Graco 232682, 232681, 232629, 232626, 232625 User Manual
...
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
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