INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
5.5 HORSEPOWER, GASOLINE POWERED
GMAX 5900 Convertible
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model Series Description
232624 A Sprayer, gas powered
232625 A Sprayer, gas powered, with RACt 5tip,
gun and hose
232626 A Sprayer, gas powered, with electric mo-
tor kit
232629 A Same as 232626 except with ETL ap-
proval to CSA and UL standards
232680 A Sprayer, gas powered, with Lo-Boy
suction set kit
232681 A Sprayer, gas powered, with RAC 5 tip,
gun and hose and Lo-Boy suction set kit
232682 A Sprayer, gas powered, with Lo-Boy suc-
tion set kit and electric motor kit
240774 A Electric motor kit converts sprayer to
electric powered sprayer.
240775 A Same as 240774 except with ETL ap-
proval to CSA and UL standards
Related Manuals
Operator 308863...........................
Displacement Pump 308798.................
Spray Gun 309091.........................
Spray Tip 309055...........................
PC Board 308919..........................
Electric Motor Kit 308920....................
Drain Valve Kit 308961......................
First choice when
quality counts.t
Model 232624
308864G
8737A
Table of Contents
Component Identification and Function 3............
Maintenance 4...................................
Troubleshooting 5................................
Repair
Bearing Housing and Connecting Rod 7...........
Drive Housing 8................................
Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley 9..
ON/OFF Switch 11.............................
Pressure Control Repair 12......................
Displacement Pump Repair 14...................
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441
ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts
Basic Sprayer 16...............................
Pinion Assembly 18............................
Pressure Control 19............................
Wiring Schematic 20............................
Clutch Assembly 21............................
Complete Sprayer 21...........................
Lo-Boy Suction Set Kit 22.......................
Technical Data 23................................
Dimensions 23...................................
Graco Phone Number 23..........................
Graco Warranty 24...............................
Warnings and Cautions
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
Fire and explosion can occur when spraying or flushing flammable
fluid in an area where air circulation is poor and flammable vapors
can be ignited by an open flame or sparks.
To help prevent a fire and explosion:
DUse outdoors or in an extremely well ventilated area.
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.
DRemove, extinguish or unplug all ignition sources;
tape wall switch. Do not smoke in spray area.
DNever fill fuel tank while the engine is running or hot.
DGround Sprayer, object being sprayed, paint and solvent pails.
DHold gun firmly to side of a grounded pail when triggering into pail.
DUse only conductive airless paint hose.
DNever run engine in inclosed area.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Fluid injection is a serious injury! If high pressure fluid pierces
your skin, the injury might look like “just a cut”. But it is a serious
wound! Get immediate medical attention.
To help prevent injection, always:
DEngage trigger safety latch when not spraying.
DPoint gun away from yourself or anyone else.
DRelieve pressure before checking or repairing any leak.
DRelieve pressure when you turn off the sprayer or stop spraying.
DDo not use components rated less than system Maximum
Working Pressure
Never allow children to use this unit. If you are injured using this
equipment, get immediate medical treatment.
2 308864
Component Identification and Function
202 Main hose
203 Whip end hose
204 Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip
C
V
H
J
D
K
A
M
Fig. 1
A Pressure Control Switch ON/OFF, enables/disables clutch function
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering carburetor
D Fuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline
E Muffler* Reduces noise of internal combustion
F Spark Plug Cable* Routes electrical current to spark plug
G Fuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor
H Choke* Enriches air/gasoline mixture for cold starting
J Throttle Lever* Adjusts engine speed for large or small orifice spray tips
K Engine Switch* Enables/disables engine operation
L Secondary Fluid Outlet Second hose and spray gun is connected here
M Pressure Control Controls clutch cycling to maintain fluid pressure
N Primary Fluid Outlet Hose and spray gun is connected here
P Engine* 5.5 HP gasoline engine
R Clutch Housing Transfers power from engine to drive assembly
S Drive Housing Transfers power from clutch to displacement pump
T Displacement Pump Provides fluid to be sprayed through spray gun
U Fluid Filter Filters fluid between source and spray gun
V Grounding Clamp and Wire Grounds sprayer system
W Pressure Drain Valve Relieves fluid pressure when open
X Cord Provides electric power from engine alienator to control and clutch
Y Clamp Locks down engine/motor and provides belt tension
* For more detailed explanations of these controls, refer to Honda engine manual; supplied
B
W
P
X
U
Y
L
N
Model 232624
R
S
G
T
202
E
F
203
204
8738A
3308864
Maintenance
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
D are instructed to relieve pressure,
D stop spraying,
D check or service any system equipment,
D or install or clean spray tip.
Pressure Relief Procedure
1. Lock gun safety latch.
2. Turn engine or electric motor ON/OFF switch to
OFF.
