INSTRUCTIONS-REPAIR
308868
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
GMaxr 3900, 5900, 5900HD
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 3900
Model Series Description
232610 A Hi-Boy
232611 A Hi-Boy with RACt 5 tip, gun and hose
232612 A Lo-Boy
232613 A Lo-Boy with RAC 5 tip, gun and hose
233005 A Hi-Boy with gauge kit
GMax 5900
Rev. L
First choice when
quality counts.t
Model Series Description
232620 A Hi-Boy
232621 A Hi-Boy with RAC 5 tip, gun and hose
232622 A Lo-Boy
232623 A Lo-Boy with RAC 5 tip, gun and hose
233006 A Hi-Boy with gauge kit
GMax 5900HD
Model Series Description
232627 A Hi-Boy
232628 A Hi-Boy with RAC 5 tip, gun and hose
233007 A Hi-Boy with gauge kit
Model 232621
8695A
All models are not available in all countries
P ATENTS PENDING
Related Manuals
Operation 308867. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 309091. . . . . . . . . . . . . . . . . . . . . . . . .
Texture Spray Gun 308491. . . . . . . . . . . . . . . . . .
Spray Tip 309055. . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board 308919. . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 308961. . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings and Cautions 2. . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 3. . . . . . . . . . . .
Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing & Connecting Rod 7. . . . . . . . . . . . .
Drive Housing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly/Rotor/Field/Shaft/Clutch 9. . . . . . . .
Clamp 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Displacement Pump 15. . . . . . . . . . . . . . . . . . . . . . . . .
Parts
GMax 3900 & GMax 5900 Hi-Boy Sprayers 16. . . . .
Pinion Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GMax 3900 & GMax 5900 Lo-Boy Sprayers 20. . . . .
Pressure Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayers 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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.
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.
3088682
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
N
L
C
D
J
H
E
R
S
W
T
203
G
F
Model 232611
202
204
8696B
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 Pressure Drain Valve Relieves fluid pressure when open
* For more detailed explanations of these controls, refer to the Honda Engines Owner’s Manual; supplied
308868 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.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
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.
Repack connecting rod (22) top needle bearing after
every pump change.
Replacement elements can be purchased from your
local HONDA dealer.
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.
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.
3088684
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.
Check everything in chart before disassembling sprayer.
PROBLEM
Engine won’t start
Engine operates, but displacement pump does not
operate
CAUSE SOLUTION
Engine switch is OFF Turn engine switch ON
Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.
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
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.
Connecting rod is worn or damaged Replace connecting rod. Page 7.
Drive housing is worn or damaged Replace drive housing. Page 8.
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 1.2
(GMax3900); 1.7
replace pinion housing.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly
positioned
Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 9.
Replace clutch. Page 9.
±0.2Ω (GMax 5900); if not,
±0.2Ω
308868 5
PROBLEM CAUSE SOLUTION
Pump output is low
Strainer (31) is clogged Clean strainer. Sprayer 232627 strainer is for
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.
Intake valve ball is packed with material Clean intake valve. Manual 308798. Do not
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
use in paint only.
Replace o-ring. Manual 308798.
leave 232627 sprayer under pressure for more
than 5 minutes when spraying texture and not
actively spraying.
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).
Excessive paint leakage into
throat packing nut
Fluid is spitting from gun
Pump is difficult to prime
Throat packing nut is loose Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings are worn or damaged Replace packings. Manual 308798.
Displacement rod is worn or damaged Replace rod. Manual 308798.
Air in pump or hose Check and tighten all fluid connections.
Reprime pump. Manual 308867.
Tip is partially clogged Clear tip. Manual 309091.
Fluid supply is low or empty Refill fluid supply. Prime pump. Manual
308867. Check fluid supply often to prevent
running pump dry.
Air in pump or hose Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well. Reas-
semble valve.
Pump packings are worn Replace pump packings. Manual 308798.
Paint is too thick Thin the paint according to the supplier’s
recommendations
Engine speed is too high Decrease throttle setting before priming pump.
Manual 308867.
Clutch squeaks each time
clutch engages
High engine speed at no
load
3088686
Clutch surfaces are not matched to each other
when new and may cause noise
Misadjusted throttle setting Reset throttle to 3600–3800 engine rpm at no
Worn engine governor Replace or service engine governor
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
load
Bearing Housing and Connecting Rod
NOTE: The item numbers referenced are for the
Hi-Boy models. The Lo-Boy models may have different
item numbers. Use the Hi-Boy item number and part to
find the corresponding Lo-Boy part and item number.
