Graco Inc 310813D User Manual

Repair

GMAX™ 3400 Airless Sprayers

Korean patent: 10-0647761

310813D

- For Portable Airless Spraying of Architectural Coatings and Paints -

3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure

Read all warnings and instructions

ti5944a

248664 ✓✓ 248666 ✓✓

ti5523a

ti5447a

310802 311861

309250 309640

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

ti5944a

Contents

Manual Conventions

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Drive Housing and Connecting Rod . . . . . . . . . . . 8

Pinion Assembly/Clutch Armature/Clamp . . . . . . . 9

Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 14

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Manual Conventions

WARNING

Hazard Symbol

WARNING: a potentially hazardous situation which, if

not avoided, could result in death or serious injury. Warnings in the instructions usually include a symbol

indicating the hazard. Read the general Warnings section for additional safety information.

GMAX 3400 Hi-Boy Sprayers . . . . . . . . . . . . . . . . 16

Pinion Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

GMAX 3400 Lo-Boy Sprayers . . . . . . . . . . . . . . . . 20

Pressure Control/Filter Assembly . . . . . . . . . . . . . 22

Pressure Control Wiring Diagram . . . . . . . . . . . . . 23

Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . 24

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or destruction of equipment.

Note

Additional helpful information.

2 310813D

Warning

The following warnings include general safety information for this equipment. Further product specific warnings may be included in the text where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.

• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate medical attention.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

310813D 3

Warning

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

SUCTION HAZARD

Never place hands near the pump fluid inlet when pump is operating or pressurized. Powerful suction could cause serious injury.

CARBON MONOXIDE HAZARD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. Do not operate in an enclosed area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

RECOIL HAZARD

Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.

4 310813D

Maintenance

Pressure Relief Procedure

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

1. Lock gun trigger safety.

2. Turn engine ON/OFF switch to OFF.

3. Move pump 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.

DAILY: Check level of TSL in displacement pump pack-

ing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion.

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 engine air filter cover and clean element. Replace element, if necessary. If operating in an unusually dusty environment: check filter daily and replace, if necessary.

Replacement elements can be purchased from your local HONDA dealer.

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.

310813D 5

Troubleshooting

Problem Cause Solution

Engine will not start Engine switch is OFF Turn engine switch ON

Engine is out of gasoline 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.

Engine operates, but displacement pump does not operate

Spark plug is disconnected of damaged Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion chamber

Pump switch is OFF Turn pump switch ON Pressure setting too low Turn pressure adjusting knob clock-

Fluid filter (29) is dirty Clean filter. Page 22. Tip or tip filter is clogged Displacement pump piston rod is stuck due to dried paint Connecting rod is worn or damaged Drive housing is worn or damaged Replace drive housing. Page 8. Electrical power is not energizing clutch field

Connect spark plug cable or replace spark plug

Remove spark plug. Pull starter 3 to 4 times. Clean or replace spark plug. Start engine. Keep sprayer upright to avoid oil seepage

wise to increase pressure.

Clean tip or tip filter. Manual 311861. Repair pump. Manual 309250.

Replace connecting rod. Page 8.

Check wiring connections. Page 11.

Reference pressure control repair. Page 13.

Troubleshooting

Reference wiring diagram. Page 23.

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 clutch wires from control board and measure resistance across clutch coil. At 70° F, the resistance must be between 1.2 +0.2Ω; if not, 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.

Adjust or replace clutch. Page 9.

6 310813D

Problem Cause Solution

Pump output is low Strainer (16) is clogged Clean strainer.

Piston ball (206) is not seating Service piston ball. Manual 309250. Piston packings are worn or damaged O-ring (227) in pump is worn or damaged Intake valve ball is not seating properly Intake valve ball is packed with material Engine speed is too low

Replace packings. Manual 309250. Replace o-ring. Manual 309250. Clean intake valve. Manual 309250. Clean intake valve. Manual 309250.

Increase throttle setting. Manual 310802. Clutch is worn or damaged Adjust or replace clutch. Page 9. Pressure setting is too low Increase pressure. Manual 310802. Fluid filter (29), tip filter or tip is

Clean filter. Manual 310802 or 311861. clogged or dirty

Large pressure drop in hose with heavy materials

Use larger diameter hose and/or

reduce overall length of hose. Use of

more than 100 ft of 1/4 in. hose signifi-

cantly reduces performance of sprayer.

Use 3/8 in. hose for optimum perfor-

mance (50 ft minimum).

Excessive paint leakage into throat packing nut

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 Displacement rod is worn or damaged

Fluid is spitting from gun Air in pump or hose

Replace packings. Manual 309250.

Replace rod. Manual 309250.

Check and tighten all fluid connections.

Prime pump. Manual 310802. Tip is partially clogged Clear tip. Manual 311861. Fluid supply is low or empty Refill fluid supply. Prime pump. Manual

310802. 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.

Troubleshooting

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 309250. Paint is too thick Thin the paint according to the sup-

plier's recommendations Engine speed is too high Decrease throttle setting before prim-

ing pump. Manual 310802.

Clutch squeaks each time clutch engages

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

Clutch surfaces need to wear into each

other. Noise will dissipate after a day of

run time.

High engine speed at no load Misadjusted throttle setting Reset throttle to 3300 engine rpm at no

load Worn engine governor Replace or service engine governor

310813D 7

Drive 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.

Drive Housing and Connecting Rod

CAUTION

DO NOT use drive housing screws (18) to align or seat bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear.

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

1. Relieve pressure, page 5.

IG. 1. Remove screws (10) and front cover (62).

2. F

3. Remove pump. Refer to Displacement Pump, Removal,

page 14.

4. Remove four screws (18) from drive housing (49).

CAUTION

Thrust washers may stick to grease inside of drive housing. Do not lose or misplace.

5. Pull connecting rod (6) and lightly tap lower rear of drive housing (49) with plastic mallet to loosen from pinion housing (50). Pull drive housing and connecting rod assembly off pinion housing.

6. Inspect crank (B) and connecting rod (6) for excessive wear and replace parts as needed.

7. Install screws (18) in drive housing. Torque evenly to note 3 value in Fig. 1.

8. Install pump. Refer to Displacement Pump, Installation, page 14.

ti5527a

ti5990a

Steel

Copper

Installation

1. Evenly lubricate inside of bronze bearing (C) in drive housing (49) with high-quality motor oil. Liberally pack top roller bearing (E), lower bearing (D) inside connecting rod (6) with bearing grease.

2. Assemble connecting rod (6) to drive housing (49). Rotate connecting rod to lowest position.

3. Apply grease to washers 52, 57 and 56. Install in order shown in F

4. Lubricate gears with 0.26 pint of 110293 grease (supplied with drive housing). Pack grease evenly around gears.

5. Clean mating surfaces of pinion and drive housings.

6. Align connecting rod with crank (B) and carefully align locating pins in drive housing (49) with holes in pinion housing (50). Push drive housing onto pinion housing or tap into place with plastic mallet.

8 310813D

IG. 2.

FIG. 1

FIG. 2

Oil

Pack with bearing grease 110293

Torque to 130 - 150 in-ib (14 - 16.9 N m)

+ 18 hidden pages