3. Unplug power supply cord (electric motor).
4. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
CAUTION
For detailed engine maintenance and specifications,
refer to separate engine manual, supplied.
DAILY: Check engine oil level and fill as necessary.
Manual 308863.
DAILY: Check that V-belt (60) is centered on pulleys
and is not inverted. Replace if worn or damaged.
DAILY: Check and fill gas tank.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
AFTER THE FIRST 20 HOURS OF OPERATION
AND EACH 100 HOURS THEREAFTER: Change
engine oil.
DAILY: Keep TSL in packing nut to help lubricate
pump packings. One full squirt of TSL is usually
enough.
5. Rotate RAC 5 tip, if used, to reverse position.
6. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
7. Lock gun safety latch.
8. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
WEEKLY: Remove cover of air filter (C) and clean
element. Replace element, if necessary. If operating in
an unusually dusty environment, check filter daily and
replace it, if necessary.
Repack connecting rod (22) top needle bearing after
every pump change.
Replacement elements can be purchased from your
local HONDA dealer.
SPARK PLUG : Use only an BPR6ES (NGK) or
W20EPR--U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing plug.
4 308864
Tr oubleshooting
WARNING
INJECTION HAZARD
To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from
moving parts, always follow Pressure Relief Procedure Warning, page 4, before checking, adjusting, cleaning or shutting down sprayer.
Check everything in chart before disassembling sprayer.
PROBLEM
Engine won’t start Engine switch is OFF Turn engine switch on.
Engine operates, but
displacement pump
doesn’t
CAUSE SOLUTION
Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.
Engine oil level low Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable disconnected or
spark plug damaged
Oil seepage into combustion
chamber
Pressure control switch turned OFF Turn on.
Pressure setting too low Increase pressure.
Displacement pump outlet filter dirty Clean filter.
Tip or tip filter clogged Clean tip or tip filter.
Broken drive belt Replace belt.
Displacement pump rod seized by
dry paint
Connecting rod worn or damaged Replace. See page 7.
Connect spark plug cable or replace spark plug.
Remove spark plug. Pull starter rope 3 or 4 times.
Clean or replace spark plug. Try to start engine.
Keep sprayer upright to avoid oil seepage.
Service pump. See page 14.
Drive housing worn or damaged Replace. See page 8.
Electrical power not energizing clutch field Check wiring connections. See page 20.
Reference control board diagnostics. See page 13.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check for
power between clutch terminals on control board.
Remove black clutch wires from control board and
measure resistance across wires. At 70_ F, t h e
resistance must be between 1.7
place pinion housing.
Have pressure control checked by authorized Graco dealer.
Clutch worn or damaged Service. See page 9.
Pinion assembly worn or damaged Service. See page 9.
±0.2Ω;ifnot,re-
5308864
PROBLEM
CAUSE SOLUTION
Pump output low
Excessive paint leakage into
throat packing nut
Strainer (31) clogged Clean.
Piston ball (25) not seating Service piston ball check. Manual 308798.
Piston packings worn or damaged Replace packings. Manual 308798.
O-ring (227) in displacement pump is worn or
damaged
Intake valve ball not seating properly Clean and service. Manual 308798.
Engine speed is too low Increase throttle setting. See Manual 308863.
V--belt slipping Tighten V --belt with clamp (101). Adjust clamp
Clutch worn or damaged Replace. See page 9.
Pressure setting is too low Increase pressure. Manual 308863.
Fluid filter (318), tip filter or tip is clogged or
dirty
Large pressure drop in hose with heavy
materials
Throat packing nut is loose Remove throat packing nut spacer. Tighten
Replace o-ring. Manual 308798.
until it takes 15 lb of force to lock clamp down.
Clean filter. Manual 308863 or 309091.
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4
in. hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum).
throat packing nut just enough to stop leakage.
Throat packings worn or damaged Replace packings. Manual 308798.
Displacement rod worn or damaged Replace rod. Manual 308798.
Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake
and tighten. Then prime pump. See Startup,
Manual 308863.
Tip partially clogged Clear.
Fluid supply is low or empty Refill and prime pump. See Startup, Manual
308863. Check fluid supply often to prevent
running pump dry.
Pump is difficult to prime Air leak Check all hose connections and tighten as
Intake valve is leaking Shut off pump and relieve pressure. Disas-
Worn packings Repack pump. Manual 308798.
Fluid is too thick Thin fluid according to supplier’s recommenda-
Engine speed is too high Decrease throttle setting before priming pump.
needed.
Reduce engine speed and cycle pump as
slowly as possible during priming.
semble and clean intake valve. Be sure ball
seat is not nicked or worn and that ball seats
well. Reassemble.
tions.
