Graco Inc 309412F User Manual

Repair Instructions

GMax

Airless Paint Sprayer

3300 psi (227bar, 22.7 MPa) Maximum Working Pressure

See page 2 for models numbers.

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

Related Manuals

Operation 309408...............................

Displacement Pump 309277......................

Spray Gun 309639..............................

Spray Tip 309640................................

PC Board 309459...............................

Drain Valve Kit 308961...........................

Clutch Replacement Kit 309890...................

7900

R

309412F

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441

Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001

ti1833a

Models

Model Series Description

233718 A Lo--Boy

233719 A Hi--Boy

233720 A Lo--Boy with RACRX tip, gun and hose

233721 A Hi--Boy with RAC X tip, gun and hose

Table of Contents

Warnings and Cautions 3.........................

Maintenance 4...................................

Troubleshooting 5................................

Repair

Rollers 8......................................

Drive Housing 9................................

Cam Follower Bearings 10......................

Engine 1 1.....................................

Pressure Control 13............................

Displacement Pump 15.........................

Parts

Pinion Assembly 17............................

Sprayers 18...................................

Pressure Control 21............................

Tip, Gun, Hose 22..............................

Dimensions 23...................................

Technical Data 23................................

Graco Warranty 24...............................

Graco Phone Number 24..........................

3094122

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: Solvent and paint fumes can ignite or

explode.

To help prevent a fire and explosion:

DUse only in an extremely well ventilated area.
DEliminate all ignition sources; such as pilot lights, cigarettes and

plastic drop cloths (static arc hazard). Do not plug or unplug
power cords or turn lights on or off in spray area.

DGround Sprayer, object being sprayed, paint and solvent pails.
DHold gun firmly to side of grounded pail when triggering into pail.
DUse only conductive airless paint hose.
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.

DDo not fill fuel tank while engine is running or hot.
DDo not flush with gasoline.

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 and high pressure hazard: High pressure spray or
leaks can inject fluid into the body.

To help prevent injection, always:

DEngage trigger safety latch when not spraying.
DKeep clear of nozzle and leaks.
DNever spray without a tip guard.
DDo PRESSURE RELIEF if you stop spraying or begin servicing

sprayer.

DDo not use components rated less than sprayer Maximum

Working Pressure.

DNever allow children to use this unit.

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.

309412 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 areinstructedtorelievethepressure,
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 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 .

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.

3094124

Troubleshooting

Relieve pressure; page 4.

PROBLEM CAUSE SOLUTION

E=XX is displayed Fault condition exists Determine fault correction from table, page 14.

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.

False tripping of Watch­Dog system. EMPTY is
displayed. Pump does
not run.

Engine operates, but
displacement pump
does not operate

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 3 to 4 times.

Clean or replace spark plug. Start engine.
Keep sprayer upright to avoid oil seepage.

Operating conditions out of WatchDog parameters Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.
Operate without WatchDog active; Manual

309408.

Low pump output. See Troubleshooting Table, Pump Outlet Low,

page 6.

Error code displayed? Determine fault correction from table, page 14.

Pump switch is OFF TurnpumpswitchON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

increase pressure.

Fluid filter (318) is dirty Clean filter. Page 20.

Tip or tip filter is clogged Clean tip or tip filter. Manual 309091.

Displacement pump piston rod is stuck due to dried
paint

Connecting rod is worn or damaged Replace connecting rod. Page 15.

Drive housing is worn or damaged Replace drive housing. Page 9.

Electrical power is not energizing clutch field Check wiring connections. Page 11.

Repair pump. Manual 309277.

Reference pressure control repair. Page 13.
Reference wiring diagram. Page 21.

With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch test points on control board.

Remove 7--pin connector from control board
and measure resistance across clutch coil. At
70_ F, the resistance must be between 1.7

±0.2Ω ; if not, replace pinion housing.

Have pressure control checked by authorized
Graco dealer.

309412 5

Troubleshooting

PROBLEM CAUSE SOLUTION

Clutch is worn, damaged, or incorrectly positioned Replace clutch. Manual 309890.

Pump output is low.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Manual

Strainer (89) is clogged Clean strainer. Sprayer 233716 strainer is for

Piston ball (206) is not seating Service piston ball. Manual 309277.

Piston packings are worn or damaged Replace packings. Manual 309277.

O-ring (227) in displacement pump is worn or dam­aged

Intake valve ball is not seating properly Clean intake valve. Manual 309277.

Intake valve ball is packed with material Clean intake valve. Manual 309277. Do not

Engine speed is too low Increase throttle setting. Manual 309408.

Clutch is worn or damaged Replace clutch. Manual 309890.

Pressure setting is too low Increase pressure. Manual 309408.

Fluid filter (318), tip filter or tip is clogged or dirty Clean filter. Manual 309408 or 309091.

Large pressure drop in hose with heavy
materials

309890.

use in paint only.

Replace o-ring. Manual 309277.

leave 233716 sprayer under pressure for more
than 5 minutes when spraying texture and not
actively spraying.

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 309277.

Displacement rod is worn or damaged Replace rod. Manual 309277.

Air in pump or hose Check and tighten all fluid connections. Re--

prime pump. Manual 309408.

Tip is partially clogged Clear tip. Manual 309091.

Fluid supply is low or empty Refill fluid s upply. Prime pump. Manual

309408. 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. Reas­semble valve.

Pump packings are worn Replace pump packings. Manual 309277.

Paint is too thick Thin the paint according to the supplier’s

recommendations

3094126

Troubleshooting

load

PROBLEM CAUSE SOLUTION

Engine speed is too high Decrease throttle s etting before priming pump.

Clutch squeaks each time
clutch engages

High engine speed at no

Gallon counter not working Bad sensor, broken or disconnected wire Check connections. Replace sensor or wire.

No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.

Clutch squeaks each time
clutch engages

Engine stalls

Clutch surfaces are not matched to each other
when new and may cause noise

Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load

Worn engine governor Replace or service engine governor

Clutch surfaces are not matched to each other
when new and may cause noise

Engine speed is to slow D Increase throttle setting

Fluid filter is clogged Relieve pressure and clean filter

Too much pump friction (new pump) Reduce pressure to 3000 psi until pump wears

Spark plug wire is loose Reconnect wire

Manual 309408.

Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.

Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time

D Adjust engine speed at no load to 3750 --

3850 rpm

in

309412 7

Rollers

Removal

1.

2. Fig. 1. Remove six cap screws (56) lock washers
(87), clip (35), and cover assembly (13).

77

87

Fig. 1

Relieve pressure; page 4.

71

109

108

59

13

87

35

56

ti1860a

Installation

1. Install rollers (109) and dowel pins (108)

2. Install cover assembly (13) with six lock washers
(87), clip (35), and cap screws (56).

Note: A screw driver may be needed to pry off cover
assembly.

3. Remove dowel pins (108) and rollers (109)

3094128