Graco GMax 3900, GMaxu0001 5900HD, GMaxu0001 5900, GMaxu0001 7900 Instruction Manual

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Page 1

INSTRUCTIONS

309XXX

KEEP FOR REFERENCE.

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

INSTRUCTIONS

First choice when

quality counts.

GMaxr 3900, 5900, 5900HD, 7900 Airless Paint Sprayers

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

Table of Manuals

Operation 308867. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump 308798. . . . . . . . . . . . . . . . . . . . . .

Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC Board 308919. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Rev. A

Model 232621

8695A

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

Graco Inc. is registered to I.S. EN ISO 9001

Page 2

OPERATION – UTILIZAÇÃO

308867

FONCTIONNEMENT –FUNCIONAMIENTO

GMaxr 3900, 5900, 5900HD, 7900

3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure Pressão Máxima De Trabalho De 3300 psi (228 bar , 22,8 MPa) Pression Maximale De Service 3300 lb/po2 (228 bar, 22.8 MPa) 3300 psi (228 bar, 22,8 MPa) Presión Máxima De Operación

232610, 232611, 232612, 232613* 232620, 232621, 232622, 232623, 232627, 232628* 232630, 232631, 232632, 232633{

All models not available in all countries Nem todos os modelos existem à disposição em todos os países

T ous les modèles ne sont pas disponibles dans tous les pays Hay modelos que no se distribuyen en todos los países

Related manuals Manuais associados Manuels afférents Manuales relacionados

*308868. . . . . . .

{308870. . . . . . .

307614. . . . . . .

308798. . . . . . .

308644. . . . . . .

Rev. C

232620

INSTRUCTIONS

READ ALL INSTRUCTION AND WARNINGS

BEFORE SETTING UP OR OPERATING THIS UNIT.

You need:

S two adjustable wrenches S two 5 gallon (20 liters) metal pails S Compatible cleaning fluids

LatexOil Base

Clothing:

S respirator S safety glasses

Fuel & oil specifications:

S Unleaded gasoline octane

86 or higher

S Do not use gasolines

containing methanol.

S SAE 10W–40

Operating Consideration:

S Always keep sprayer upright

while operating or transporting

INSTRUCTIONS

LIRE TOUTES LES INSTRUCTIONS ET A VERTISSEMENTS

AVANT DE PRÉPARER OU F AIRE FONCTIONNER CET

Matériel requis:

S Deux clés à molette S Deux seaux métalliques de 5 gallons

(20 litres)

S Nettoyants liquides compatibles

APPAREIL.

Spécifications des carburants et des huiles:

S Essence sans plomb, indice

d’octane 86 et supérieur

S Ne pas utiliser d’essences

contenant du méthanol

S SAE 10W–40

INSTRUÇÕES

LEIA TODAS AS INSTRUÇÕES E ADVERTÊNCIAS

ANTES MONT AR OU UTILIZAR EST A UNIDADE.

Você precisa de:

S Duas chaves inglesas S Dois baldes metálicos de 20 litros S Líquidos de limpeza compatíveis

À base de óleo Látex

Vestuário:

S Máscara de respiração S Óculos protetores

Especificações do combustível e óleo:

S Gasolina sem chumbo de

86 octanas ou mais

S Não use gasolina contendo

metanol

S SAE 10W–40

Conselho para a operação:

S Mantenha o pulverizador sempre

na vertical quando o estiver utilizando ou transportando

INSTRUCCIONES

LEA TODAS LAS INSTRUCCIONES Y ADVERTENCIAS

ANTES DE PREP ARAR U OPERAR ESTA UNIDAD.

Necesita:

S Dos llaves ajustables S Dos recipientes metálicos de

20 litros (5 galones)

S Fluidos de limpieza compatibles

Especificaciones de combustible y aceite:

S Gasolina sin plomo de octanaje

86 o superior

S No use gasolina que

contengan metanol

S SAE 10W–40

Émail (base d’huile)

Protection personnelle:

S Respirateur S Lunettes de protection

Latex

Précautions:

S T oujours maintenir le bec

pulvérisateur vers le haut pendant le fonctionnement ou le transport

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

Graco Inc. is registered to I.S. EN ISO 9001

Óleo Látex

Vestuario:

S Mascarilla S Gafas de seguridad

Consideraciones para la operación:

S Mantenga siempre el pulverizador

en posición vertical mientras lo opere o transporte

Page 3

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:

Use outdoors or in an extremely well ventilated area. Do 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.

Remove, extinguish or unplug all ignition sources;

tape wall switches. Do not smoke in spray area.

Never fill fuel tank while the engine is running or hot. Ground Sprayer, object being sprayed, paint and solvent pails. Hold gun firmly to side of a grounded pail when triggering into pail. Use only conductive airless paint hose. Never run engine in inclosed area.

ADVERTÊNCIA

Poderá ocorrer incêndio e explosão quando for pulverizado ou injetado líquido inflamável numa área onde houver má circulação de ar; vapores inflamáveis poderão incendiar-se a partir de uma chama ou fagulhas a descoberto.

Para ajudar a evitar incêndio e explosão:

Utilize no exterior ou numa área muito bem ventilada. Não utilize 1,1,1–tricloroetano, cloreto de metileno, outros solventes de

hidrocarbonetos halogenados ou líquidos contendo tais solventes em equipamento de alumínio pressurizado. Tal utilização poderá resultar numa reação química, com possibilidade de explosão.

Retire, elimine ou desligue todas as fontes de ignição; coloque fita

adesiva na tomada da parede. Não fume na área de pulverização.

Nunca abasteça o depósito de combustível com o motor em funciona-

mento ou quente.

Ponha em contato com a terra o pulverizador, o objeto a ser pulveriza-

do, e os baldes de tinta e de solventes.

Segure a pistola firmemente de encontro ao lado de um balde em contato

com a terra, quando estiver descarregando para dentro do mesmo.

Utilize somente tubos flexíveis condutores para pintura a alta pressão. Nunca faça funcionar o motor numa área fechada.

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:

Engage trigger safety latch when not spraying. Point gun away from yourself or anyone else. Relieve pressure before checking or repairing any leak. Relieve pressure when you turn off the sprayer or stop spraying. Do not use components rated less than system

Working Pressu re

Never allow children to use this unit. If you are injured using this equipment, get immediate medical treatment.

Maximum

MISE EN GARDE

Risque d’incendie et d’explosion imminent pendant la pulvérisation

ou le rinçage à pression de fluides inflammables dans une zone à mauvaise circulation d’air et en présence de gaz inflammables pouvant s’allumer par une flamme nue ou des étincelles.

Pour éviter les risques d’incendie et d’explosion: Manipuler les fluides à l’air libre ou dans une zone extrêmement

bien aérée.

Ne jamais utiliser de trichloroéthane 1,1,1, de chlorure de méthylène,

d’autres solvants à base d’hydrocarbures halogénés, ni de produits contenant de tels solvants dans un équipement sous pression en aluminium. Cela pourrait provoquer une réaction chimique avec risque d’explosion.

Retirer, éteindre ou déboucher toute source d’inflammation, recouvrir

tout interrupteur mural avec du ruban adhésif. Ne pas fumer dans la zone de pulvérisation.

Ne jamais remplir le réservoir d’essence lorsque le moteur est chaud

ou en marche.

Mettre à la terre le pulvérisateur, l’objet à pulvériser ainsi que les

seaux de peinture et de solvants.

Tenir le pistolet fermement contre la paroi d’un seau mis à la

terre lorsqu’on pulvérise dans le seau.

N’utiliser qu’un flexible pour peinture pulvérisée sans air. Ne jamais mettre en marche un moteur dans une zone fermée.

A injeção de líquido é um ferimento grave! Se o líquido a alta pressão penetrar na sua pele, o ferimento poderá parecer “simplesmente

um corte”. Mas é um ferimento grave! Procure o médico imediatamente.

Para ajudar a evitar injeção de líquido, faça sempre o seguinte:

Engate o trinco de segurança do gatilho quando não estiver pulveri-

zando.

Sempre aponte a pistola para longe de você mesmo(a) ou de outras

pessoas.

Alivie a pressão antes de verificar ou reparar qualquer vazamento. Alivie a pressão quando desligar o pulverizador ou parar de pulverizar. Não utilize componentes classificados para uma pressão nominal

inferior à pressão máxima de trabalho dos sistemas.

