INSTRUCTIONS-REPAIR
308870
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
GMaxr 7900
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 7900
Model Series Description
232630 B Hi-Boy
232631 B Hi-Boy with RAC 5 tip, gun and hose
232632 B Lo-Boy
232633 B Lo-Boy with RAC 5 tip, gun and hose
233008 A Hi-Boy with Gauge Kit
All models are not available in all countries
P ATENTS PENDING
Rev. F
First choice when
quality counts.t
Related Manuals
Operation 308867. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 309091. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 309055. . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board 308919. . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 308961. . . . . . . . . . . . . . . . . . . . . .
Table of Contents
Warnings and Cautions 2. . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 3. . . . . . . . . . . .
Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Rollers 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower Bearings 8. . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly/Rotor/Field/Shaft/Clutch 9. . . . . . . .
Clamp 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9035B
Pressure Control 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 15. . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Pinion Assembly 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hi-Boy Sprayers 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lo-Boy Sprayers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayers 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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.
3088702
Component Identification and Function
202Main hose
203Whip end hose
204Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip
K
A
M
X
Fig. 1
V
P
B
U
L
N
C
D
J
H
E
G
R
F
S
W
T
203
Model 232631
202
204
9034B
A Pressure Control Switch ON/OFF, enables/disables clutch function and pressure control
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering the carburetor
D Fuel Tank* Uses 86 octane unleaded 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* 4–cycle 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 Pail Hanger Provides a hanger for paint pail
X Drain Valve Relieves fluid pressure when open
* For more detailed explanations of these controls, refer to the Honda Engines Owner’s Manual; supplied
308870 3
Maintenance
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
D are instructed to relieve the pressure,
D stop spraying,
D check or service any of the system equipment,
D or install or clean the spray tip.
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
CAUTION
For detailed engine maintenance and specifications,
refer to separate Honda Engines Owner’s Manual,
supplied.
DAILY: Check engine oil level and fill as necessary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
DAILY: Check and fill the gas tank.
AFTER THE FIRST 20 HOURS OF OPERATION:
Drain engine oil and refill with clean oil. Reference
Honda Engines Owner’s Manual for correct oil viscos-
ity.
WEEKLY: Remove air filter cover and clean element.
Replace element, if necessary. If operating in an
unusually dusty environment: check filter daily and
replace, if necessary.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY
loosen tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose.
Replacement elements can be purchased from your
local HONDA dealer.
WEEKLY: Check level of TSL in displacement pump
packing nut. Fill nut, if necessary. Keep TSL in nut to
help prevent fluid buildup on piston rod and premature
wear of packings.
AFTER EACH 100 HOURS OF OPERATION:
Change engine oil. Reference Honda Engines Owner’s
Manual for correct oil viscosity.
SPARK PLUG: Use only BPR6ES (NGK) or
W20EPR–U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug
wrench when installing and removing plug.
3088704
Troubleshooting
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.
PROBLEM CAUSE SOLUTION
Engine won’t start
Engine operates, but displacement pump does not
operate
Engine switch is OFF Turn engine switch ON
Engine is out of gas Refill gas tank. Honda Engines Owner’s Manu-
Engine oil level is low Try to start engine. Replenish oil, if necessary.
Spark plug cable is disconnected or damaged Connect spark plug cable or replace spark
Cold engine Use choke
Fuel shutoff lever is OFF Move lever to ON position
Oil is seeping into combustion chamber Remove spark plug. Pull starter rope 3 or 4
Pressure control switch is OFF Turn pressure control switch ON.
Pressure setting is too low Turn pressure adjusting knob clockwise to
Fluid filter (318) is dirty Clean filter. Page 22.
Tip or tip filter is clogged Clean tip or tip filter. Manual 309091.
Displacement pump piston rod is stuck due to
dried paint
al.
Honda Engines Owner’s Manual.
plug
times. Clean or replace spark plug. Try to start
engine. Keep sprayer upright to avoid oil seepage.
increase pressure.
Repair pump. Manual 308798.
