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

INSTRUCTIONS-REPAIR

KEEP FOR REFERENCE.

Read this and all related manuals for important warnings and instructions.

INSTRUCTIONS

308868

Rev. L

First choice when quality counts.t

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

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

PATENTS 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	Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . .	15
Component Identification and Function . . . . . . . . . . . .	3	Parts
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	GMax 3900 & GMax 5900 Hi-Boy Sprayers . . . . .	16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
Repair		GMax 3900 & GMax 5900 Lo-Boy Sprayers . . . . .	20
Bearing Housing & Connecting Rod . . . . . . . . . . . . .	7	Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8	Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . .	24
Pinion Assembly/Rotor/Field/Shaft/Clutch . . . . . . . .	9	Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10	Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11	Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .	25
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11	Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26
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.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment 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.

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.

2308868

Component Identification and Function

202Main hose			V	D C
203Whip end hose
204Contractor gun with RAC 5
	DripLess tip guard and 517 size SwitchTip					J
				H
				E
				R		G
	K	P				F
				S
	A	B	U
				W	Model 232611
				T
						202
	M
	X		N			204
				203
			L
Fig. 1						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:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor 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.

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.

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 operation.

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 viscosity.

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.

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.

4308868

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	CAUSE	SOLUTION
	Engine won’t start	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.
			Honda Engines Owner’s Manual.
		Spark plug cable is disconnected or damaged	Connect spark plug cable or replace spark
			plug
		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
			times. Clean or replace spark plug. Try to start
			engine. Keep sprayer upright to avoid oil seep-
			age.
	Engine operates, but dis-	Pressure control switch is OFF	Turn pressure control switch ON.
	placement pump does not
		Pressure setting is too low	Turn pressure adjusting knob clockwise to
	operate
			increase pressure.
		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	Repair pump. Manual 308798.
		dried paint
		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 ±0.2Ω
			(GMax3900); 1.7 ±0.2Ω (GMax 5900); if not,
			replace pinion housing.
			Have pressure control checked by authorized
			Graco dealer.
		Clutch is worn, damaged, or incorrectly	Replace clutch. Page 9.
		positioned
		Pinion assembly is worn or damaged	Repair or replace pinion assembly. Page 9.

308868 5

PROBLEM	CAUSE	SOLUTION
Pump output is low	Strainer (31) is clogged	Clean strainer. Sprayer 232627 strainer is for
		use in paint only.
	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	Replace o-ring. Manual 308798.
	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
		leave 232627 sprayer under pressure for more
		than 5 minutes when spraying texture and not
		actively spraying.
	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	Clean filter. Manual 308867 or 309091.
	dirty
	Large pressure drop in hose with heavy	Use larger diameter hose and/or reduce overall
	materials	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 perfor-
		mance (50 ft minimum).
Excessive paint leakage into	Throat packing nut is loose	Remove throat packing nut spacer. Tighten
throat packing nut		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.
Fluid is spitting from gun	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.
Pump is difficult to prime	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 surfaces are not matched to each other	Clutch surfaces need to wear into each other.
clutch engages	when new and may cause noise	Noise will dissipate after a day of run time.
High engine speed at no	Misadjusted throttle setting	Reset throttle to 3600–3800 engine rpm at no
load		load
	Worn engine governor	Replace or service engine governor

6308868

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.

Relieve pressure; page 4.

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).

29

26

Fig. 2

7675B

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.

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.

6. Refer to Displacement Pump, Installation, page 15.

1	C	E 2
		2
		D
		22	12, 13	3
B				23
20				14
F 26
29
33
62		34 21
28
A			32
54
1 Oil			30

2Pack with bearing grease 114819

3GMax 3900: Torque to 200 in-lb (22.6 N m) GMax 5900: Torque to 25 ft-lb (34 N m)

8697A

Fig. 3	Model 232610 shown

308868 7

Drive Housing

Removal

1.

Relieve pressure; page 4.

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.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.

2 10

17

B

19

3

		B
		1	91
	1	GMax 3900 only	91	18
	2	Torque to 125 in-lb – GMax 3900
				92
		Torque to 200 in-lb – GMax 5900
				91
	3	Apply remaining grease to these areas

Fig. 4

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.

20h

20g

20

17

81 2

TI0178A

8308868