Nunca permita que crianças utilizem esta unidade. Se sofrer algum ferimento durante a utilização deste equipamento, procure o médico imediatamente.

ADVERTENCIA

Pueden ocurrir incendios y explosiones cuando se pulveriza fluido inflamable o cuando se lava con este tipo de fluido en un área donde la circulación de aire es deficiente y los vapores inflamables se pueden encender al contacto con el fuego o chispas.

Para prevenir incendios y explosiones:

Use en espacios abiertos o en un área muy bien ventilada. No utilice nunca tricloretano–1,1,1, cloruro de metileno, u otros di-

solventes a base de hidrocarburos halógenos o fluidos que contengan tales disolventes en un equipo a presión de aluminio. El uso de estas sustancias puede provocar una intensa reacción química, con riesgos de explosión.

Retire, apague o desconecte todas las fuentes de ignición; asegure el

interruptor de la pared con cinta. No fume en el área de pulverización.

Nunca llene el estanque de combustible mientras el motor esté en

marcha o caliente.

Ponga a tierra el pulverizador, el objeto que recibe el chorro pulverizado,

las cubetas de pintura y disolvente.

Sostenga firmemente la pistola a un lado de la cubeta puesta a

tierra cuando dispare dentro de ella.

Use solamente mangueras para pintura conductora sin aire. Nunca haga andar el motor dentro de un área cerrada.

L’injection de fluide constitue une lésion grave! Si un fluide haute pression perce la peau, la blessure peut paraître comme une

«simple coupure». Mais i l s’agit bien d’une lés i on grave! Consul t er immédiatement un médecin.

Pour éviter les risques d’injection, toujours:

Bloquer le loquet de sécurité de la gâchette à la fin de la pulvérisation. Pointer le pistolet loin de soi-même et toute autre personne à proximité Décharger la pression avant de vérifier ou réparer une fuite. Décharger la pression après la mise hors tension du pulvérisateur ou

à la fin de la pulvérisation.

Ne pas utiliser de composants dont la pression nominale est inférieure

à la pression maximale de service du système. Ne jamais permettre aux enfants d’utiliser cet appareil. En cas de blessure pour avoir utilisé cet appareil, consulter immédiatement un médecin.

¡La inyección de fluido en la piel es una lesión seria! Si fluido de alta presión le penetra la piel, la lesión podría parecer “sólo un

corte”. ¡Es una lesión seria! Consulte de inmediato al médico.

Para prevenir la inyección en la piel, siempre:

Enganche el seguro del gatillo cuando no use el pulverizador. No apunte la pistola ni a sí mismo ni a los demás. Alivie la presión antes de inspeccionar o reparar cualquier filtración. Alivie la presión cuando apague el pulverizador o deje de usarlo. No use componentes cuya capacidad nominal sea inferior a la

presión máxima de operación del sistema.

No permita que niños usen esta unidad. Si se lesiona usando este equipo, sométase de inmediato a tratamiento médico.

3308867

Page 4

CONTROLS / CONTROLES / COMMANDES / CONTROLES

On/Off Switch Aan/Uit Schakelaar Interrupteur Marche/Arrêt Ein-Aus-Schalter

Pressure Control / Controle da pressão / Système de contrôle de la pression / Dispositivo de control de la presión

On/Off Switch Interruptor de ligar e desligar Interrupteur marche/arrêt Interruptor de encendido/apagado

Engine Controls Controles do motor Commandes de moteur Controles del motor

Drain V alve Válvula de drenagem Vidange Válvula de vaciado

Trigger Lock Fecho do gatilho Loquet de sécurité Seguro del gatillo

4 308867

8695A

Page 5

PRESSURE RELIEF / ALÍVIO DE PRESSÃO / DÉCHARGE DE PRESSION / ALIVIO DE LA PRESIÓN 1→5

Follow 1–5 when you stop spraying.

Siga os passos de 1–5 quando parar de pulverizar.

Suivre les étapes 1 à 5 lorsqu’on arrête de pulvériser.

Siga los pasos 1–5 cuando deje de usar el pulverizador.

STARTUP / P ARTIDA / DÉMARRAGE / PUESTA EN MARCHA 1→24

WARNING ADVERTÊNCIA

Flush with warm soapy water. Faça a descarga com água morma e sabão dissolvido. Rincer avec de l’eau tiède savonneuse. Enjuague con agua tibia con jabón.

MISE EN GARDE ADVERTENCIA

Flush with mineral spirits. Faça a descarga com álcool mineral. Rincer avec une eseence minérale. Enjuague con alcohol mineral.

Start Engine / Partida do motor / Démarrage / Partida del motor 4→11

WARNING ADVERTÊNCIA MISE EN GARDE ADVERTENCIA

54 6

Cold Engine Starts Partida do motor a frio Démarrages à froid Partida del motor en frío

5308867

Page 6

Flush / Descarga / Vidange / Enjuague 12→19

WASTE

RESÍDUOS

À JETER

DESECHO

RESÍDUOS

À JETER

DESECHO

WASTE

FLUSH

DESCARGA

VIDANGE

ENJUAGUE

20 SEC.

Start Engine

Partida do motor

Démarrage

Partida del motor

FLUSH

DESCARGA

VIDANGE

ENJUAGUE

1 MIN.

FLUSH

DESCARGA

VIDANGE

ENJUAGUE

10 SEC.

FLUSH

DESCARGA

VIDANGE

ENJUAGUE

Prime / Preparação / Amorçage / Cebado 20→23

WARNING ADVERTÊNCIA MISE EN GARDE ADVERTENCIA

WASTE

AFVAL

REBUT

ABFAL

PAINT TINTA

PEINTURE

PINTURA

21 2220

WASTE

AFVAL

REBUT

ABFAL

Watch for paint Cuidado com a tinta Vérifier l’arrivée de la peinture Observe cuando salga pintura

PAINT TINTA

PEINTURE

PINTURA

WASTE

AFVAL

REBUT

ABFAL

Watch for paint Cuidado com a tinta Vérifier l’arrivée de la peinture Observe cuando salga pintura

SPRAY / PULVERIZAÇÃO / PULVÉRISATION / PULVERISACIÓN 1→4

WARNING ADVERTÊNCIA

1234

MISE EN GARDE ADVERTENCIA

6 308867

Page 7

CLEAR CLOG / DESOBSTRUÇÃO / DÉCRASSEMENT / DESTAPAR

WARNING ADVERTÊNCIA

1 23

MISE EN GARDE ADVERTENCIA

CHANGE P AINT / TROCA DE TINTA / CHANGEMENT DE PEINTURE / CAMBIAR PINTURA

231

Flush

Descarga

Pressure Relief

Alívio de pressão

Vidange

Décharge de pression

Alivio de la presión

Enguaje

SHUTDOWN / DESATIVAÇÃO / ARRÊT / PARADA

WARNING ADVERTÊNCIA MISE EN GARDE ADVERTENCIA

Pressure Relief

Alívio de pressão

Décharge de pression

Alivio de la presión

2534

Prime

Preparação

Amorçage

Cebado

Flush

Descarga

Vidange Enguaje

FLUSH

DESCARGA

VIDANGE

ENJUAGUE

20 SEC.

Pressure Relief

Alívio de pressão

Décharge de pression

Alivio de la presión

7308867

Page 8

10 1 1 12

FLUSH

DESCARGA

SPOELEN

VIDANGE

RINÇAGE

ENJUAGUE

SPÜLUNG

14 16

Pressure Relief

Alívio de pressão

Décharge de pression

Alivio de la presión

19 20 21

Mineral Spirits Álcool mineral

Essence minérale

Alcohol mineral

Mineral Spirits

White spirit

Lösungsbenzin

Thinner

1715

20 SEC.

WASTE

RESÍDUOS

À JETER

DESECHO

8 308867

Page 9

Graco Standard W arranty Garantia Standard da Graco

Garantie standard de Graco Garantía estándar Graco

Graco warrants all equipment referenced in this document which is 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 W ARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED T O WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR 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, or any 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 W ARRANTIES OF MERCHANTABILITY AND FITNESS FOR A P ARTICULAR 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.