Roller bearings are worn or damaged Replace connecting rod. Page 7.
Drive housing is worn or damaged Replace drive housing. Page 7.
Electrical power is not energizing clutch field Check wiring connections. Page 11.
Reference control board diagnostics. Page 14.
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, the resistance must be between 1.7
not, replace clutch coil 241121.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn or damaged Replace clutch. Page 9.
Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 9.
±0.2Ω; if
308870 5
PROBLEM CAUSE SOLUTION
Pump output is low
Excessive paint leakage into
throat packing nut
Strainer (31) is clogged Clean strainer
Piston ball (25) is not seating Service piston ball. Manual 308798.
Piston packings are worn or damaged Replace packings. Manual 308798.
O-ring (227) in displacement pump is worn or
damaged
Intake valve ball is not seating properly Clean intake valve. manual 308798.
Engine speed is too low Increase throttle setting. Manual 308867.
Clutch is worn or damaged Replace clutch. Page 9.
Pressure setting is too low Increase pressure. Manual 308867.
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
Throat packings are worn or damaged Replace packings. Manual 308798.
Replace o-ring. Manual 308798.
Clean filter. Manual 308867 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.
Fluid is spitting from gun
Pump is difficult to prime
Clutch squeaks each time
clutch engages
Displacement rod is worn or damaged Replace rod. Manual 308798.
Air in pump or hose Check and tighten all fluid connections.
Tip is partially clogged Clear tip. Manual 309091.
Fluid supply is low or empty Refill fluid supply. Prime pump. Manual
Air in pump or hose Check and tighten all fluid connections.
Intake valve is leaking Clean intake valve. Be sure ball seat is not
Pump packings are worn Replace pump packings. Manual 308798.
Paint is too thick Thin the paint according to the supplier’s
Engine speed is too high Decrease throttle setting before priming pump.
Clutch surfaces are not matched to each other
when new and may cause noise
Reprime pump. Manual 308867.
308867. Check fluid supply often to prevent
running pump dry.
Reduce engine speed and cycle pump as
slowly as possible during priming.
nicked or worn and that ball seats well. Reassemble valve.
recommendations
Manual 308867.
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time
Engine stalls
3088706
Engine speed is to slow D Increase throttle setting
D Adjust engine speed at no load to 3750 –
3850 rpm
Fluid filter is clogged Relieve pressure and clean filter
Too much pump friction (new pump) Reduce pressure to 3000 psi until pump wears
in
Spark plug wire is loose Reconnect wire
Rollers
Removal
1.
2. Fig. 2. Remove six cap screws (10) lock washers
(9) and cover assembly (24).
Note: A screw driver may be needed to pry off
cover assembly.
3. Remove dowel pins (97) and rollers (98)
Installation
1. Install rollers (98) and dowel pins (97)
2. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
Relieve pressure; page 4.
Drive Housing
Removal
1.
2. Fig. 2. Remove six cap screws (10) lock washers
(9) and cover assembly (24).
Relieve pressure; page 4.
20
98
97
9
9
99
24
Fig. 2
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (18),
washers (82) and (83) and to areas called out by
note 1. Use full 0.68 pint (0.32 liter) of grease for
GMax 7900.
9033A
10
3. Fig. 3. Remove two screws (99) and washers (9).
4. Remove four cap screws (10) lock washers (9)
from drive housing (20).
5. Lightly tap around drive housing (20) to loosen
drive housing. Pull drive housing straight off pinion
housing. Be prepared to support gear cluster (18),
which may also come out.
10
9
1
20h
20g
18
B
82
83
20
9
2. Place bronze colored washer (83) and silver
colored washer (82) onto drive housing (20). Install
gear cluster (18) through washers (83) and (82).
3. Place bronze colored washer (20g) and silver
colored washer (20h) on shaft protruding from
large shaft of drive housing (20). Align gears and
push new drive housing straight onto pinion housing and locating pins (B).
4. Install two washers (9) and screws (99).
5. Install four lock washers (9) and cap screws (10)
into drive housing (20).
6. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
99
1
Apply remaining grease to these areas
Fig. 3
9032A
308870 7
Cam Follower Bearings
Removal
1.
2. Fig. 16. Cycle pump piston rod (222) to lowest
position. Turn engine off.
3. Fig. 4. Remove six cap screws (10), lock washers
(9) and cover assembly (24).
Note: A screw driver may be needed to pry off
cover assembly.
4. Remove four dowel pins (97) and rollers (98).
5. From front, drive out pump pin (101) with a screw
driver.
6. Remove two retainer rings (20d).
7. Remove cam follower plate (20b).
Note: Two 1/2 in. x 13 bolts may be
needed to remove cam follower plates.
8. Remove two cam follower bearings (20c).
Relieve pressure; page 4.
Installation
1. Install two cam follower bearings (20c).
2. Install cam follower plate (20b).
3. Install two retainer rings (20d).
4. Drive in pump pin (101) until it engages with pump
pin retaining clip (20a).
5. Install four rollers (98) and dowel
pins (97).
6. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
20c
20
98
97
9
10
20a
20b
20d
101
9047A
Fig. 4
24
3088708
Pinion Assembly/Rotor/Field/Shaft/Clutch
Removal
If pinion assembly (19) is not removed from clutch
housing (5), do 1. through 4. Otherwise, start at 5.
6. Fig. 8. Remove retaining ring (19e).
7. Tap pinion shaft (19d) out with plastic mallet.
1.
Relieve pressure; page 4.
2. Disconnect field cable (X) from pressure control
and engine lead.
X
Bottom View
Fig. 5
9027A
3. Fig. 6. Remove five screws (26) and lockwashers
(17) and pinion assembly (19).
26
17
19
19e
19d
Fig. 8
9031A
8. Fig.9. Use an impact wrench or wedge something
between armature (4a) and clutch housing to hold
engine shaft during removal.
9. Remove four screws (16) and lockwashers (17).
10. Remove armature (4a).
4a
17
16
26
Fig. 6
17
9029A
4. Fig. 7. Place pinion assembly (19) on bench with
rotor side up.
5. Remove four screws (72) and lockwashers (17).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
72
17
E
Fig. 7
9030A
Fig. 9
9028A
308870 9
Pinion Assembly/Rotor/Field/Shaft/Clutch
Installation
1. Fig. 10. Lay two stacks of two dimes on smooth
bench surface.
2. Lay armature (4a) on two stacks of dimes.
6. Fig. 8. Tap pinion shaft (19d) in with plastic mallet.
7. Install retaining ring (19e) with beveled side facing
field (Y).
3. Press center of clutch down on bench surface.
4a
Fig. 10
0.12 ±.01 in. (3.0 ±.25 mm)
8705A
4. Install armature (4a) on engine drive shaft.
5. Install four screws (16) and lockwashers (17) with
torque of 125 in-lb.
Clamp
Removal
1. Fig. 11. Loosen two screws (16) on clamp (8),
2. Push screwdriver into slot in clamp (8) and remove
clamp.
Installation
8. Fig. 7. Place pinion assembly on bench with rotor
side up.
9. Apply locktite to screws. Install four screws (16)
and lockwashers (17). Alternately torque screws
to 125 in-lb until rotor is secure. Use threaded
holes to hold rotor.
10. Fig. 6. Install pinion assembly (19) with five screws
(10) and lockwashers (9).
11. Fig. 5. Connect field cable (X) to pressure control
and engine lead.
1
Face of clutch housing
2
1.812 ±.010 in. (46.02 ±.25 mm)
3
Torque to 125 ±.10 in-lb (14 ±1.1 Nm)
4
Chamfer this side
1
5
1. Fig. 11. Install engine shaft key (7).
2. Tap clamp (8) on engine shaft (A) with plastic
mallet.
3. Press clamp (8) onto engine shaft (A). Maintain
dimension shown note 2 in Fig. 11. Chamfer side
must face engine.
Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (5). Use accurate
measuring device to measure distance between
bar and face of clamp. Adjust clamp as necessary.
Torque two screws (16) to 125 ±10 in-lb (14 ±1.1
Nm).
7
Fig. 11
2
8
16
4
3
03483
B
A
30887010
Clutch Housing
Removal
1. Fig. 12. Remove four capscrews (75) and lockwashers (77) which hold clutch housing (5) to
engine.
2. Remove screw (15) from under mounting plate (D).
3. Remove engine key (7).
4. Pull off clutch housing (5).
Installation
1. Fig. 12. Push on clutch housing (5).
2. Install four capscrews (75) and lockwashers (77)
and secure clutch housing (5) to engine. Torque to
200 in-lb (22.6 NSm).
3. Install capscrew (15) from beneath mounting
plate (D). Torque to 26 ft-lb (35.2 NSm).
Engine
Fig. 12
7
D
15
5
77
75
9025A
Removal
1. Remove Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing, as in-
structed on pages 7, 9 and 10.
2. Fig. 13. Disconnect all necessary wiring.
3. Fig. 14. Remove two locknuts (71) and screws
(70) from base of engine.
4. Lift engine carefully and place on work bench.
NOTE: All service to the engine must be performed by
an authorized HONDA dealer.
71
87
Green
1
70
71
Fig. 14
Installation
1. Lift engine carefully and place on cart.
9026A
Fig. 13
2
1
To the field
2
2
To the engine
9027A
2. Fig. 14. Install two screws (70) in base of engine
and secure with locknuts (71). Torque to 200 in-lb
(22.6 NSm).
3. Fig. 13. Connect all necessary wiring.
4. Install Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing, as
instructed on pages 7, 9 and 10.
308870 11
On/Off Switch
Removal
1.
2. Fig. 15. Remove five screws (307) and
cover (322).
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 switch.
307
303
Relieve pressure; page 4.
1
A309
302
Installation
1. Install new ON/OFF switch (309) so tabs of switch
snap into place on inside of pressure control
housing.
2. Connect two wires (A) to ON/OFF switch.
3. Install pressure control cover (322) with five
screws (307).
313
310
315 319
318a
322
Fig. 15
D
E
1
Locate switch terminals as shown
318z
318aa
8711A
30887012
Pressure Control
Control Board
Removal
1.
2. Fig. 15. Remove five screws (307) and
cover (322).
3. Fig. 22. Disconnect at control board (302):
D Four clutch leads: two violet and two black.
D Lead (D) from potentiometer.
D Lead (E) from transducer.
D Two red leads (A) to ON/OFF switch (309).
4. Fig. 15. Remove five screws (303), green ground
wire and control board (302).
Relieve pressure; page 4.
Pressure Control Transducer
Removal
1.
2. Fig. 15. 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).
Relieve pressure; page 4.
Installation
When installing replacement control board, follow
instructions with control board to set model type.
1. Fig. 15. Install green ground wire and control
board (302) with five screws (303).
2. Fig. 22. 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. Fig. 15. Install cover (322) with five screws (307).
5. Remove pressure control transducer (318z) and
packing o-ring (318aa) from filter housing (318a).
Installation
1. Fig. 15. 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 motor control board (302).
4. Install cover (322) with five screws (307).
Pressure Adjust Potentiometer
Removal
1.
2. Fig. 15. 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.
Installation
1. Install seal (311) on potentiometer (310).
2. Fig. 15. 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).
308870 13
Pressure Control
Control Board Diagnostics
1. Fig. 15. 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.
30887014
Removal
Displacement Pump
1. Flush pump.
2. Fig. 16. Cycle pump with piston rod (222) in lowest
position.
3.
4. Fig. 16. Remove suction tube (30) and hose (33).
33
Fig. 16
Relieve pressure; page 4.
222
9024C
30
9024B
Repair
5. Fig. 17. Use screwdriver to push out pump
pin (101).
20a
101
Detail A
Fig. 17
6. Fig. 18. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 18
9019B
9022A
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 (101) and retaining
clip (20a) are properly installed. See Detail A. Fig.