Removal
1.
2. Fig. 3. Remove screws (14) and front cover (23).
3. For Hi-Boy models; remove spring clip (32) and
drain hose (54). Unscrew suction tube (30) from
pump, hold wrench on pump intake valve (A) to
keep pump from loosening. For Lo-Boy models;
unscrew swivel union (30aa) from pump.
4. Disconnect pump outlet hose (33) from displacement pump outlet nipple (62).
5. Fig. 2. Use screwdriver to push up retaining spring
(26) at top of pump. Push out pin (29).
Relieve pressure; page 4.
2. Assemble connecting rod (22) and bearing housing
(21).
3. Clean mating surfaces of bearing and drive housings.
4. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (20) with
holes in bearing housing (21). Push bearing housing onto drive housing or tap into place with plastic
mallet.
CAUTION
DO NOT use bearing housing screws (13) to align
or seat bearing housing with drive housing. Align
these parts with locating pins (F), to avoid premature bearing wear.
5. Install screws (13) and lockwashers (12) on bearing housing. Torque evenly to note 3 value in Fig. 3.
29
Fig. 2
6. Fig. 3. Loosen retaining nut (34). Unscrew and
remove displacement pump (28).
7. Remove four screws (13) and lockwashers (12)
from bearing housing (21).
8. Pull connecting rod (22) and lightly tap lower rear
of bearing housing (21) with plastic mallet to
loosen from drive housing (20). Pull bearing housing and connecting rod assembly (22) off drive
housing.
9. Inspect crank (B) for excessive wear and replace
parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (C) in
bearing housing (21) with high-quality motor oil.
Liberally pack top roller bearing (E), lower bearing
(D) inside connecting rod assembly (22) with
bearing grease.
26
7675B
6. Refer to Displacement Pump, Installation, page 15.
2
1
C
B
20
F
29
33
1
Oil
2
Pack with bearing grease 114819
3
GMax 3900: Torque to 200 in-lb (22.6 Nm)
GMax 5900: Torque to 25 ft-lb (34 Nm)
Fig. 3
26
62
28
A
54
Model 232610 shown
E
D
22
34
2
21
12, 13
32
30
3
23
14
8697A
308868 7
Drive Housing
Removal
1.
Relieve pressure; page 4.
2. Fig. 4. Remove bearing housing. Do 1. through 8.
of Bearing Housing and Connecting Rod procedure on page 7.
3. Remove two screws (81) and lockwashers (17).
4. Remove four screws (10) and lockwashers (17)
from pinion housing (19).
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.
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (18) and
to areas called out by note 3. Use full 0.62 pint
(0.29 liter) of grease for GMax 3900 and 0.68 pint
(0.32 liter) of grease for GMax 5900.
2. Place bronze colored washer (20g) on shaft protruding from large shaft of drive housing (20).
Note: If replacing a washer with pin holes with a
washer without pin holes, remove guide pins from
housing. Place silver colored washer (20h) on
pinion housing. Align gears and push new drive
housing straight onto pinion housing and locating
pins (B).
3. Install four screws (10) and lockwashers (17) from
pinion housing (19).
4. Install two screws (81) and lockwashers (17).
5. Fig. 3. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod procedure on page 7.
B
1
GMax 3900 only
2
Torque to 125 in-lb – GMax 3900
Torque to 200 in-lb – GMax 5900
3
Apply remaining grease to these areas
Fig. 4
2
10
17
B
19
3
20h
20g
20
17
91
1
91
81
2
18
92
91
TI0178A
3088688
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.
X
Bottom View
Fig. 5
8699A
3. Fig. 6. Remove five screws (10) and lockwashers
(17) and pinion assembly (19).
10
17
19
19e
19d
Fig. 8
8703A
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
10
Fig. 6
17
8700A
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
8701A
Fig. 9
8704A
308868 9
Pinion Assembly/Rotor/Field/Shaft/Clutch
Installation
1. Fig. 10. Lay two stacks of two dimes on smooth
6. Fig. 8. Tap pinion shaft (A) in with plastic mallet.
bench surface.
2. Lay armature (4a) on two stacks of dimes.
7. Install retaining ring (Z) with beveled side facing
field (Y).