PARA CLIENTES BRASILEIROS DA GRACO

As partes confirmam que solicitaram que o presente documento, assim como todos os demais documentos, notas e processos legais inseridos, atribuídos ou instituídos de acordo com o mesmo ou relacionados direta ou indiretamente com o este documento, sejam redigidos em inglês.

AUX CLIENTS DE GRACO AU CANADA

Les parties conviennent avoir demandé que le présent document, ainsi que tout autre document, avis et procédures judiciaires inclus, donnés dans les présentes ou institués en vertu des présentes, ou en relation directe ou indirecte aux présentes, soient rédigés en anglais.

PARA CLIENTES DE GRACO EN COLOMBIA

Las partes reconocen que han solicitado que el presente documento, como asimismo todos los documentos, notificaciones y compromisos legales que se suscriban, presentados o instituidos por el presente o relacionados directa e indirectamente con éste, sean redactados en inglés.

ADDITIONAL WARRANTY COVERAGE / COBERTURA DE GARANTIA ADICIONAL / GARANTIE PROLONGÉE / COBERTURA ADICIONAL DE LA GARANTÍA /

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”. A Graco fornece prorrogação de garantia e garantia de desgaste para os produtos descritos no “Graco Contractor Equipment Warranty Program” (Programa de garantia de equipamento do empreiteiro da Graco). Graco n’offre pas de garantie prolongée ni de garantie contre l’usure pour les produits décrits dans le “Programme de garantie des équipements pour entrepreneur de Graco”. Graco ofrece una garantía extendida y una garantía de desgaste para los productos consignados en el “Programa de Garantía de Equipo Graco para Contratistas”.

TO PLACE AN ORDER OR FOR SERVICE

PARA EFETUAR ENCOMENDAS OU PARA ASSISTÊNCIA TÉCNICA

POUR PLACER UNE COMMANDE OU DEMANDER DU SERVICE

PARA REMITIR UN PEDIDO O SOLICITAR SERVICIO

, contact your Graco distributor.

, contate o seu distribuidor da Graco.

, contactez votre distributeur Graco.

, póngase en contacto con el distribuidor de Graco.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the

T odos os dados escritos e visuais contidos neste documento refletem as mais recentes informações sobre o produto disponíveis na época da

T oute information écrite et graphique incluse dans ce document reflète les caractéristiques les plus récentes des produits au moment d’aller sous

T oda la información escrita y visual contenida en este documento refleja la información de producto más reciente manejada al momento de la

publicação. A Graco reserva-se o direito de efetuar alterações em qualquer momento sem aviso prévio.

presse. Graco se réserve le droit d’apporter des modifications en tout temps sans avis.

publicación. Graco se reserva el derecho de introducir cambios en cualquier momento sin aviso.

Foreign Offices: Belgium, England, Korea, France, Germany, Hong Kong, Japan

Escritórios estrangeiros: Bélgica, Inglaterra, Coréia, França, Alemanha, Hong Kong, Japão

International: Belgique, Angleterre, Corée, France, Allemagne, Hong Kong, Japon

Oficinas internacionales: Bélgica, Inglaterra, Corea, Francia, Alemania, Hong Kong, Japón

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

right to make changes at any time without notice.

Sales Offices: Minneapolis, Detroit

Escritórios de Vendas: Minneapolis, Detroit

Bureaux des ventes: Minneapolis, Détroit

Oficina de ventas: Minneapolis, Detroit

http://www.graco.com

PRINTED IN USA 308867 November 1998, Revised March 1999

9308867

Page 10

INSTRUCTIONS-REPAIR

308868

KEEP FOR REFERENCE.

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

INSTRUCTIONS

GMaxr 3900 and 5900 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 RAC IV tip, gun and hose 232612 A Lo-Boy 232613 A Lo-Boy with RAC IV tip, gun and hose

GMax 5900

Model Series Description

232620 A Hi-Boy 232621 A Hi-Boy with RAC IV tip, gun and hose 232622 A Lo-Boy 232623 A Lo-Boy with RAC IV tip, gun and hose

Rev. A

First choice when

quality counts.

Model 232621

All models are not available in all countries

U.S. PATENT NO. 4,323,741; 4,397,610 PATENTED 1983, CANADA AND OTHER P ATENTS PENDING

8695A

Related Manuals

Operation 308867. . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump 308798. . . . . . . . . . . . . . . . .

Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . .

Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .

PC Board 308816. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Table of Contents

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

Parts

GMax 3900 & GMax 5900 Hi-Boy Sprayers 15. . . . .

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

GMax 3900 & GMax 5900 Lo-Boy Sprayers 18. . . . .

Complete Sprayers 20. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Graco Phone Number 23. . . . . . . . . . . . . . . . . . . . . . . . . .

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

Graco Inc. is registered to I.S. EN ISO 9001

Page 11

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 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:

Use outdoors or in an extremely well ventilated area. Do 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.

Remove, extinguish or unplug all ignition sources;

tape wall switch. Do not smoke in spray area.

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 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:

Working Pressu re

Never allow children to use this unit. If you are injured using this equipment, get immediate medical treatment.

Maximum

3088682

Page 12

Component Identification and Function

202Main hose 203Whip end hose 204Contractor gun with RAC IV

DripLess tip guard and 517 size SwitchTip

Fig. 1

W T

203

Model 232611

202

204

8696A

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

 

Page 13

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:

 are instructed to relieve the pressure,  stop spraying,  check or service any of the system equipment,  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,

loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose.

VERY SLOWLY

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.

3088684

Page 14

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 operates, but disp

placement pump does not operate

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 21. Tip or tip filter is clogged Clean tip or tip filter. Manual 307614. 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.

Clutch is worn, damaged, or incorrectly positioned

Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 9.

Reference control board diagnostics. Page 13.

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.

Check control board fuse. If blown, replace with equivalent automotive fuse.

Have pressure control checked by authorized Graco dealer.

Replace clutch. Page 9.

308868 5

Page 15

PROBLEM CAUSE SOLUTION

Pump output is low

Excessive paint leakage into throat packing nut

Strainer (31) is clogged Clean strainer 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. 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

Throat packing nut is loose Remove throat packing nut spacer. Tighten

Throat packings are worn or damaged Replace packings. Manual 308798.

Replace o-ring. Manual 308798.

Clean filter. Manual 308867 or 307614.

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).

throat packing nut just enough to stop leakage.

Fluid is spitting from gun

Pump is difficult to prime

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 307614. 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.



Page 16

Bearing Housing and Connecting Rod

NOTE: The item numbers referenced are for the

Hi-Boy models. The Lo-Boy models 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 displace-

ment pump outlet nipple (62).

5. Fig. 2. Use screwdriver to push up retaining spring

(26) at top of pump. Push out pin (29).

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.

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.

6. Refer to Displacement Pump, Installation, page 14.

D 22

12, 13

Oil

Pack with bearing grease 114819

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

Fig. 3

Model 232610 shown

8697A

308868 7

Page 17

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). Place silver colored washer (20h) on pins 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.

GMax 3900 only

Torque to 125 in-lb – GMax 3900 Torque to 200 in-lb – GMax 5900

Apply remaining grease to these areas

Fig. 4

20h

20g

8698A



Page 18

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 (Z).

7. Tap pinion shaft (A) out with plastic mallet.

1. Relieve pressure; page 4.

2. Disconnect field cable (X) from pressure control.

Bottom View

Fig. 5

8699A

3. Fig. 6. Remove five screws (10) and lockwashers

(17) and pinion assembly (19).

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).

Fig. 6

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.

Fig. 7

8701A

Fig. 9

8704A

308868 9

Page 19

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

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.

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 Nm).

Face of clutch housing

1.550 ±.010 in. (39.37 ±.25 mm); GMax 3900

1.812 ±.010 in. (46.02 ±.25 mm); GMax 5900

T orque to 125 ±.10 in-lb (14 ±1.1 Nm)

Fig. 11

03483

30886810

Page 20

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 Nm).

3. Install capscrew (15) from beneath mounting plate (D). Torque to 26 ft-lb (35.2 Nm).

Engine

Fig. 12

8708A

Removal

1. Remove Pinion Assembly/Rotor/Field/Pinion/ Clutch, Clamp and Clutch Housing, as in-

structed on pages 7, 9 and 10.

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.