17.
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure locknut is properly tightened.
1. Fig. 19. Pull piston rod out 1.0 in. Screw in pump
until holes in housing plates and piston rod align.
2. Fig. 17. See Detail A. Push pin (101) into hole
until retaining clip (20a) snaps over pin.
Fig. 20. Screw jam nut down onto pump until nut
stops. Screw pump up into pump plate until it stops.
Back off pump one full turn and 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
±5 ft–lb (102 Nm).
Fig. 20
Fig. 21. Fill packing nut with Graco TSL until fluid flows
onto the top of seal.
9021A
Fig. 19
1.0 in.
9020A
Fig. 21
9023A
308870 15
Pump Pin Clip
Displacement Pump
Removal
1. Remove pump (28).
2. Remove two bolts (86), washers (25), pump bracket (85), pail hook (94) and shield (95).
3. Fig. 17. Remove clip (230).
Installation
1. Fig. 17. Install clip (230).
2. Install shield (95), pail hook (94) and pump bracket
(85) with two washers (25) and bolts (86). Torque
bolts to 40 ft-lb (54 NSm).
3. Install pump (28).
30887016
Parts List & Drawing – Pinion Assembly
Ref No. 19 and 20
Ref No. 19: Pinion Housing Assembly 241116 Ref No. 20: Drive Housing Assembly 241537
Ref
No. Part No. Description Qty
19a 241 121 PINION HOUSING, COIL 1
19b 105489 PIN 2
19d 241114 PINION SHAFT
19e 112770 RETAINING RING, large
19e
19d
10 (Ref)
9 (Ref)
19a
20h
20g
83 (Ref)
1
Ref
No. Part No. Description Qty
20 DRIVE HOUSING 1
20a 194060 RETAINING CLIP, pump pin 1
20b 193656 CAM FOLLOWER PLATE 1
20c 114691 CAM FOLLOWER BEARING 2
20d 114828 RETAINER CLIP 2
20g 114697 WASHER 1
20h 114698 WASHER 1
101 195523 PIN 1
20
9 (Ref)
99 (Ref)
18 (Ref)
82 (Ref)
20c
20b
20d
101
1
Pinion housing/coil assembly (19a) includes clutch field and all bearings, pins and o-rings
20a
9046A
308870 17
Model 232630
Ref 11
40
45
DETAIL A
37
Parts Drawing – Hi-Boy Sprayer s
Label
1
2
See page 17 for the parts.
3
See manual 308798
for the parts.
4
See page 22 for the parts.
5
See page 22 for the parts.
87
93
78
29
3
2
11
DETAIL A
49
47
38
39
52
Ref 35
56
8699A
10
97
9027A
24
9
10
36
20
Bottom View
2
98
9
99
961
19
2
20h
2
20g
2
72
17
4b
83
18
1
82
103
26
95
17
5
7
8
94
85
101
17
33
16
86
25
4a
43
70
61
71
42
34
77
73
80
17
16
62
28
21
15
35
64
65
30
52
105
44
41
12
71
33(Ref)
4
88
104
62
102
64(Ref)
31
9018D
30887018
Parts List – Hi-Boy Sprayers
Models 232630*
Ref
No. Part No. Description Qty
Ref
No. Part No. Description Qty
1 114530 ENGINE 1
2 113084 RIVET, blind 2
3 192014 PLATE, indicator 1
4 241113 CLUTCH ASSEMBLY,1
includes 4a, 4b, 16, 17, 72, 80
4a .ARMATURE, clutch, 5 in. 1
4b .ROTOR, 5 in. 1
5 193531 CLUTCH HOUSING 1
7 183401 KEY, parallel 1
8 193680 CLAMP 1
9 104008 WASHER, spring, lock 12
10 101864 CAPSCREW, socket head, 10
1/4–20 x 3/4 in.
11 239998 CART HANDLE & HOSE RACK 1
12 193682 CAP, end 2
15 113802 SCREW, flange, hex hd, 1
3/8–16 x 5/8 in.
