Graco 233005, 232612, 233007, 233006, 232627 User Manual

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 Nm)
GMax 5900: Torque to 25 ft-lb (34 Nm)

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