T o the field

T o the engine

Green

Fig. 14

Installation

1. Lift engine carefully and place on cart.

8710A

Fig. 13

GMax 5900 only

Black

2. Fig. 14. Install two screws (70) in base of engine and secure with locknuts (71). Torque to 200 in-lb (22.6 Nm).

3. Fig. 13. Connect all necessary wiring.

8709A

4. Install Pinion Assembly/Rotor/Field/Pinion/ Clutch, Clamp and Clutch Housing, as

instructed on pages 8, 9 and 10.

308868 11

Page 21

On/Off Switch

Removal

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.



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



Pressure Control

Removal

2. Fig. 15. Remove five screws (307) and cover (322).

3. Fig. 22. Disconnect at control board (302):

 Four clutch leads: two violet and two black.  Lead (D) from potentiometer.  Lead (E) from transducer.

Relieve pressure; page 4.

E Locate switch terminals as shown

318z

Control Board

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):

 Two red leads (A) to ON/OFF switch (309).  Lead (E) to transducer.

318aa



 Two red leads (A) to ON/OFF switch (309).

4. Fig. 15. Remove five screws (303), green ground wire and control board (302).

30886812

 Lead (D) to potentiometer.  Four clutch leads: two violet and two black.

3. Fig. 15. Install cover (322) with five screws (307).

Page 22

Pressure Control Transducer

Removal

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.

Pressure Adjust Potentiometer

Removal

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.

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).

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) and have bottom of knob clear plate by .040 to .060 in.

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).

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 (GMax3900); 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 Replace clutch armature and rotor

308868 13

Page 23

Removal

Displacement Pump

1. Flush pump.

3. Fig. 16. Cycle pump with piston rod (222) in its lowest position.

4. Fig. 16. Remove suction tube (30) and hose (33).

Fig. 16

Relieve pressure; page 4.

222

7672B

Repair

5. Fig. 17. Use screwdriver: push retaining spring up and push out pin (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 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 Nm).

Fig. 20

Fig. 21. Fill packing nut with Graco TSL until fluid flows onto the top of seal.

7673B

1.5 in.

Fig. 19

30886814

7676B

Fig. 21

7677B

Page 24

Parts Drawing – GMax 3900 and GMax 5900 Hi-Boy Sprayers

Models 232610 and 232620

Ref 11

3 2

DETAIL A

49 35

DETAIL A

37 38

Ref 35

Label

See page 17 for the parts.

See manual 308798 for the parts.

See page 21 for the parts.

Used on GMax 5900, Model 232620 Used on GMax 3900, Model 232610

20h

68 26

20g

8699A

Bottom View

70 61

30 31

33(Ref) 53

54(Ref)

8712A

308868 15

Page 25

Parts List – GMax 3900 and GMax 5900 Hi-Boy Sprayers

Models 232610 and 232620

Ref No. Part No. Description Qty

1 ENGINE

108879 GMax 3900, Model 232610 1

114530 GMax 5900, Model 232620 1 2 1 13084 RIVET , blind 2 3 192014 PLATE, indicator 1 4 CLUTCH ASSEMBL Y ,

includes 4a, 4b, 16, 17, 80 241 109 GMax 3900, Model 232610 1 241 113 GMax 5900, Model 232620 1

4a .ARMA TURE, clutch, 4 in., 1

GMax 3900, Model 232610

.ARMA TURE, clutch, 5 in., 1

GMax 5900, Model 232620

4b .ROTOR

4 in., GMax 3900, Model 232610 1

5 in., GMax 5900, Model 232620 1

5 CLUTCH HOUSING

193540 GMax 3900, Model 232610 1 193531 GMax 5900, Model 232620 1

7 183401 KEY , parallel 1 8 193680 CLAMP 1 10 CAPSCREW , socket head, 1/4–20 x 3/4 in.

100644 GMax 3900, Model 232610 9 101864 GMax 5900, Model 232620 4

11 239998 CART HANDLE & HOSE RACK 1 12 106115 LOCKWASHER, spring, 3/8 in. 4 13 CAPSCREW , socket head,

107210 GMax 3900, Model 232610; 3/8–16 x 1.5 in. 4 114666 GMax 5900, Model 232620; 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, Model 232610 21 105510 GMax 5900, Model 232620 11

18 GEAR COMBINATION

241439 GMax 3900, Model 232610 1 241440 GMax 5900, Model 232620 1

19 PINION ASSEMBL Y; Parts, page 17

241 108 GMax 3900, Model 232610 1 241 112 GMax 5900, Model 232620 1

20 DRIVE HOUSING; Parts, page 17

241007 GMax 3900, Model 232610 1 24101 1 GMax 5900, Model 232620 1

21 BEARING HOUSING

240523 GMax 3900, Model 232610 1 241015 GMax 5900, Model 232620 1

22 CONNECTING ROD

241008 GMax 3900, Model 232610 1 241012 GMax 5900, Model 232620 1

23 COVER, HOUSING, DRIVE

179899 GMax 3900, Model 232610 1 241308 GMax 5900, Model 232620 1

26 SPRING, retaining

176817 GMax 3900, Model 232610 1 183169 GMax 5900, Model 232620 1

28 DISPLACEMENT PUMP

Parts, manual 308798 239923 GMax 3900, Model 232610 1 240291 GMax 5900, Model 232620 1

29 PIN, straight

176818 GMax 3900, Model 232610 1 183210 GMax 5900, Model 232620 1

30 TUBE, intake

192641 GMax 3900, Model 232610 1 193097 GMax 5900, Model 232620 1

Ref No. Part No. Description Qty

31 STRAINER

32 194194 CLIP , spring 1 33 240795 HOSE, coupled 1 34 NUT , retaining

35 CART FRAME

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, Model 232620 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, Model 232610 2

51 109032 SCREW, mch, pn hd; 6 53 164672 ADAPTER 2

54 194178 HOSE, drain 1 55 194125 LABEL, danger 1 56 194126 LABEL, warning 1 61 114678 BUSHING, strain relief 1 62 NIPPLE, 3/8–18 npsm(m) x 1/4 npt(m)

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

75 109031 SCREW, cap, sch 4 76 101864 SCREW, cap, sch 4 77 WASHER, lock, spring

78 114687 CLIP , retainer 1 80 HUB, armature 1 81 107218 SCREW 2 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 194195 DEFLECTOR 1 91 WASHER

92 114699 WASHER 1



181072 GMax 3900, Model, 232610 1 189920 GMax 5900, Model, 232620 1

192723 GMax 3900, Model 232610 1 193031 GMax 5900, Model 232620 1

240696 GMax 3900, Model 232610 1 240726 GMax 5900, Model 232620 1

192027 GMax 3900, Model 232610 2 191084 GMax 5900, Model 232620 2

106062 GMax 3900, Model 232610 2 17981 1 GMax 5900, Model 232620 2

193682 CAP , end; GMax 5900, Model 232620 2

GMax 3900, Model 232610 only

183461 GMax 3900, Model 232610 1 162485 GMax 5900, Model 232620 1

109031 GMax 3900, Model 232610 4 108842 GMax 5900, Model 232620 4

104008 GMax 3900, Model 232610 4 100214 GMax 5900, Model 232620 4

114672 GMax 3900, Model 232610 3 114672 GMax 5900, Model 232620 2

Danger & Warning labels, tags, and cards are free.

30886816

Page 26

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, Model 232610 1 241114 GMax 5900, Model 232620 1

19e* RETAINING RING, large

1 13094 GMax 3900, Model 232610 1 1 12770 GMax 5900, Model 232620 1

*Must be ordered separately ..

19e

19d

19b

10 (Ref)

17 (Ref)

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 ASSEMBL Y 20g* W ASHER

194173 GMax 3900, Model 232610 1 107089 GMax 5900, Model 232620 1

20h* WASHER

194172 GMax 3900, Model 232610 1 194411 GMax 5900, Model 232620 1

*Must be ordered separately ..

20h

20g

91 (Ref)

18 (Ref)

Only used on GMax 3900, Models 232610 and 232612

91 (Ref)

92 (Ref)

17 (Ref)

81 (Ref)

8715A

308868 17

Page 27

Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayers

Models 232612 and 232622

Ref 11

3 2

DETAIL A

37 38

Ref 35

Label

See page 17 for the parts.

See manual 308798 for the parts.

See page 21 for the parts.