16 108803 CAPSCREW, sch, 1/4–2 x 1 in. 6
17 105510 LOCKWASHER, spring, 1/4 in. 15
18 241539 GEAR COMBINATION 1
includes 91 and 92
19 241116 PINION ASSEMBLY; Parts, page 17 1
20 241537 DRIVE HOUSING; Parts, page 17 1
21 114967 COUPLING 1
24 241536 COVER, housing, dr5e, kit 1
25 100018 WASHER, lock, spring 1
26 100644 SCREW, cap 5
28 240917 DISPLACEMENT PUMP 1
Parts, manual 308798
29 194438 TUBE, nylon, split 1
30 244823 TUBE, intake 1
includes 21
31 189920 STRAINER 1
33 240795 HOSE, coupled 1
34 193394 NUT, retaining 1
35 241324 CART FRAME 1
36 194068 LABEL, identification 1
37 183350 WASHER, plain 2
38 110243 RING, retaining 2
39 108795 SCREW, mch, pn hd, 10–32 x 5/16 in. 4
40 191084 SLEEVE 2
41 179811 WHEEL, semi–pneumatic 2
42 101242 RING, retaining 2
43 104811 HUBCAP 2
44 154636 WASHER 2
45 112827 BUTTON, snap 2
47 237686 GROUNDING CLAMP & WIRE 1
49 112798 SCREW, hex washer hd, No. 8 x 3/8 in 1
52 114984 SCREW, mch, pn hd; 2
56Y 194126 LABEL, warning 1
61 114678 BUSHING, strain relief 1
62 162485 NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3
64 194178 HOSE, drain 1
65 241718 DEFLECTOR 1
70 110837 SCREW, flng, hex hd, 2
71 110838 LOCKNUT, heavy hex, 5/16–18 6
72 101682 SCREW, cap, sch 4
73 108842 SCREW, cap, sch 4
77 100214 WASHER, lock, spring 4
78 114687 CLIP, retainer 1
80 HUB, armature 1
82 114699 WASHER, thrust 1
83 114672 WASHER, thrust 1
85 194118 BRACKET, pump 1
86 110343 SCREW, cap, sch 2
87 240997 CONDUCTOR, ground 1
88 110249 ADAPTER, male elbow, 90_ 1
93 108851 WASHER 2
94 241540 PAIL HOOK Repair Kit; includes 95 1
95 195377 GROMMET, pump 1
96 206994 THROAT SEAL LIQUID; not shown 1
97 114695 DOWEL PIN 4
98 241322 ROLLER assembly 4
99 114693 SCREW, cap, sch 2
101 195523 PIN 1
102 240987 PLUG, packless, 3/8 in. 1
103Y 194317 LABEL, warning 1
104Y 195119 LABEL, warning; not shown 1
105 194194 CLIP, spring. 1
Y Danger & Warning labels, tags, and cards are free.
* Model 23308 includes Gauge Kit 241339
5/16–18 x 1–1/2 in.
308870 19
Parts Drawing – Lo-Boy Sprayers
Model 232632
Ref 11
40
45
30ae
30ad
30a
11
DETAIL A
49
35
DETAIL A
37
39
51
Ref 35
56
70
1
30c
1
Label
2
See page 17 for the parts.
3
See manual 308798
for the parts.
4 See page 22 for the parts.
72
30b
4b
26
17
5
7
17
30e
8
17
16
4a
10
30f
93
87
5
78
29
9
19
2
20h
2
20g
61
2
83
Bottom V iew
2
20
98
9027A
97
9
10
101
18
82
103
95
94
85
99
9
36
24
25
86
34
43 4142
47
71
15
77
73
80
17
16
30ac
30ab
33
62
28
3
71
52
44
3
2
12
4
104
30d
33 (Ref)
62
102
30aa
9016A
30b (Ref)
30887020
Parts List – Lo-Boy Sprayers
Model 232632
Ref
No. Part No. Description Qty
Ref
No. Part No. Description Qty
1 114530 ENGINE 1
2 113084 RIVET, blind 2
3 192014 PLATE, indicator 1
4 241113 CLUTCH ASSEMBLY,1
includes 4a, 4b, 16, 17, 72, 80
4a .ARMATURE, clutch, 5 in. 1
4b .ROTOR, 5 in. 1
5 193531 CLUTCH HOUSING 1
7 183401 KEY, parallel 1
8 193680 CLAMP 1
9 104008 WASHER, spring, lock 12
10 101864 CAPSCREW, socket head, 10
1/4–20 x 3/4 in.