Manual 308863.
High engine speed at no
load
Clutch squeaks each time
clutch engages
6 308864
Misadjusted throttle setting. Reset engine throttle to 3600 -- 3800 rpm at no
Worn engine governor Replace or service engine governor
Clutch surfaces are not matched to each other
when new and may cause noise
load
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time
Bearing Housing and Connecting Rod
Removal
1.
Relieve pressure; page 4.
2. Stop sprayer at bottom of stroke to get crank (E) in
lowest position.To lower crank manually, remove
spark plug and carefully rotate crank by pulling
starter rope.
3. Fig. 3. Remove front cover (13). Unclip drain hose
(108) from pump. Unscrew pump suction tube
(107) from pump. Disconnect pump hose (47).
4. Push up retaining spring (18). Push pin (19) out
rear.
19
Fig. 2
18
7675B
5. Loosen locknut (20). Unscrew displacement
pump (21).
6. Remove four screws and lockwashers (44, 45).
7. Tap lower rear of bearing housing (17) with a
plastic mallet to loosen from drive housing (12).
Pull bearing housing and connecting rod assembly
(14) straight off drive housing.
3. Clean mating surfaces of bearing and drive housings (17, 12).
4. Align connecting rod (14) with crank (E) and drive
housing locating pins (12b) with bearing housing
(17) holes. Push bearing housing onto drive housing or tap into place with plastic mallet.
CAUTION
Do not use bearing housing screws (44) to align or
seat bearing housing; this may cause bearing and
drive housing misalignment and result in premature
bearing wear.
5. Install screws and lockwashers (44, 45). Tighten
screws evenly to 25 ft-lb (34 N¡m).
6. Install pump; page 14.
7. Fig. 3. Install remaining parts.
2
C
2
D
14
45, 44
3
13
12
E
12b
57
17
18
1
19
B
8. Remove pail hanger (59) and install it on new
bearing housing.
9. Inspect crank (E) for excessive wear and replace
parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (B) in
bearing housing (17) with high-quality motor oil.
Liberally pack top roller bearing (C), lower bearing
(D) inside connecting rod assembly (14) with
bearing grease 114819.
2. Assemble connecting rod (14) and bearing
housing (17).
47
108
1
Oil
2
Pack with bearing grease 114819
3
Torque to 25 ft-lb (34 N¡m)
Fig. 3
20
59
21
106
107
8697A
7308864
Drive Housing
1.
Removal
2. Fig. 4. Remove bearing housing. Do Removal of
Bearing Housing and Connecting Rod proce-
dure on page 7.
Relieve pressure; page 4.
2. Place bronze colored washer (12g) on shaft protruding from large shaft of drive housing (12).
Note: If replacing a washer with pin holes with a
washer without pin holes, remove guide pins from
housing. Place silver colored washer (12h) on pinion housing. Assemble washers (15) and (16) onto
gear (7). Align gears and push new drive housing
straight onto pinion housing and locating pins (A).
3. Install four screws (9) and lockwashers (10) to
pinion housing (8) and drive housing (12).
3. Remove two screws (41) and lockwashers (10).
4. Remove four screws (9) and lockwashers (10)
from pinion housing (8).
5. Lightly tap around drive housing (12) to loosen
drive housing. Pull drive housing straight off pinion
housing (8). Be prepared to support gear cluster
(7) which may also come out.
CAUTION
Do not drop gear cluster (7) when removing drive
housing (12). Gear cluster is easily damaged. Gear
may stay engaged in drive housing or pinion housing.
Installation
1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (18) and to
areas called out by note 2. Use full 0.68 pint (0.32
liter) of grease.
4. Install two screws (41) and lockwashers (10) to
drive housing (12).
5. Fig. 4. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod procedure on page 7.
1
9
10
A
8
2
A
15
7
16
15
1
Torque to 200 in-lb
2
Apply remaining grease to these areas
Fig. 4
12h
12g
12
10
41
TI0178B
1
8 308864
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
X
Removal
If pinion assembly (8) is not removed from clutch
housing (3), do 1. through 4. Otherwise, do 1 and then
startat5.
1.
Relieve pressure; page 4.
2. Disconnect field cable (X) from pressure control.
Fig. 5
Bottom View
8739A
39
6
E
Fig. 7
6. Fig. 8. Remove retaining ring (Z).
7. Tap pinion shaft (A) out with plastic mallet.
Z
A
8701A
3. Fig. 6. Remove five screws (5) and lockwashers
(6) and pinion assembly (8).
5
6
8
5
Fig. 6
6
4. Fig. 7. Place pinion assembly (8) on bench with
rotor side up.