Used on GMax 5900, Model 232622 only

Used on GMax 3900, Model 232612 only

20h

20g

Bottom View

8699A

26 29

35 47

30886818

30d

30b (Ref)

30aa

30a 30b 30e 30f

30ae

30ad

53 89

30c 30g

30ab

8713A

Page 28

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, Model 232612 1

114530 GMax 5900, Model 232622 1 2 1 13084 RIVET , blind 2 3 192014 PLATE, indicator 1 4 CLUTCH ASSEMBL Y ,

includes 4a, 4b, 16, 17, 80 241 109 GMax 3900, Model 232612 1 241 113 GMax 5900, Model 232622 1

4a .ARMA TURE, clutch, 4 in., 1

GMax 3900, Model 232612

.ARMA TURE, clutch, 5 in., 1

GMax 5900, Model 232622

4b .ROTOR

4 in., GMax 3900, Model 232612 1

5 in., GMax 5900, Model 232622 1

5 CLUTCH HOUSING

193540 GMax 3900, Model 232612 1 193531 GMax 5900, Model 232622 1

7 183401 KEY , parallel 1 8 193680 COLLAR, shaft 1 10 CAPSCREW , socket head, 1/4–20 x 3/4 in.

100644 GMax 3900, Model 232612 9 101864 GMax 5900, Model 232622 4

11 239998 CART HANDLE & HOSE RACK 1 12 106115 LOCKWASHER, spring, 3/8 in. 4 13 CAPSCREW , socket head,

107210 GMax 3900, Model 232612; 3/8–16 x 1.5 in. 4 114666 GMax 5900, Model 232622; 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, Model 232612 21 105510 GMax 5900, Model 232622 11

18 GEAR COMBINATION

241439 GMax 3900, Model 232612 1 241440 GMax 5900, Model 232622 1

19 PINION ASSEMBL Y; Parts, page 17

241 108 GMax 3900, Model 232612 1 241 112 GMax 5900, Model 232622 1

20 DRIVE HOUSING

241007 GMax 3900, Model 232612 1 24101 1 GMax 5900, Model 232622 1

21 BEARING HOUSING

240014 GMax 3900, Model 232612 1 240724 GMax 5900, Model 232622 1

22 CONNECTING ROD

241008 GMax 3900, Model 232612 1 241012 GMax 5900, Model 232622 1

23 COVER, HOUSING, DRIVE

179899 GMax 3900, Model 232612 1 241308 GMax 5900, Model 232622 1

26 SPRING, retaining

176817 GMax 3900, Model 232612 1 183169 GMax 5900, Model 232622 1

28 DISPLACEMENT PUMP , Manual 308798

239923 GMax 3900, Model 232612 1 240291 GMax 5900, Model 232622 1

29 PIN, straight

176818 GMax 3900, Model 232612 1 183210 GMax 5900, Model 232622 1

30 241287 ASSEMBLY, tube, suction 30a 241 124 .TUBE, suction, 5 gallon (20 liter) 1 30aa 240513 ..SWIVEL, tube, inlet 1 30ab 176450 ..GUARD, hose 1

Ref No. Part No. Description Qty

30ac 194306 ..HOSE, fluid 1 30ad 101818 ..CLAMP , hose 2 30ae 170957 ..TUBE, suction 1 30b 194180 .HOSE, drain 1 30c 194191 .CLIP , spring 1 30d 162453 .NIPPLE 1 30e 194195 .DEFLECTOR 1 30f 187147 .STRAINER 1 30g 144958 .STRAP, tie 1 33 240795 HOSE, coupled 1 34 NUT , retaining

35 CART FRAME

37 183350 WASHER, plain 2 38 110243 RING, retaining 2 39 108795 SCREW, mch, pn hd, 10–32 x 5/16 in. 6 40 SLEEVE

41 WHEEL, semi-pneumatic

42 101242 RING, retaining 2 43 104811 HUBCAP 2 44 154636 WASHER, GMax 5900, Model 232622 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, Model 232612 2

51 109032 SCREW, GMax 3900, Model 232612 only 6 52 100020 WASHER, GMax 3900, Model 232612 only 4 53 164672 ADAPTER 2 55 194125 LABEL, danger 1 56 194126 LABEL, warning 1 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

75 109031 SCREW, cap, sch 4 77 WASHER, lock, spring

78 114687 CLIP , retainer 1 80 HUB, armature 1 81 107218 SCREW 2 82 206994 THROAT SEAL LIQUID; not shown 1 87 240997 CONDUCTOR, ground 1 89 240131 PLUG, packless 1 89 Washer

92 114699 WASHER 1



192723 GMax 3900, Model 232612 1 193031 GMax 5900, Model 232622 1

240728 GMax 3900, Model 232612 1 240727 GMax 5900, Model 232622 1

192027 GMax 3900, Model 232612 2 191084 GMax 5900, Model 232622 2

106062 GMax 3900, Model 232612 2 17981 1 GMax 5900, Model 232622 2

193682 CAP , end; GMax 5900, Model 232622 2

183461 GMax 3900, Model 232612 1 162485 GMax 5900, Model 232622 1

109031 GMax 3900, Model 232612 4 108842 GMax 5900, Model 232622 4

104008 GMax 3900, Model 232612 4 100214 GMax 5900, Model 232622 4

114672 GMax 3900, Model 232612 3 114699 GMax 5900, Model 232622 2

Danger & Warning labels, tags, and cards are free.

308868 19

Page 29

Parts List & Drawing – Complete Sprayers

Models 232611, 232613, 232621, 232623

GMax 3900 and GMax 5900 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 15

232621 GM5900 Hi-Boy Sprayer 1

See parts list on page 15

232613 GM3900 Lo-Boy Sprayer 1

See parts list on page 19

232623 GM5900 Lo-Boy Sprayer 1

See parts list on page 19

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)

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

204 220955 CONTRACTOR SPRAY GUN

Includes RAC IV and 517–size SwitchTip See 307614 for parts 1

 DripLess Tip Guard

Accessories

202

204

203

0160

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 185956 Spanish 185961 German 186041 Greek 186045 Korean 186049 English 194125

Displacement Pump Repair Kits

Packing repair kits.

GMax 3900 239928 GMax 5900 240248

03497A

30886820

Page 30

Parts Drawing – Sprayer

GMax 3900 and 5900 Sprayers Models 232610 through 232613 and 232619

Models 232620 through 232623 and 232629

309

308

320

314 313

310 312

321

301

305

304

306

302

303 315

307

318f

304

318e

319

318d

318b

318c

318z

307

322

305

311

310

318aa

318a

318g

318h

318m

318n

318l

318j

318k

8716A

308868 21

Page 31

Parts List – Sprayer

Models 232610 through 232613 and 232619; 232620 through 232623 and 232629

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 1 311 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 240777 FILTER, fluid 1 318a 193651 HOUSING, filter 1 318b 104361 O-RING 1 318c 186075 SUPPORT, filter 1 318d 167025 STRAINER, mesh, 60 1

REF

NO. PART NO. DESCRIPTION QTY

318e 171941 SPRING, compression 1 318f 192706 BOWL, filter 1 318g 193710* SEAL, valve 1 318h 193709* SEAT, valve 1 318j 194102* HANDLE, valve 1 318k 1 14688* NUT, cap, hex hd 1 318l 114708* SPRING, compression 1 318m 114797* GASKET 1 318n 240914* VALVE 1 318z 240314 TRANSDUCER, pressure control 1

318aa111457 O-RING 1 319 110997 SCREW, flange, hex 3 320 114532 TIE, wire, twist 1

 189246 LABEL, warning 1

321 322 241444 COVER, pressure control 1

* Drain valve replacement kit 241276 available; includes

318g through 318n

 Replacement warning labels may be ordered free of charge

includes 318aa

309 (Ref)

304 (Ref)

Fig. 22

Green

Black

Red

Red (+)

Violet

Wiring Diagram

310

318z (Ref)

302 (Ref)

(Ref)

Potentiometer

Pressure transducer

318aa (Ref)

30886822

Page 32

Technical Data

PTFE

PTF

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 93 (25). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum delivery rating

GMax3900 1.15 gpm (4.4 liter/min). . . . . . . . . . . . .

GMax5900 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 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,

Viton, Delrin, leather, aluminum, tungsten car- bide,nickle-plated carbon steel, stainless steel, chrome plating

NOTE: Delrin, , Viton are trademarks

. . . . . . . . . . . . . .