3. Press center of clutch down on bench surface.
8. Fig. 7. Place pinion assembly on bench with rotor
4a
0.12 ±.01 in. (3.0 ±.25 mm)
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
Fig. 10
4. Install armature (4a) on engine drive shaft.
8705A
holes to hold rotor.
10. Fig. 6. Install pinion assembly (19) with five screws
(10) and lockwashers (17).
5. Install four screws (16) and lockwashers (17) with
torque of 125 in-lb.
11. Fig. 5. Connect field cable (X) to pressure control.
Clamp
Removal
1. Fig. 11. Loosen two screws (16) on clamp (8),
2. Push screwdriver into slot in clamp (8) and remove
clamp.
Installation
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 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).
1
Face of clutch housing
1.550 ±.010 in. (39.37 ±.25 mm); GMax 3900
2
1.812 ±.010 in. (46.02 ±.25 mm); GMax 5900
3
Torque to 125 ±.10 in-lb (14 ±1.1 Nm)
4
Chamfer this side
1
5
7
B
Fig. 11
A
16
2
8
4
3
03483
30886810
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
5
77
75
D
15
8708A
Removal
1. Remove Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing, as in-
structed on pages 9, 10 and 11.
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
1
3
87
Green
70
71
Fig. 14
Installation
1. Lift engine carefully and place on cart.
8710A
Fig. 13
2. Fig. 14. Install two screws (70) in base of engine
and secure with locknuts (71). Torque to 200 in-lb
(22.6 NSm).
1
2
3
2
8709A
To the field
2
To the engine
3
GMax 5900s only
3. Fig. 13. Connect all necessary wiring.
4. Install Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing, as
instructed on pages 9 and 10 and 11.
308868 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
30886812
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).
308868 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 1.2 ±0.2Ω (GMax 3900);
1.7 ±0.2Ω (GMax 5900) 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.
30886814
Removal
Displacement Pump
1. Flush pump.
2.
3. Fig. 16. Cycle pump with piston rod (222) in its
lowest position.
4. Fig. 16. Remove suction tube (30) and hose (33).
33
Fig. 16
Relieve pressure; page 4.
222
30
7672B
Repair
5. Fig. 17. Use screwdriver: push retaining spring up
and push out pin (29).
29
Fig. 17
6. Fig. 18. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 18
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 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 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
2. Fig. 17. Push pin (29) into hole. And push retaining
spring into groove all the way around connecting
rod.
Fig. 20. Screw jam nut down onto pump until nut
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" 5 ft–lb (102 Nm).
Fig. 20
Fig. 21. Fill packing nut with Graco TSL until fluid flows
onto the top of seal.
7673B
Fig. 19
1.5 in.
7676B
Fig. 21
7677B
308868 15
Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayers
Models 232610, 232620 and 232627
Label
Ref 11
40
45
3
2
DETAIL A
37
38
39
Ref 35
1
2
See page 18 for the parts.
3
See manual 308798
for the parts.
4
See page 22 for the parts.
5
Used on GMax 5900, 5900HD
Used on GMax 3900
6
93 and 94 used on GMax 5900HD
7
Used on GMax 3900, 5900
8
9
72
17
4b
6
19
2
20h
2
20g
2
91
5
61 (Ref)
2
20
87
Bottom V iew
17
81
22
12
78
13
4
8699A
(Ref)
11
DETAIL A
49
35
47
70
61
71
56
6
91
1
10
17
5
18
92
55
68
26
29
7
4a
33
62
54
34
28
3
8
17
16
21
67
23
36
14
32
77
73
80
90
17
30
31
8
16
15
71
43
42
51
33(Ref)
53
41
44
5
50
4
7
93
53
88
89
54(Ref)