5. Remove four screws (39) and lockwashers (6).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
8740A
Fig. 8
8703A
8. Fig. 10. Remove drive belt shield (74) and
belt (68).
9. Hold pulley (2) and remove four screws (3a) and
washers (3h) from hub (3d). Remove armature
(3g) and spacer (3f).
10. Remove set screw (112a) from bushing (112).
Remove three bolts (112b) and three washers
(112c). Use bolts to remove pulley from bushing.
Remove pulley and key (1).
1 1. Remove three screws (27) from beneath mounting
plate (D).
12. Lift off clutch housing (3).
13. Remove retaining ring (3b). Pull jack shaft assembly (3c) out.
9308864
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Installation
1. Fig. 10. Install jack shaft assembly (3c). Install
retaining ring (3b).
2. Fig. 9. Lay two stacks of two dimes on smooth
bench surface.
3. Lay armature (4a) on two stacks of dimes.
4. Press center of clutch down on bench surface.
4a
Fig. 9
5. Place spacer (3f) and armature (3d, 3g) on jack
shaft assembly.
6. Install three screws (27) through mounting plate
(D) and into clutch housing (3).
to
7. Insta
to three bolts (112). Install bushing in pulley (2)
with three bolts (112b). Install set screw (112a) in
bushing. End of jackshaft (3c) must be 0.090 in.
below flush with end of bushing.
ll key (1) in bushing (112). Apply Locktite
0.12 ±.01 in. (3.0 ±.25 mm)
8705A
E
1 1. Install five screws (5) and lockwashers (6).
12. Fig. 8. Tap pinion shaft (A) in with plastic mallet.
13. Install retaining ring (Z).
14. Fig. 7. Place pinion assembly on bench with rotor
side up.
15. Apply locktite to screws. Install four screws (39)
and lockwashers (6). Alternately torque screws to
125 in-lb until rotor is secure.
16. Install pinion assembly with five screws (5) and
lockwashers (6).
17. Fig. 5. Connect field cable (X) to pressure control.
71
74
1
3b
3c
1 12a
1 12b
3e
3f
3g
3d
8. Hold pulley (2) and install four screws (3a) and
washers (3h) in hub (3d). Torque to 125 in-lb
(14 N¡m).
9. Install drive belt shield (74).
10. Push drive housing (12) and pinion housing (8)
assembly onto clutch housing (3). Tap lightly on
front of bearing housing (17) with a plastic mallet
to push drive housing and pinion housing assembly onto clutch housing.
68
Fig. 10
3h
3a
D
112
2
27
8741A
10 308864
On/Off Switch
Removal
1.
2. Fig. 11. Remove five screws (307) and
cover (322).
Relieve pressure; page 4.
Installation
1. Install new ON/OFF switch (309) so tabs of switch
snap into place on inside of pressure control
housing.
3. Disconnect two wires (A) from ON/OFF
switch (309).
4. Press in on two retaining tabs on each side of
ON/OFF switch (309) and remove.
1
A309
301
302
307
322
Fig. 11
303
D
E
1
Locate switch terminals as shown
2. Connect two wires (A) to ON/OFF switch.
3. Install pressure control cover (322) with five
screws (307).
313
310
315 319
318z
318aa
318a
8711A
11308864
Pressure Control
Control Board
Removal
1.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Fig. 18. Disconnect at control board (302):
D Four clutch leads: two violet and two black.
D Lead (D) from potentiometer.
D Lead (E) from transducer.
Relieve pressure; page 4.
Pressure Control Transducer
Removal
1.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (E) from control board (302).
4. Remove three screws (319) and fluid filter (318)
from control plate (301). Carefully pull transducer
connector through rubber grommet (315).
5. Remove pressure control transducer (318z) and
packing o-ring (318aa) from filter housing (318a).
Relieve pressure; page 4.
Pressure Adjust Potentiometer
D Two red leads (A) to ON/OFF switch (80).
4. Remove five screws (303), green ground wire and
circuit board (302).
Installation
1. Fig. 11. Install control board (302) and green
ground wire with five screws (303).
2. Connect to control board (302):
D Two red leads (A) to ON/OFF switch (309).
D Lead (E) to transducer.
D Lead (D) to potentiometer.
D Four clutch leads: two violet and two black.
3. Install cover (322) with five screws (307).
Installation
1. Fig. 11. Install packing o-ring (318aa) and pressure
control transducer (318z) in filter housing (318a).
Torque to 30--35 ft-lb.
2. Carefully feed transducer connector through
rubber grommet (315). Install fluid filter (318) on
control plate (301) with three screws (319).
3. Connect lead (E) to control board (302).
4. Install cover (322) with five screws (307).
Removal
1.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (D) from control board (302).