, Nylon, polyurethane, UHMW polyethylene,

Model 232610

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). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 232620

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

Dimensions

GMax 3900

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). . . . . . . . . . . . . . . . . . . . . . . . . . . .

GMax 5900

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

1–800–690–2894 T oll Free

, contact your Graco distributor, or call this number to identify the distributor closest to you:

308868 23

Page 33

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 IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER W ARRANTIES, 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 , or any 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 wi ll 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.

Foreign Offices: Belgium, England, Korea, France, Germany , Hong Kong, Japan

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

30886824

Sales Offices: Minneapolis, Detroit

http://www.graco.com

PRINTED IN USA 308868 January 1999

Page 34

INSTRUCTIONS-PARTS LIST

308–798

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

Displacement Pump

3600 psi (250 bar, 24.8 MPa) Maximum Working Pressure

Model 239–923, Series A

Used in the Ultra Used in the GMax and GMx 3900 Sprayers

Model 240–291, Series A

Used in the Ultra Used in the GMax and GMx 5900 Sprayers Used in the GMax 10000 Sprayers

Max

and Ultimate

Max

and Ultimate

795 and 1095 Sprayers

1595 Sprayers

First choice when

quality counts.



Rev. G

Supercedes Rev. F

Model 240–917, Series A

Used in the GMax and GMx 7900 Sprayers

Model 240–800, Series A

Used in the GMax 5900HD and Mark V Sprayers

8016A

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

Graco Inc. is registered to I.S. EN ISO 9001

Page 35

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts, Pump

239–923 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

INSTRUCTIONS

 This equipment is for professional use only.

240–291 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240–217 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240–800 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number 20. . . . . . . . . . . . . . . . . . . . . . . . . .

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

 Read all instruction manuals, tags, and labels before operating the equipment.  Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.

 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.  Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 15 for the maximum working pressure of this equipment.

 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

 Do 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.

 Comply with all applicable local, state, and national fire, electrical, and safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

 Keep clear of all moving parts when starting or operating the pump.  Before servicing the equipment, follow the Pressure Relief Procedure on page 3 to prevent the

equipment from starting unexpectedly.

2 308-798

Page 36

Service

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

 are instructed to relieve the pressure,  stop spraying,  check or service any of the system equipment,  or install or clean the spray nozzle.

1. Engage gun safety latch.

2. Turn ON/OFF switch to OFF.

3. Unplug power cord.

4. Disengage gun safety latch. Hold metal part of gun against grounded metal pail and trigger gun into pail to relieve pressure.

Tools Needed

Vise 12 in. adjustable, open end wrench (2) Hammer, 20 oz maximum Small screwdriver Throat Seal Liquid Pick or long small screwdriver

Cleaning and Inspecting Parts

1. Clean and inspect parts. Pay particular attention to the ball seats in the intake valve and piston, which must have no nicks or wear, and to the inside of the sleeve and the outside of the piston rod, which must not be worn or scratched. Replace worn or damaged parts.

5. Engage gun safety latch.

6. Open any fluid drain valves in system. Leave drain valve open until ready to dispense again.

Pump Repair Kit

239–923 239–928 240–291 240–248 240–917 240–916 240–800 240–248

WARNING

COMPONENT RUPTURE HAZARD

Never use sharp or pointed tools to remove sleeve or other components

which could result in pump rupture and cause serious bodily injury. If the sleeve cannot be removed easily, return the sleeve and cylinder to your Graco distributor for removal.

2. Remove and clean the sleeve when you are repacking the pump.

3308-798

Page 37

Repair When Pump Is Off The Sprayer

Service

Disassembling the pump

Fig. 23. Remove packing nut (202) and throat adjustment spacer (228).

202 228

Fig. 25. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal.

227

Fig.

7570A

Fig. 26. Tap piston rod out of cylinder with a hammer or flip over and tap piston rod out against a bench.

Note: Sleeve may come out of cylinder with piston rod.

Fig. 23

Fig. 24. Unscrew intake valve from cylinder.

7568A

Fig. 26

Fig. 27. Remove piston rod from sleeve, or remove sleeve from cylinder.

7571a

Fig. 24

4 308-798

7569A

Fig. 27

7572A

Page 38

Service

WARNING

COMPONENT RUPTURE HAZARD

Do not clean or wipe the piston valve threads. Cleaning the piston valve

threads could destroy the special sealing patch and cause the piston valve to come loose during operation, causing pump bursting and possible serious bodily injury .

Fig. 28. Unscrew piston valve from piston rod. Clean and inspect parts. The piston has a special thread locking/sealing patch. Do not remove the patch. The patch allows four disassembly/assembly procedures before it is necessary to apply Loctite to the threads.

Fig. 30. Remove throat packings and glands from cylinder. Discard throat packings and glands.

Used on 240–291 240–800

240–917

Fig. 28

Fig. 29. Remove packings and glands from piston rod.

Used on 240–291 240–800

240–917

7576A

Fig. 30

Assembling the pump

Fig. 31. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (219) on piston rod. Alternately stack UHMWPE (208) and leather (218) packings (note orientation) on piston rod. Install female gland (217). Install backup washer (216) and u-cup (209) (note orientation) on piston valve (210). The special sealing patch on piston valve threads is good for four repackings. Use Loctite on piston valve threads after four repackings.

Used on 240–291 240–800

240–917

7573B

210 216

Fig. 29

7574B

Fig. 31

218

209

217

208219

7574B

5308-798

Page 39

Service

Fig. 32. Install ball (206) in piston rod. If Loctite is applied to piston valve threads, ensure that none gets on ball.

206

Fig. 32

7575A

Fig. 33. Tighten piston valve to piston rod as specified:

Torque to 32 "3 ft-lb

(239–923)

Torque to 40 "3 ft-lb (240–291, 240–800)

Fig. 34. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Place male gland (204) in cylinder. Alternately stack UHMWPE (203) and leather packings (223) (note orientation). Place female gland (224) in top of cylinder. Seat packings.

Used on

240–291

224

240–800

240–917

223

203

204

Fig. 34

7573B

Fig. 35. Install seal (201) into packing nut (202). Install throat adjustment spacer onto packing nut. Loosely install packing nut into cylinder.

Torque to 50 "5 ft-lb

(240–917)

Fig. 33

7576A

Fig. 35

201

202

7581A

6 308-798

Page 40

Service

Fig. 36. Grease piston packings and sleeve top edge.

Fig. 38. Grease top inch or two of piston rod that will go through the cylinder throat packings.

Fig. 38

7579A

Fig. 39. Grease o-ring (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylinder. Replace o-ring (207) if desired.

Note: O-ring (207) is not required for safe pump operation.

Fig. 36

7578A

Fig. 37. Carefully slide piston assembly into top of sleeve. Assure u-cup is not rolled over or damaged.

Fig. 37

7577A

Fig. 39

207

221

7582A

7308-798

Page 41

Service

Fig. 40. Reassemble intake valve with new o-ring (227), seat (212) and ball (214). Seat may be flipped over and used on other side. Clean seat thoroughly.

214 212 227

Fig. 40

Fig. 41. Install intake valve on cylinder. If a wrench is used torque as follows:

67"5 ft-lb (for model 239–923) 80"5 ft–lb (for models 240–291 & 240–800)

100"5 ft–lb (for model 240–917). If a wrench is not used, be sure intake valve is bottomed out against cylinder.

7570A

Fig. 42. Torque seal and packing nut (202) down onto throat nut spacer (228) to 100 "10 in-lb.

Remove throat nut spacer (228) when pump packings begin to leak after much use. Then tighten packing nut down until leakage stops or lessens. This allows approximately 100 gallons of additional operation before a repacking is required.

202 228

7568A

Fig. 42

Fig. 41

8 308-798

7569A

Page 42

Notes

9308-798

Page 43

Repair When Pump Is On The Sprayer

WARNING

INJECTION HAZARD

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief

Procedure on page 3.

Fig. 1. Remove intake valve.

Service

Fig. 2. Use screwdriver to push retaining spring up and push pin out.

Fig. 1

7673A

Fig. 2

Fig. 3. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal.

227

Fig. 3

7570A

7674A

10 308-798

Page 44

Service

Fig. 4. Remove piston rod and sleeve.