11 239998 CART HANDLE & HOSE RACK 1
12 193682 CAP, end 2
15 113802 SCREW, flange, hex hd, 1
3/8–16 x 5/8 in.
16 108803 CAPSCREW, sch, 1/4–2 x 1 in. 6
17 105510 LOCKWASHER, spring, 1/4 in. 15
18 241539 GEAR COMBINATION 1
includes 91 and 92
19 241116 PINION ASSEMBLY; Parts, page 17 1
20 241537 DRIVE HOUSING; Parts, page 17 1
24 241536 COVER, housing, drive, kit 1
25 100018 WASHER, lock, spring 1
26 100644 SCREW, cap 5
28 240917 DISPLACEMENT PUMP 1
Parts, manual 308798
29 194438 TUBE, nylon, split 1
30 241288 ASSEMBLY, tube, suction 1
30a 241269 .TUBE, suction, 30 gallon (120 liter) 1
. includes 30aa through 30ae
30aa 198119 ..SWIVEL, tube, inlet 1
30ab 176450 ..GUARD, hose 1
30ac 194307 ..HOSE, fluid 1
30ad 101818 ..CLAMP, hose 2
30ae 192633 ..TUBE, suction 1
30b 194180 .HOSE, drain 1
30c 194194 .CLIP, spring 1
30d 162453 .NIPPLE 1
30e 241718 .DEFLECTOR 1
30f 112604 .STRAINER 1
33 240795 HOSE, coupled 1
34 193394 NUT, retaining 1
35 241324 CART FRAME 1
36 194068 LABEL, identification 1
37 183350 WASHER, plain 2
38 110243 RING, retaining 2
39 108795 SCREW, mch, pn hd, 10–32 x 5/16 in. 4
40 191084 SLEEVE 1
41 179811 WHEEL, semi–pneumatic 1
42 101242 RING, retaining 2
43 104811 HUBCAP 2
44 154636 WASHER 2
45 112827 BUTTON, snap 2
47 237686 GROUNDING CLAMP & WIRE 1
49 112798 SCREW, hex washer hd, No. 8 x 3/8 in 1
52 114984 SCREW, mch, pn hd; 2
56Y 194126 LABEL, warning 1
61 114678 BUSHING, strain relief 1
62 162485 NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3
64 194178 HOSE, drain 1
65 241718 DEFLECTOR 1
70 110837 SCREW, flng, hex hd, 2
71 110838 LOCKNUT, heavy hex, 5/16–18 6
72 101682 SCREW, cap, sch 4
73 108842 SCREW, cap, sch 4
77 100214 WASHER, lock, spring 4
78 114687 CLIP, retainer 1
80 HUB, armature 1
82 114699 WASHER, thrust 1
83 114672 WASHER, thrust 1
85 194118 BRACKET, pump 1
86 110343 SCREW, cap, sch 2
87 240997 CONDUCTOR, ground 1
88 110249 ADAPTER, male elbow, 90_ 1
93 108851 WASHER 2
94 241540 PAIL HOOK Repair Kit; includes 95 1
95 194681 GROMMET, pump 1
96 206994 THROAT SEAL LIQUID; not shown 1
97 114695 DOWEL PIN 4
98 241322 ROLLER assembly 4
99 114693 SCREW, cap, sch 2
101 195523 PIN 1
102 240987 PLUG, packless, 3/8 in. 1
103Y 194317 LABEL, warning 1
104Y 195119 LABEL, warning 1
Y Danger & Warning labels, tags, and cards are free.