4. Loosen set screws on potentiometer knob (313)
and remove knob, shaft nut, lockwasher (310) and
pressure adjust potentiometer (310).
5. Remove seal (311) from potentiometer (310).
Relieve pressure; page 4.
12 308864
Installation
1. Install seal (311) on potentiometer (310).
2. Fig. 11. Install pressure adjust potentiometer (310),
shaft nut, lockwasher (310) and potentiometer
knob (313).
a. Turn potentiometer shaft (310) clockwise to
internal stop. Assemble potentiometer knob
(313) to strike pin on plate (312).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
3. Connect lead (D) to control board (302).
4. Install cover (322) with five screws (307).
Pressure Control
Control Board Diagnostics
1. Fig. 11. Remove five screws (307) and
cover (322).
2. Start sprayer.
LED
BLINKS
Two times
repeatedly
Three
times repeatedly
Four times
repeatedly
Five times
repeatedly
SPRAYER OPERATION INDICATES WHAT TO DO
Sprayer shuts down and LED continues to blink two times repeatedly
Sprayer shuts down and LED continues to blink three times repeatedly
Sprayer shuts down and LED continues to blink four times repeatedly
Sprayer shuts down and LED continues to blink five times repeatedly
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
Run away pressure.
Pressure greater than
4500 psi (310 bar, 31
MPa).
Pressure transducer is
faulty or missing
Generator voltage is
low
High clutch current 1. Check clutch 5-pin bulkhead con-
1. Check pressure transducer connection at control board
2. Replace pressure transducer
3. Replace control board
1. Check pressure transducer connection at control board
2. Replace pressure transducer
3. Replace control board
1. Increase engine throttle
2. Check wiring connections
3. Service Honda engine alternator
nector. Clean contacts.
2. Measure 1.7 ±0.2Ω across clutch
field at 70_F
3. Replace clutch field assembly
Six times
repeatedly
Sprayer shuts down and LED continues to blink six times repeatedly
High clutch temperature 1. If clutch is new, let sprayer cool
down and then restart
2. Inspect clutch. Replace clutch if
there is excessive wear.
3. Remove pump pin, separate pinion housing from clutch housing.
Rotate rotor clockwise to check
for excessive drag.
13308864
Displacement Pump
Removal
1. Flush pump.
2.
3. Fig. 12. Cycle pump with piston rod (222) in its
lowest position.
4. Fig. 12. Remove suction tube (107) and hose (47).
47
Fig. 12
5. Fig. 13. Use screwdriver: push retaining spring up
and push out pin (19).
Relieve pressure; page 4.
222
107
7672B
Repair
19
Fig. 13
6. Fig. 14. Loosen jam nut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 14
7675B
7673B
See manual 308798 for pump repair instructions.
Installation
WARNING
If pin works loose, parts could break off due to
force of pumping action. Parts could project
through the air and result in serious injury or property damage. Make sure pin and retaining spring
are properly installed.
CAUTION
If the pump jam nut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure jamnut is properly tightened.
1. Fig. 15. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
2. Fig. 13. Push pin (19) into hole. And push retaining
spring into groove all the way around connecting
rod.
3. Fig. 16. Screw jam nut down onto pump until
stops. Screw pump up into bearing housing until it
is stopped by jam nut. Back off pump and jam nut
to align pump outlet to back. Tighten jam nut by
hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately 75 5ft--lb(102
N¡m).
Fig. 16
4. Fig. 17. Fill packing nut with Graco TSL, through
one of the slits, until fluid flows onto the top of
seal.
7673B
Fig. 15
14 308864
1.5 in.
7676B
Fig. 17
7677B
Notes
15308864
Model 232624, Series A
74
71
79
72
2112
79
3
132
Parts -- Basic Sprayer
1
1 12b68
1 12a
1
65
5
6
3
5
See exploded view on page 18
2
See parts in manual 308798
3
See Engine Detail on page 17
4
See parts on page 19
5
See parts on page 21
6
Label
9
10
1
8
83
12h
12g
7
16
131
90
39
10
41
6
4
76
15
11
6
DETAIL A
76 Ref
75
81
64
63
62
14
45
44
13
17
50
51
42(Ref)
49
52
8(Ref)
102
82
101
117
103
122
40
43
27
48
1
12
57
18
19
21
55
56
2
62
47
61
108
20
59
105
106
107
104
42
4
86
46
2526
16 308864
Bottom View
87
8739A
88
109
108(Ref)
47(Ref)
60
58
8742B
Parts -- Basic Sprayer
A
Y
X
Ref.
No. Part No. Description Qty.