Fig. 4

7746A

Fig. 4. Invert piston rod and sleeve and pound on hard surface until piston rod comes out of sleeve.

Fig. 7. Invert piston rod and insert into cylinder to force out throat packings.

Fig. 5

Fig. 6. Remove packing nut (202)

Fig. 6

202

7572A

7726A

Fig. 7

Fig. 8. Insert piston rod into cylinder with pin hole up and piston valve down. Insert pin into piston rod and crank shaft.

7675A

Fig. 8

7747A

11308-798

Page 45

Service

Fig. 9. Remove piston valve from piston rod with a wrench.

Fig. 9

7748A

Fig. 11. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (204). Alternately stack UHMWPE (203) and leather (223) packings (note orientation). Install female gland (224). Install seal (201) and packing nut (202) and throat adjustment spacer (228).

224

Used on 240–291,

240–917 & 240–800

201

203

223

202 228

204

Fig. 10. Remove pin and piston rod from cylinder.

Fig. 10

7675A

7573B

7581A

Fig. 11

Fig. 12. Remove packings and glands from piston rod.

Used on 240–291 240–800

240–917

Fig. 12

7749B

12 308-798

Page 46

Service

Fig. 13. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (219) on piston rod. Alternately stack UHMWPE (208) and leather (218) packings (note orientation) on piston rod. Install female gland (217). Install backup washer (216) and u-cup (209) (note orientation) on piston valve (210). The special sealing patch on piston valve threads is good for four repackings. Use Loctite on piston valve threads after four repackings.

219

Used on 240–291 240–800

217

240–917

209

216

210

7749B

Fig. 13

218

208

Fig. 15. Grease piston packings and sleeve top edge.

Fig. 15

7578A

Fig. 16. Carefully slide piston assembly into top of sleeve. Assure u-cup is not rolled over or damaged.

Fig. 32. Install ball (206) in piston rod. If Loctite is applied to piston valve threads, ensure that none gets on ball. Install piston valve on piston rod. Torque as follows:

32 "3 ft-lb (for model 239–923) 40 "3 ft-lb (for model 240–291 & 240–800) 50 "5 ft-lb (for model 240–217)

206

Fig. 16

7577A

Fig. 17. Grease top inch or two of piston rod that will go through the cylinder throat packings.

Fig. 14

7575A

Fig. 17

7579A

13308-798

Page 47

Service

Fig. 18. Grease o-ring (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylinder. Replace o-ring (207) if desired.

Note: O-ring (207) is not required for safe pump operation.

Fig. 20. Push in pin.

Fig. 20

7675A

Fig. 21. Reassemble intake valve with new o-ring (227), seat (212) and ball (204). Seat may be flipped over and used on other side. Clean seat thoroughly.

204 212

207

221

Fig. 18

7750A

Fig. 19. Use screwdriver to push retaining spring up.

227

Fig. 21

Fig. 22. Install intake valve on cylinder. Wrench torque as follows:

67 "5 ft-lb (for model 239–923) 80 "5 ft-lb (for model 240–291 & 240–800) 100 "5 ft-lb (for model 240–917)

7570B

Fig. 19

14 308-798

7674A

Fig. 22

7678A

Page 48

Service

PTFE

Cross Sectional Reference

222

Leather

224 223

205

221 220

207 219

218

201

202 228

203 204

206

208

Pump 240–291 & 240–917

V-Maxt UHWMPE, blue

Pump 240–291 & 240–917

V-Maxt UHWMPE, blue

209 210

221 215

212 227

Fig 23

Technical Data

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . .

3600 psi (250 bar, 24.8 MPa)

Fluid inlet size

239–923 & 240–291 3/4 npt(f). . . . . . . . . . . . . . . . . . . .

240–917 & 240–800 1 npt(f). . . . . . . . . . . . . . . . . . . . . .

Fluid outlet size

239–923 1/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240–291, 240–217 & 240–800 3/8 npt(f). . . . . . . . . . .

217

216 214

213

7683B

Wetted parts stainless steel, R,. . . . . . . . . . . . . . .

leather, polyurethane, zinc-plated carbon steel,

tungsten carbide, chrome plating,

DelrinR, polyethylene

NOTE: DelrinR and R are registered trade- marks LoctiteR is a registered trademark of the Loctite Company.

15308-798

Page 49

Parts – Pump 239–923

PTFE

Model 239–923, Series A

Carbon Steel Displacement Pump

Ref No. Part No. Description Qty.

201* 179–810 SEAL, throat 1 202 193–046 NUT, packing 1 203* 192–692 V-PACKING, throat, 3

V-Max UHMWPE, blue 204* 178–942 GLAND, male, throat 1 205 240–522 CYLINDER, pump 1 206* 105–444 BALL, sst, 0.3125 in. 1 207* 114–054 PACKING, o-ring 1 208* 192–693 V-PACKING, piston 3

V-Max UHMWPE, blue 209* 107–093 SEAL, u-cup 1 210 239–932 VALVE, piston 1 212† 239–922 KIT, seat, carbide 1

includes 214 and 227 213 192–724 VALVE, intake (foot) 1 214*† 105–445 BALL, sst, 0.5000 in. 1 215 192–624 GUIDE, ball 1 216* 181–338 WASHER, backup 1 217* 178–969 GLAND, female, piston 1 218* 178–939 V-PACKING, leather, piston 2 219* 192–848 GLAND, male 1 220 240–521 SLEEVE, cylinder 1 221* 108–526 O-RING,  2 222 240–518 ROD, piston 1 223* 178–940 V–PACKING, leather, throat 2 224* 178–943 GLAND, female 1 227*† 107–079 PACKING, o-ring 1 228 192–714 SPACER, throat, nut 1

* These parts are also included in Repair Kit

239–928, which may be purchased separately.

†

These parts are also included in Carbide Seat Kit

239–922, which may be purchased separately.

*223

201*

202

228

224*

204*

205

207*

221*

220

203*

*208

†*214

†*227

221*

222

219*

218*

217*

209* 216*

206*

210

215

212†

213

16 308-798



Page 50

Parts – Pump 240–291

Model 240–291, Series A

Carbon Steel Displacement Pump

201*

Ref No. Part No. Description Qty.

201* 183–171 PLUG 1 202 193–032 NUT, packing 1 203* 193–124 V-PACKING 4

V-Max UHMWPE, blue 204* 183–176 GLAND, packing, male, throat 1 205 240–520 CYLINDER, pump 1 206* 101–947 BALL, sst, 0.3750 in. 1 207* 106–556 PACKING, o-ring 1 208* 193–125 V-PACKING, piston 4

V-Max UHMWPE, blue 209* 108–690 SEAL, u-cup 1 210 240–150 VALVE, piston 1 212† 193–028 SEAT, carbide 1

includes 214 and 227 213 193–030 HOUSING, intake (foot) 1 214*† 102–972 BALL, sst, 0.875 in. 1 215 193–027 GUIDE, ball 1 216* 186–653 WASHER, back–up 1 217* 183–185 GLAND, female, piston 1 218* 183–174 V-PACKING, leather, piston 3 219* 183–178 GLAND, packing, male 1 220 240–525 SLEEVE, cylinder 1 221* 107–098 PACKING, o–ring 2 222 240–517 ROD, piston 1 223* 183–175 V–PACKING, leather, throat 3 224* 183–177 GLAND, packing, female 1 227*† 108–526 PACKING, o-ring 1 228 193–127 SPACER, nut 1

* These parts are also included in Repair Kit

240–248, which may be purchased separately.

†

These parts are also included in Carbide Seat Kit

240–524, which may be purchased separately.

*203

202

228

224*

223*

204*

205

207*

221*

*218

†*214

†*227

221*

222

219*

208*

217* 209*

216*

206*

210

215

212†

213

220

7953A

17308-798

Page 51

Parts – Pump 240–917

Model 240–917, Series A

Carbon Steel Displacement Pump

Ref No. Part No. Description Qty.