94
7
8713B
30886816
Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers
Models 232610, 232620 and 232627*
Ref
No. Part No. Description Qty
1 ENGINE
108879 GMax 3900 1
114530 GMax 5900, 5900HD 1
2 113084 RIVET, blind 2
3 192014 PLATE, indicator 1
4 CLUTCH ASSEMBL Y,
includes 4a, 4b, 16, 17, 80
241109 GMax 3900 1
241113 GMax 5900, 5900HD 1
4a .ARMATURE, clutch, 4 in., 1
GMax 3900
.ARMATURE, clutch, 5 in., 1
GMax 5900, 5900HD
4b .ROTOR
4 in., GMax 3900 1
5 in., GMax 5900, 5900HD 1
5 CLUTCH HOUSING
193540 GMax 3900 1
193531 GMax 5900, 5900HD 1
6 LOCKWASHER, spring, 1/4 in.
105510 GMax 3900 4
104008 GMax 5900, 5900HD 4
7 183401 KEY, parallel 1
8 193680 CLAMP 1
9 CAPSCREW, socket head, 1/4–20 x 3/4 in.
100644 GMax 3900 4
101864 GMax 5900, 5900HD 4
10 100644 CAPSCREW, socket head, 1/4–20 x 3/4 in. 5
11 239998 CART HANDLE & HOSE RACK 1
12 106115 LOCKWASHER, spring, 3/8 in. 4
13 CAPSCREW, socket head,
107210 GMax 3900; 3/8–16 x 1.5 in. 4
114666 GMax 5900, 5900HD; 3/8–16 x 2.25 in. 4
14 114418 SCREW, self–tap, fil hd, 8–32 x 1 in. 4
15 113802 SCREW, flange, hex hd, 3/8–16 x 5/8 in. 1
16 108803 CAPSCREW, sch, 1/4–2 x 1 in. 6
17 LOCKWASHER, spring, 1/4 in.
105510 GMax 3900 17
105510 GMax 5900, 5900HD 11
18 GEAR COMBINATION
241439 GMax 3900 1
241440 GMax 5900, 5900HD 1
19 PINION ASSEMBLY; Parts, page 18
241108 GMax 3900 1
241112 GMax 5900, 5900HD 1
20 DRIVE HOUSING; Parts, page 18
241007 GMax 3900 1
241011 GMax 5900, 5900HD 1
21 BEARING HOUSING; includes 67 and 68
240523 GMax 3900 1
241015 GMax 5900, 5900HD 1
22 CONNECTING ROD
241008 GMax 3900 1
241012 GMax 5900, 5900HD 1
23 COVER, HOUSING, DRIVE
179899 GMax 3900 1
241308 GMax 5900, 5900HD 1
26 SPRING, retaining
176817 GMax 3900 1
183169 GMax 5900, 5900HD 1
28 DISPLACEMENT PUMP; Manual 308798
239923 GMax 3900 1
240291 GMax 5900 1
240800 GMax 5900HD 1
29 PIN, straight
176818 GMax 3900 1
183210 GMax 5900, 5900HD 1
30 TUBE, intake
192641 GMax 3900 1
193097 GMax 5900 1
Ref
No. Part No. Description Qty
31 STRAINER
32 CLIP, spring
33 240795 HOSE, coupled 1
34 NUT, retaining
35 CART FRAME
36 193698 LABEL, identification, GMax 3900 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 SLEEVE
41 WHEEL, semi–pneumatic
42 101242 RING, retaining 2
43 104811 HUBCAP 2
44 154636 WASHER, GMax 5900, 5900HD only 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.
50 193700 PLUG, tubing; GMax 3900 2
51 114984 SCREW, mch, pn hd; GMax 3900 only 2
53 164672 ADAPTER 2
54 194178 HOSE, drain 1
55
56
61 114678 BUSHING, strain relief 1
62 183461 NIPPLE, GMax 3900 1
67 192719 HANGER, pail 1
68 112746 LOCKNUT, 5/16–18 2
70 110837 SCREW, flng, hex hd, 5/16–18 x 1–1/2 in. 2
71 110838 LOCKNUT, heavy hex, 5/16–18 6
72 101682 SCREW, cap, sch 4
73 SCREW, cap, sch 4
77 WASHER, lock, spring
78 114687 CLIP, retainer 1
80 HUB, armature 1
81 SCREW
82 206994 THROAT SEAL LIQUID; not shown 1
87 240997 CONDUCTOR, ground 1
88 110249 ADAPTER, male elbow, 90_ 1
89 240131 PLUG, packless 1
90 241718 DEFLECTOR 1
91 114672 WASHER, GMax 3900 (3); 5900, 5900HD (2)
92 114699 WASHER 1
93** 162485 ADAPTER 1
94** 240987 PLUG, packless, 3/8 in. 1
181072 GMax 3900 1
189920 GMax 5900, 5900HD 1
194194 GMax 3900, 5900 1
194525 GMax 5900HD 1
192723 GMax 3900 1
193031 GMax 5900, 5900HD 1
240696 GMax 3900 1
240726 GMax 5900, 5900HD 1
193683 LABEL, identification, GMax 5900 1
192027 GMax 3900 2
191084 GMax 5900, 5900HD 2
106062 GMax 3900 2
179811 GMax 5900, 5900HD 2
193682 CAP, end; GMax 5900, 5900HD 2
Y 194125 LABEL, danger 1
Y 194126 LABEL, warning 1
162485 NIPPLE, GMax 5900, 5900HD 1
109031 GMax 3900 4
108842 GMax 5900, 5900HD 4
104008 GMax 3900 4
100214 GMax 5900, 5900HD 4
107218 GMax 3900 2
114686 GMax 5900 2
Y Danger & Warning labels, tags, and cards are free
* Models 233005 through 233007 include Pressure
Gauge Kit 241339
** 5900HD only
308868 17
Parts List & Drawing – Pinion Assembly
Ref No. 19 and 20
Ref No. 19: Pinion Housing Assembly 241108 for
GMax 3900; Pinion Housing Assembly 241112 for
GMax 5900
Ref
No. Part No. Description Qty
19 PINION HOUSING 1
19b 105489 PIN 2
19d* PINION SHAFT
241110 GMax 3900 1
241114 GMax 5900, 5900HD 1
19e* RETAINING RING, large
113094 GMax 3900 1
112770 GMax 5900, 5900HD 1
*Must be ordered separately..