1 183401 KEY, parallel 1
2 193548 PULLEY 1
3 241306 CLUTCH HOUSING ASSY 1
4 241113 ROTOR, clutch, 5 in. 1
5 100644 CAPSCREW, sckt hd,, 1/4--20 x 3/4 in. 4
6 105510 LOCKWASHER, spring, 1/4 in. 1 1
7 241440 GEAR, combination 1
8 241112 PINION ASSEMBL Y; Parts, page 18 1
9 101864 CAPSCREW, socket head, 4
1/4--20 x 3/4 in.
10 104008 WASHER, lock, spring 4
11Y 194125 LABEL, danger 1
12 24101 1 DRIVE HOUSING 1
13 241308 COVER, HOUSING, DRIVE 1
14 241012 CONNECTING ROD KIT 1
15 1 14672 WASHER, thrust 2
16 1 14673 WASHER 1
17 241015 BEARING HOUSING 1
18 183169 SPRING, retaining 1
19 183210 PIN, straight, 3/8 x1/8 in. 1
20 193031 NUT, retaining 1
21 240291 PUMP, displacement;1
Parts, Manual 308798
25 1 14425 BUSHING, strain relief 1
26 1 14794 CORD, power, convertible 1
27 1 12395 SCREW, 3/8--16 x 3/4 in. 3
39 101682 SCREW, cap, sch 4
40 237686 GROUNDING CLAMP & WIRE 1
41 1 14686 SCREW, cap, sch 2
42 PRESSURE CONTROL 1
Parts, page 19
43 1 12798 SCREW, thread forming 1
44 1 14666 CAPSCREW, socket head, 4
45 1061 15 LOCKWASHER, spring, 3/8 in. 4
46 155699 ELBOW, street 1
47 222516 FLUID HOSE, 3/8 in. ID, 3/8 npt 1
couplings, 2.5 ft long, spring guards 1
48 193682 CAP, end; 2
49 154636 WASHER, 5/8 in. 2
50 101242 RING, retaining 2
51 10481 1 HUBCAP 2
52 17981 1 WHEEL, semi--pneumatic 2
56 1 14818 SCREW, self--tap 4
57 1 12746 LOCKNUT, 5/16--18 2
58 240131 PLUG, packless 1
59 192719 HANGER, pail 1
60 164672 ADAPTER 2
61 162485 NIPPLE, 3/8--18 npsm(m) x 1/4 npt(m) 1
62 240712 FRAME, cart 1
63 1 10243 RING, retaining 2
64 183350 WASHER 2
65 241003 GUARD, back 1
68 193547 BELT, 4V 1
71 1 11801 SCREW, cap, flng hd 4
72 1 14827 SPACER, hex 2
74 194099 GUARD, belt front 1
75 191084 SLEEVE, cart 2
76 239998 CART HANDLE 1
79 1 14810 EXTRUSION, trim 2
81 1 12827 BUTTON, snap 2
82 1 14809 BUSHING, strain relief 1
83 108795 SCREW, cap, sch 4
86 1 10838 LOCKNUT, w/nylon insert, 5/16--18 4
87 1 14391 SCREW, grounding 1
88 1 14687 CLIP, retainer 1
90 1 14806 EXTRUSION, gasket 1
Ref.
No. Part No. Description Qty.
101 241935 LATCH, adjustable 1
102 110885 SCREW, mach, pnhd, thrd forming 2
103 108947 NUT, square 2
104 187147 STRAINER 1
105 241718 .DEFLECTOR 1
106 194194 CLIP, spring 1
107 193097 TUBE, intake 1
108 194178 HOSE, coupled 1
109 110249 ADAPTER, male elbow, 90_ 1
1 11 206994 THROAT SEAL LIQUID, 1
117 114271 STRAP, retaining 1
122 114984 SCREW, tapping, pnhd, #10 x 1/2 in. 2
131 290228 LABEL, caution 1
132 ENGINE ASSY See Engine Detail 1
A 183401 KEY, parallel 1
B 193548 PULLEY 1
C 110996 NUT, flng hd, hex 8
D 114653 SCREW, cap, flng hd 4
E 112406 CAPSCREW, hex hd 2
F 194198 GUARD, lower engine 1
G 194087 HANDLE, slide 1
H 114530 ENGINE, 5.5 HP 1
JY 194126 LABEL, warning 1
K 114805 JACK, 1/4, motor 1
L 194181 BOX, junction, engine 1
M 114816 NUT, hex 1
N 114813 SCREW, mach, hex washer hd 1
P 109099 BUSHING, snap 1
R 112586 SCREW, cap, hex hd, flanged 2
S 241313 PLATE, mount motor 1
T 194130 BRACKET, clamp 1
U 114959 BUSHING, 3/4 in. (3 bolts, 3 washers) 2
V 194414 BRACKET, J-box 1
W 194925 BRACKET, tension 1
X 192014 PLATE, indicator 1
Y 113084 RIVET, blind (not shown) 2
Z 111800 SCREW, cap, flanged hd 2
8 oz (0.27 liter) (not shown)
Engine Detail
K
M
N
G
W
C
Y Replacement Danger and Warning labels, tags and
cards are available at no cost.