5/16–18 x 1–1/2 in.
308870 21
Parts Drawing – Sprayer
Models 232630 through 232633
309
308
320
314
313
310
312
321
301
305
304
306
302
303
315
307
318f
304
318e
319
318d
318b
318c
318z
323
307
322
305
311
310
318aa
318a
318g
318h
318m
318n
318l
318j
318k
8716A
30887022
Parts List – Sprayer
Models 232630 through 232633
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 114708 SPRING, compression 1
318m 114797 GASKET 1
318n 245103* VALVE 1
318z 240314 TRANSDUCER, pressure control 1
318aa111457 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 includes 318g through
318n
Y Replacement warning labels may be ordered free of charge
includes 318aa
309
(Ref)
304
(Ref)
Fig. 22
Green
Black
Red
Red (+)
Violet
Wiring Diagram
310
D
E
A
318z
(Ref)
302
(Ref)
(Ref)
Potentiometer
Pressure
transducer
318aa
(Ref)
9279
308870 23
Parts List & Drawing – Complete Sprayers
Models 232631, 232633
Includes items 201 to 204
Ref
No. Part No. Description Qty
201 232631 Hi-Boy Sprayer 1
See parts list on page 18
232633 Lo-Boy Sprayer 1
See parts list on page 21
202 240797 HOSE, grounded, nylon; 3/8 in. ID; 1
cpld 3/8 npsm(fbe); 50 foot (15 m);
spring guards both ends
3300 psi (227 bar, 27.7 MPa)
203 238358 HOSE, grounded, nylon; 3/16 in. ID;
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;
3 foot (0.9 m); spring guards both ends 1
204 220955 CONTRACTOR SPRAY GUN
Includes RAC 5
and 517–size SwitchTip
See 309091 for parts 1
t DripLesst Tip Guard
t
Accessories
DANGER LABELS
An 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 shows the best placement of these labels for good visibility.
Order the labels from your Graco distributor.
204
203
202
0160
Displacement Pump Repair Kit
Packing repair kit.
GMax 7900 240916
French 194931
Spanish 194932
German 194933
Greek 194934
Korean 194935
English 194317
Apply other
language here
9036A
30887024
Technical Data
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)
Noise Level
Sound power 105 dBa. . . . . . . . . . . . . . . . . . . . . . . . .
per ISO 3744
Sound pressure 96 dBa. . . . . . . . . . . . . . . . . . . . . . . .
measured at 3.1 feet (1 m)
Cycles/gallon (liter) 69 (18). . . . . . . . . . . . . . . . . . . . . . . .
Dimensions
Model 232630, 233008
Hi-Boy without hose or gun
Weight (dry, without packaging) 175 lb (79.4 kg). . . . .
Height 41 in. (104.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 38 in. (96.5 cm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum delivery rating 2.1 gpm (7.9 liter/min). . . . . .
Maximum tip size 1 gun with 0. 046 in. tip. . . . . . . . . .
2 guns with 0.033 in. tip
3 guns with 0. 026 in. tip
4 guns with 0. 022 in. 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 in. npt (m). . . . . . . . . . . . . . . . . . . . . .
Fluid outlet size 1/4 npsm from fluid filter. . . . . . . . . . . .
Wetted parts zinc-plated carbon steel,. . . . . . . . . . . . . .
rNylon, polyurethane, UHMW polyethylene,
PTFE,
Vitonr, Delrinr, leather, aluminum, tungsten car-
bide,nickle-plated carbon steel, stainless steel,
chrome plating
NOTE: Delrinr andrVitonr are trademarks of the DuPont
Company.
Model 232632
Lo-Boy Cart without hose or gun
Weight (dry, without packaging) 180 lb (82.1 kg). . . . .
Height 41 in. (104.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 38 in. (96.5 cm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–690–2894 Toll Free
308870 25
Graco 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 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 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 , o r a ny
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 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 procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the 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 308870 March 1999, Revised 3/2001
30887026
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