Tip Size . . . . . . . . . . . . . . 1 gun with 0.041 tip
2 guns with 0.028 tip
DANGER LABELS
The English language DANGER label is on your
sprayer. If you have painters who do not read En-
glish, order one of the following labels to apply to
your sprayer. The drawing below shows the best
placement of these labels for good visibility.
Inlet Paint Strainer . . . . . . . . . . . 16 mesh (1190 micron)
Stainless steel screen, reusable
Outlet Paint Filter . . . . . . . . . . . . . 60 mesh (250 micron)
Stainless steel screen, reusable
Order the labels directly from your Graco distributor.
Pump inlet Size . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)
Fluid Outlet Size . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted parts . . . . . . . . . . . . . . zinc-plated carbon steel,
PTFE, Nylon, polyurethane, UHMW polyethylene,
FKM, POM, leather, aluminum, tungsten car-
bide,nickle-plated carbon steel, stainless steel,
chrome plating
French
Spanish 194932
German 194933
Greek
Korean
194931
194934
194935
Apply other
language here
English 194125
03497A
309411
25
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Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-
dance 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 sub-
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call this number to identify the
distributor near you:1–800–690–2894 Toll Free
All written and visual data contained in this document reflects latest product information available at time of publication. Graco
reserves right to make changes at any time without notice.
MM 309411
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Printed in USA 309411
1/2002 Rev. 5/2008
26
309411
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