19e
19d
19b
10 (Ref)
17 (Ref)
19
20h
20g
Ref No. 20: Drive Housing Assembly 241007 for
GMax 3900; Drive Housing Assembly 241011 for
GMax 5900
Ref
No. Part No. Description Qty
20 DRIVE HOUSING 1
20g* WASHER
107089 GMax 3900 1
194173 GMax 5900, 5900HD 1
20h* WASHER
194411 GMax 3900 1
194172 GMax 5900, 5900HD 1
*Must be ordered separately..
91 (Ref)
91 (Ref)
2
1
18 (Ref)
92 (Ref)
1
Only used on GMax 3900, Models 232610 and 232612
2
Pinion housing assembly (19) includes clutch field and connector
20
17 (Ref)
81 (Ref)
TI0177A
30886818
Notes
308868 19
Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayer s
Models 232612 and 232622
Ref 11
40
45
3
2
11
DETAIL A
49
DETAIL A
37
38
39
Ref 35
56
70
22
12
78
4
8699A
(Ref)
1
Label
2
See page 18 for the parts.
3
See manual 308798
for the parts.
4
See page 22 for the parts.
5
Used on GMax 5900, only
6
Used on GMax 3900, only
72
17
4b
87
5
61 (Ref)
2
17
Bottom V iew
81
9
6
2
19
20h
2
20g
2
20
91
13
1
91
6
18
21
23
92
10
17
5
7
55
26
29
36
8
17
16
33
62
34
14
35
47
43
42
71
30886820
4a
30a
28
3
30b
30e
30f
30ae
30c
30g
30
77
73
80
17
16
30aa
15
30ac
51
41
44
5
50
4
30d
30ad
53
89
30b (Ref)