L
H
V
J
P
E
F
A
U
D
R
B
Z
C
T
S
8743
17308864
Parts List & Drawing -- Pinion Assembly
Ref No. 8 and 12
Ref No. 8: Pinion Housing Assembly 241112 Ref No. 12: Drive Housing Assembly 241011
Ref
No. Part No. Description Qty
8 PINION HOUSING 1
8b 105489 PIN 2
8d* 193358 PINION SHAFT 1
8e* 112770 RETAINING RING, large 1
*Must be ordered separately
8d
8e
8b
9 (Ref.)
10 (Ref.)
8
12h
Ref
No. Part No. Description Qty
12 HOUSING, drive 1
12g* 194173 WASHER 1
12h* 194172 WASHER 1
*Must be ordered separately
12g
15 (Ref)
12
10 (Ref.)
9 (Ref.)
7(Ref.)
16 (Ref)
TI0177B
18 308864
Parts Drawing -- Sprayer
Ref No. 42
Pressure Control Assembly
309
308
320
314
313
310
312
301
305
304
306
302
303
315
307
318f
304
318a
319
318d
318b
318c
318z
323
307
322
305
31 1
310
318aa
318a
318g
318h
318m
318n
318l
318j
318k
8716A
19308864
Parts List -- Sprayer
Models 232624
REF
NO. PART NO. DESCRIPTION QTY
301 193653 PLATE, control 1
302 241093 BOARD, PC 1
303 111839 SCREW, mch pan, 6--32 x 1/2 in. 5
304 240776 HARNESS, wiring. 1
305 193497 GASKET, control 2
306 193652 HOUSING, control box 1
307 114631 SCREW, mch, pan hd 10
308 193052 PLATE, instruction 1
309 114277 SWITCH, rocker, (spst) 1
310 241443 POTENTIOMETER, pressure control 1
31 1 193657 GASKET, potentiometer 1
312 193654 PLATE, instruction 1
313 114273 KNOB, potentiometer 1
314 193072 LABEL, control 1
315 114629 GROMMET, transducer 1
318 FILTER, fluid 1
318a 193651 HOUSING, filter 1
318b 104361 O-RING 1
318c 186075 SUPPORT, filter 1
318d 167025 STRAINER, mesh, 60 1
318e 171941 SPRING, compression 1
REF
NO. PART NO. DESCRIPTION QTY
318f 192706 BOWL, filter 1
318g 193710* SEAL, valve 1
318h 193709* SEAT, valve 1
318j 194102* HANDLE, valve 1
318k 114688* NUT, cap, hex hd 1
318l 1 14708* SPRING, compression 1
318m 114797* GASKET 1
318n 245103* VALVE 1
318z 240314 TRANSDUCER, pressure control 1
318aa 111457 O-RING 1
319 110997 SCREW, flange, hex 3
320 114532 TIE, wire, twist 1
Y 189246 LABEL, warning 1
321
322 241444 COVER, pressure control 1
323 193684 LABEL, identification 1
* Drain valve replacement kit 245103 available; includes
318g through 318n
Y Replacement warning labels may be ordered free of charge
includes 318aa
309
(Ref)
304
(Ref)
Pressure Control Wiring Diagram
Green
Black
D
Red
Potentiometer
E
Red
A
318z
(Ref)
Violet
302
(Ref)
310
(Ref)
Pressure
transducer
318aa
(Ref)
Fig. 18
20 308864
8714A
Parts List & Drawing --Clutch Assembly
Ref No. 3
Clutch Housing Assembly 241306
Includes 3b, 3c, 3e, 3j and 3k
Ref
No. Part No. Description Qty
Ref
No. Part No. Description Qty
3a* 108803 SCREW, hex, sch 4
3b 114962 RING, retaining, internal 1
3c 241305 SHAFT, drive, input 1
includes 3b,3j, and 3k
3d* 193510 HUB, armature 1
3e 193493 HOUSING, clutch 1
3f 194059 STOP, armature 1
3b
3c
3e
3g* 193681 ARMATURE, clutch 1
3h* 105510 WASHER, lock, spring 8
3j 115078 O-RING 1
3k 115079 O-RING 1
* Clutch replacement kit 241113 includes 3a, 3d, 3g, 3h, 4, 6,
39
3j
3k
3f
3g*
3d*
39*(Ref)
6*(Ref)
4*(Ref)
Parts -- Complete Sprayer
Model 232625
Includes items 125 to 128
Ref.