30ab
8713A
Parts List – GMax 3900 and GMax 5900 Lo–Boy Sprayers
Models 232612 and 232622
Ref
No. Part No. Description Qty
1 ENGINE
108879 GMax 3900 1
114530 GMax 5900 1
2 113084 RIVET, blind 2
3 192014 PLATE, indicator 1
4 CLUTCH ASSEMBL Y,
includes 4a, 4b, 16, 17, 80
241109 GMax 3900 1
241113 GMax 5900 1
4a .ARMATURE, clutch, 4 in., 1
GMax 3900
.ARMATURE, clutch, 5 in., 1
GMax 5900
4b .ROTOR
4 in., GMax 3900 1
5 in., GMax 5900 1
5 CLUTCH HOUSING
193540 GMax 3900 1
193531 GMax 5900 1
6 LOCKWASHER, spring, 1/4 in.
105510 GMax 3900 1
104008 GMax 5900 1
7 183401 KEY, parallel 1
8 193680 COLLAR, shaft 1
9 CAPSCREW, socket head, 1/4–20 x 3/4 in.
100644 GMax 3900 4
101864 GMax 5900 4
10 100644 CAPSCREW, socket head, 1/4–20 x 3/4 in. 5
11 239998 CART HANDLE & HOSE RACK 1
12 106115 LOCKWASHER, spring, 3/8 in. 4
13 CAPSCREW, socket head,
107210 GMax 3900; 3/8–16 x 1.5 in. 4
114666 GMax 5900; 3/8–16 x 2.25 in. 4
14 114418 SCREW, self–tap, fil hd, 8–32 x 1 in. 4
15 113802 SCREW, flange, hex hd,, 3/8–16 x 5/8 in. 1
16 108803 CAPSCREW, sch, 1/4–2 x 1 in. 6
17 LOCKWASHER, spring, 1/4 in.
105510 GMax 3900 17
105510 GMax 5900 11
18 GEAR COMBINATION
241439 GMax 3900 1
241440 GMax 5900 1
19 PINION ASSEMBLY; Parts, page 18
241108 GMax 3900 1
241112 GMax 5900 1
20 DRIVE HOUSING
241007 GMax 3900 1
241011 GMax 5900 1
21 BEARING HOUSING
240523 GMax 3900 1
241015 GMax 5900 1
22 CONNECTING ROD
241008 GMax 3900 1
241012 GMax 5900 1
23 COVER, HOUSING, DRIVE
179899 GMax 3900 1
241308 GMax 5900 1
26 SPRING, retaining
176817 GMax 3900 1
183169 GMax 5900 1
28 DISPLACEMENT PUMP, Manual 308798
239923 GMax 3900 1
240291 GMax 5900 1
29 PIN, straight
176818 GMax 3900 1
183210 GMax 5900 1
30 241287 ASSEMBLY, tube, suction
30a 241124 .TUBE, suction, 5 gallon (20 liter) 1
includes 30aa through 30ae
30aa 240513 ..SWIVEL, tube, inlet 1
Ref
No. Part No. Description Qty
30ab 176450 ..GUARD, hose 1
30ac 194306 ..HOSE, fluid 1
30ad 101818 ..CLAMP, hose 2
30ae 170957 ..TUBE, suction 1
30b 194180 .HOSE, drain 1
30c 194194 .CLIP, spring 1
30d 162453 .NIPPLE 1
30e 241718 .DEFLECTOR 1
30f 187147 .STRAINER 1
30g 144958 .STRAP, t i e 1
33 240795 HOSE, coupled 1
34 NUT, retaining
35 CART FRAME
36 193698 LABEL, identification, GMax 3900 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 SLEEVE
41 WHEEL, semi-pneumatic
42 101242 RING, retaining 2
43 104811 HUBCAP 2
44 154636 WASHER, GMax 5900 only 2
45 112827 BUTTON, snap 2
46 108068 PIN, spring, straight, 3/16 x 1–1/4 in. 2
47 237686 GROUNDING CLAMP & WIRE 1
49 112798 SCREW, hex washer hd, No. 8 x 3/8 in 1
50 193700 PLUG, tubing; GMax 3900 2
51 114984 SCREW 2
52 100020 WASHER, GMax 3900 only 4
53 164672 ADAPTER 2
55
56
61 114678 BUSHING, strain relief 1
62 NIPPLE, 3/8–18 npsm(m) x 1/4 npt(m)
70 110837 SCREW, flng, hex hd, 5/16–18 x 1–1/2 in. 2
71 110838 LOCKNUT, heavy hex, 5/16–18 6
72 101682 SCREW, cap, sch 4
73 SCREW, cap, sch 4
77 WASHER, lock, spring
78 114687 CLIP, retainer 1
80 HUB, armature 1
81 SCREW
82 206994 THROAT SEAL LIQUID; not shown 1
87 240997 CONDUCTOR, ground 1
89 240131 PLUG, packless 1
91 Washer
92 114699 WASHER 1
192723 GMax 3900 1
193031 GMax 5900 1
240728 GMax 3900 1
240727 GMax 5900 1
193683 LABEL, identification, GMax 5900 1
192027 GMax 3900 2
191084 GMax 5900 2
106062 GMax 3900 2
179811 GMax 5900 2
193682 CAP, end; GMax 5900 2
Y 194125 LABEL, danger 1
Y 194126 LABEL, warning 1
183461 GMax 3900 1
162485 GMax 5900 1
109031 GMax 3900 4
108842 GMax 5900 4
104008 GMax 3900 4
100214 GMax 5900 4
107218 GMax 3900 2
114686 GMax 5900 2
114672 GMax 3900 3
114672 GMax 5900 2
Y Danger & Warning labels, tags, and cards are free.
308868 21
Parts Drawing – Sprayer
GMax 3900 and 5900 Sprayers
Models 232610 through 232613
Models 232620 through 232623; 232627 and 232628
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
30886822
Parts List – Sprayer
Models 232610 through 232613; 232620 through 232623; 232627 and 232628
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
Pressure Control Wiring Diagram
Green
Black
D
Red
Potentiometer
E
Red
A
318z
(Ref)
Violet
302
(Ref)
310
(Ref)
Pressure
transducer
318aa
(Ref)
8716A
308868 23
Parts List & Drawing – Complete Sprayers
Models 232611, 232613, 232621, 232623, 232628
GMax 3900, 5900, 5900HD Airless Paint Sprayers
Includes items 201 to 204
Ref
No. Part No. Description Qty
201 232611 GM3900 Hi-Boy Sprayer 1
See parts list on page 16
232621 GM5900 Hi-Boy Sprayer 1
See parts list on page 16
232628 GM5900HD Hi-Boy Sprayer 1
See parts list on page 16
232613 GM3900 Lo-Boy Sprayer 1
See parts list on page 21
232623 GM5900 Lo-Boy Sprayer 1
See parts list on page 21
202 240794 HOSE, grounded, nylon; 1/4 in. ID; 1
cpld 1/4 npsm(fbe); 50 foot (15 m);
spring guards both ends
3300 psi (227 bar, 27.7 MPa)
240797* HOSE, grounded, nylon; 3/8 in. ID; 1
cpld 1/4 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
241735* HOSE, grounded, nylon; 1/4 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 HandTitet Guard
See 309091 for parts 1
241705* TEXTURE SPRAY GUN
Includes GHD527 Heavy Duty SwitchTip
and Guard
See 308491 for parts 1
t 517–size SwitchTipt
Ref
No. Part No. Description Qty
205 159841* BUSHING, 3/8 X 14 IN. 1
* 5900HD only
204
203
0160
205
202
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.
Apply other
language here
French 194931
Spanish 194932
German 194933
Greek 194934
Korean 194935
English 194125
30886824
Displacement Pump Repair Kits
Packing repair kits.
GMax 3900 239928
GMax 5900, 5900HD 240248
03497A
Technical Data
Honda GX120 Engine
Power Rating @ 3700 rpm
ANSI 4.0 Horsepower. . . . . . . . . . . . . . . . . . . . . . .
DIN 6270B/DIN 6271
NA 2.1 Kw – 2.8 Ps. . . . . . . . . . . . . . . . . . . . . .
NB 2.6 Kw – 3.6 Ps. . . . . . . . . . . . . . . . . . . . . .
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)
GMax3900 182 (48). . . . . . . . . . . . . . . . . . . . . . . . . . .
GMax5900, 5900HD 93 (25). . . . . . . . . . . . . . . . . . . .
Maximum delivery rating
GMax3900 1.15 gpm (4.4 liter/min). . . . . . . . . . . . .
GMax5900, 5900HD 1.5 gpm (5.7 liter/min). . . . . . .
Maximum tip size
GMax3900 1 gun with 0. 034 in. tip. . . . . . . . . . . . .
2 guns with 0.024 in. tip
3 guns with 0. 017 in. tip
GMax5900, 5900HD 1 gun with 0. 041 in. tip. . . . .
2 guns with 0.028 in. tip
3 guns with 0. 022 in. tip
4 guns with 0. 019 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: Delrinrrand Vitonr are trademarks of the DuPont
Company.
Dimensions
GMax 3900
Model 232610, 233005
Hi-Boy without hose or gun
Weight (dry, without packaging) 110 lb (49.9 kg). . . . .
Height 40 in. (101.6 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 37 in. (94 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
GMax 5900, 5900HD
Model 232620, 232627, 233006 and 233007
Hi-Boy without hose or gun
Weight (dry, without packaging) 150 lb (68 kg). . . . . . .
Height 41 in. (104.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 39 in. (99.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number
Model 232612
Lo-Boy Cart without hose or gun
Weight (dry, without packaging) 110 lb (49.9 kg). . . . .
Height 40 in. (101.6 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 37 in. (94 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232622
Lo-Boy without hose or gun
Weight (dry, without packaging) 150 lb (68 kg). . . . . . .
Height 41 in. (104.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . .
Length 39 in. (99.1 cm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22 in. (55.9 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
308868 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 P ARTICULAR 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 308868 January 1999, Revised 4/2001
30886826
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