No. Part No. Description Qty.
125 232624 CONVERTIBLE GMax 5900C Sprayer
See parts list on page 16 1
126 240794 HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(fbe); 50 ft (15 m);’
spring guards both ends 1
127 238358 HOSE, grounded, nylon; 3/16” ID;
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;
3 ft (0.9 m); spring guards both ends 1
128 220955 “CONTRACTOR” SPRAY GUN
Includes RAC 5
and 517 --size SwitchTip
See 309091 for parts 1
t DripLesst Tip Guard
t
3a*3h*
8745A
126
128
127
0160
21308864
Parts -- Lo-Boy Suction Set Kit
A
Model 241287
Includes items 401 to 407
Ref.
No. Part No. Description Qty.
401 241124 .TUBE, suction, 5 gallon (20 liter) 1
includes 401a through 401e
401a 240513 ..SWIVEL, tube, inlet 1
401b 176450 ..GUARD, hose 1
401c 194306 ..HOSE, fluid 1
401d 101818 ..CLAMP, hose 2
401e 170957 ..TUBE, suction 1
402 194180 .HOSE, drain 1
403 194194 .CLIP, spring 1
404 162453 .NIPPLE 1
405 187147 .STRAINER 1
406 241718 .DEFLECTOR 1
407 144958 .STRAP, tie 1
404
402
401a
401
402(REF)
406
405
401e
401d
403
407
401b
401c
8744
22 308864
Technical Data
Graco Phone
Honda GX160 Engine
Power Rating @ 3700 rpm
ANSI 5.5 Horsepower.......................
DIN 6270B/DIN 6271
NA 2.9 Kw -- 4.0 Ps......................
NB 3.6 Kw -- 4.9 Ps......................
Maximum Working Pressure 3300 psi..............
(227 bar, 22.7 MPa)
Cycles/Gallon (liter) 93 (25)........................
Maximum Delivery 1.25 gpm (4.7 liter/min)..........
Fuel Tank Capacity 0.95 gallons (3.6 liter)...........
Maximum Tip Size 1 gun with 0.041 tip..............
2 guns with 0.028 tip
Inlet Paint Strainer 16 mesh (1190 micron)...........
Stainless steel screen, reusable
Outlet Paint Filter 60 mesh (250 micron).............
Stainless steel screen, reusable
Pump inlet Size 3/4 npt (m).......................
Fluid Outlet Size 1/4 npsm from fluid filter...........
Wetted parts zinc-plated carbon steel,..............
r, Nylon, polyurethane, UHMW polyethylene,
Tef lo n
Viton
r,Delrinr, leather, aluminum, tungsten car-
bide,nickle-plated carbon steel, stainless steel,
chrome plating
NOTE: Delrinr,Teflonr,Vitonr are trademarks of the DuPont
Company.
Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify distributor closest to
you: 1--800--690--2894 Toll Free
DANGER LABELS
The English language DANGER label is on your
sprayer. If you have painters who do not read English, order one of the following labels to apply to
your sprayer. The drawing below shows the best
placement of these labels for good visibility.
Order the labels directly from your Graco distributor.
Apply other
language here
French 194931
Spanish 194932
German 194933
Greek 194934
Korean 194935
English 194125
03497A
Dimensions
Model 232624
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)............................
23308864
Graco Warranty
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on date of sale by an authorized Graco distributor to original purchaser for use. With exception of any
special extended or limited warranty published by Graco, Graco will, for a period of twelve months from date of sale, repair or replace
any part of equipment determined by Graco to be defective. This warranty applies only when equipment is installed, operated and
maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or improper design, manufacture,
installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon prepaid return of equipment claimed to be defective to an authorized Graco distributor for
verification of claimed defect. If claimed defectis verified, Graco willrepair orreplace free ofcharge any defective parts. equipmentwill
be returned to original purchaser transportation prepaid. If inspection of equipment does not disclose any defect in material or
workmanship, repairs will be made at a reasonable charge, which charges may include costs of parts, labor, and transportation.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lostsales, injury toperson or property, orany
otherincidental or consequential loss) shallbe available. Any actionfor breach of warranty must bebrought within two (2) years ofdate
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, gas engines,
switches, hose, etc.),are subject to warranty, if any,of theirmanufacturer. Graco will provide purchaserwith 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 furnishing, performance, or use of any products or othergoods sold hereto, whether due to a breach of contract, breach
of warranty, negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in “Graco Contractor Equipment Warranty
Program”.
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.
International Offices: Belgium, Korea, Hong Kong, Japan
Sales Offices: Minneapolis, Detroit
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441
http://www.graco.com
PRINTED IN USA 308864 February 1999, 08/2009
24 308864
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