201* 112–590 PLUG 1 202 189–589 NUT, packing 1 203* 193–722 V-PACKING 6

V-Max UHMWPE, blue 205 240–920 CYLINDER, pump 1 206* 107–203 BALL, sst, 0.3750 in. 1 207* 107–306 PACKING, o-ring 1 209* 112–589 SEAL, u-cup 1 210 240–580 VALVE, piston 1 212† 240–918 SEAT, carbide 1

includes 214 and 227 213 193–393 HOUSING, intake (foot) 1 214*† 107–167 BALL, sst, 0.875 in. 1 215 193–391 GUIDE, ball 1 216* 189–587 WASHER, back–up 1 217* 189–588 GLAND, female, piston 1 218* 112–591 V-PACKING, leather, piston 8 219* 189–585 GLAND, packing, male 2 220 240–921 SLEEVE, cylinder 1 221* 108–822 PACKING, o–ring 2 222 240–919 ROD, piston 1 224* 189–584 GLAND, packing, female 1 227*† 107–098 PACKING, o-ring 1 228 193–397 SPACER, nut 1

* These parts are also included in Repair Kit

240–916, which may be purchased separately.

*203

201*

202

228

224*

218*

219*

205

*218

221

222

219

203

217 209

216

206

210

215

†

These parts are also included in Carbide Seat Kit

240–918, which may be purchased separately.

207*

221*

220

†*214

212†

†*227

213

8557A

18 308-798

Page 52

Parts – Pump 240–800

Model 240–800, Series A

Carbon Steel Displacement Pump

Ref No. Part No. Description Qty.

201* 183–171 PLUG 1 202 193–032 NUT, packing 1 203* 193–124 V-PACKING 4

V-Max UHMWPE, blue 204* 183–176 GLAND, packing, male, throat 1 205 241–334 CYLINDER, pump 1 206* 101–947 BALL, sst, 0.3750 in. 1 207* 106–556 PACKING, o-ring 1 208* 193–125 V-PACKING, piston 4

V-Max UHMWPE, blue 209* 108–690 SEAL, u-cup 1 210 240–150 VALVE, piston 1 212† 193–028 SEAT, carbide 1

includes 214 and 227 213 194–326 HOUSING, intake (foot) 1 214*† 102–972 BALL, sst, 0.875 in. 1 215 193–027 GUIDE, ball 1 216* 186–653 WASHER, back–up 1 217* 183–185 GLAND, female, piston 1 218* 183–174 V-PACKING, leather, piston 3 219* 183–178 GLAND, packing, male 1 220 240–525 SLEEVE, cylinder 1 221* 107–098 PACKING, o–ring 2 222 241–285 ROD, piston 1 223* 183–175 V–PACKING, leather, throat 3 224* 183–177 GLAND, packing, female 1 227*† 108–526 PACKING, o-ring 1 228 193–127 SPACER, nut 1

* These parts are also included in Repair Kit

240–248, which may be purchased separately.

*203

201*

202

228

224*

223*

204*

222

205

207*

221*

*218

†*214

†*227

221*

222

219*

208*

217* 209*

216*

206*

210

215

212†

213

†

These parts are also included in Carbide Seat Kit

240–524, which may be purchased separately.

220



19308-798

Page 53

Graco Standard Warranty

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER W ARRANTIES, 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 , or any 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 MERCHANT ABILITY 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.

FOR GRACO CANADA CUSTOMERS

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”.

Graco Phone Number

TO PLACE AN ORDER

1–800–690–2894 T oll Free

, contact your Graco distributor, or call this number to identify the distributor closest to you:

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.

Sales Offices: Minneapolis, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, France, Germany , Hong Kong, Japan

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

PRINTED IN U.S.A. 308–798 November 1997, Revised January 1999

20 308-798

http://www.graco.com

Page 54

INSTRUCTIONS-PARTS LIST

307–614

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

First choice when

quality counts.

Contractor Airless Spray Gun

3600 psi (252 bar , 25.2 MPa) MAXIMUM WORKING PRESSURE

Model 220–955, Series D

Includes RACr DripLesst Guard, 517 size SwitchTipt, and 2 finger trigger. Four finger trigger is optional; see parts list.

Model 235–990, Series C

Includes the Standard (non-reversing) DripLesst Tip Guard and 4-finger trigger. Spray tip not included. Order separately.

Model 217–593, Series E

Includes the Standard (non-reversing) DripLesst Tip Guard. Spray tip not included. Order separately.

Rev. P

Supersedes N

Model 820–165, Series D

Includes RACr DripLesst Guard, 517 size SwitchTipt, and 2 finger trigger. Four finger trigger is optional; see parts list.

Patents Pending



Models 220–955, 820–165



Model 217–593

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

http://www.graco.com

Graco Inc. is registered to I.S. EN ISO 9001

Page 55

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation/Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

System Requirements 5. . . . . . . . . . . . . . . . . . . . . . . . . .

How to Use the Trigger Safety Latch 5. . . . . . . . . . . . .

How to Use the Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Adjust the Spray Pattern 6. . . . . . . . . . . . . . . . . .

How to Clean the Spray Tip

and Clear a Spray Tip Obstruction 7. . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

WARNINGWARNING

FIRE AND EXPLOSION HAZARD

How to Clean the Filter 8. . . . . . . . . . . . . . . . . . . . . . . . . .

Service 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Drawing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Numbers 15. . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.

 If there is any static sparking or you feel an electric shock while using this equipment, stop

spraying immediately. Do not use the equipment until you identify and correct the problem.

 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed.

 Keep the spray area free of debris, including solvent, rags, and gasoline.  Electrically disconnect all equipment in the spray area.  Extinguish all open flames or pilot lights in the spray area.  Do not smoke in the spray area.  Do not turn on or off any light switch in the spray area while operating or if fumes are present.  Do not operate a gasoline engine in the spray area.  Ground the equipment and the object being sprayed. See Grounding on page 5.

2 307-614

Page 56

WARNINGWARNING

INJECTION HAZARD

Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury.

 Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious

injury. Get immediate medical attention.

 Do not point the gun at anyone or at any part of the body.  Do not put your hand or fingers over the spray tip.  Do not stop or deflect leaks with your hand, body, glove or rag.  Do not “blow back” fluid; this is not an air spray system.  Always have the tip guard and the trigger guard on the gun when spraying.  Check the gun diffuser operation weekly. Refer to the gun manual.  Be sure the gun trigger safety operates before spraying.  Lock the gun trigger safety when you stop spraying.  Follow the Pressure Relief Procedure on page 5 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

 Tighten all fluid connections before operating the equipment.  Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do

not repair high pressure couplings; you must replace the entire hose.

 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by

kinks or bends near the couplings.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

 Know the specific hazards of the fluid you are using.  Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

 Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid

and solvent manufacturer.

RECOIL HAZARD

Due to the high pressure fluid emitted, a strong recoil action may occur when you trigger this gun. If you are unprepared, your hand could be forced back toward your body or you could lose your balance and fall, resulting in serious injury.

307-614 3

Page 57

INSTRUCTIONS

WARNINGWARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

 This equipment is for professional use only.  Read all instruction manuals, tags, and labels before operating the equipment.  Use the equipment only for its intended purpose. If you are uncertain about usage, call your

Graco distributor.

 Do not alter or modify this equipment.  Check equipment daily. Repair or replace worn or damaged parts immediately.  Do not exceed the maximum working pressure of the lowest rated system component. Refer to

the Technical Data on page 15 for the maximum working pressure of this equipment.

 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the

Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

 Do 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.

 Do not use hoses to pull equipment.  Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-

pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).  Do not lift pressurized equipment.  Comply with all applicable local, state, and national fire, electrical, and safety regulations.  Wear ear protection when operating this equipment.

4 307-614

Page 58

System Requirements

Installation/Operation

WARNING

Keep the wallet-sized warning card provided with this gun with the operator at all times. The card contains important treatment information should an injection injury occur. Additional cards are available at no charge from Graco Inc.

WARNING

Be sure your system has a bleed-type master air valve (pneumatic pumps only) and a pressure drain valve. These accessories help reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, if you are adjusting or repairing the pump or gun.

1. The bleed-type master air valve (air-powered pumps only) relieves air trapped between this valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly.

2. The pressure drain valve assists in relieving fluid pressure in the displacement pump, hose and gun: triggering the gun to relieve pressure may not be sufficient.

3. Strain the fluid you are spraying if it contains particles which could clog the spray tip.

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:

 are instructed to relieve the pressure,  stop spraying,  check or service any of the system equipment,  or install or clean the spray tip.

Pressure Relief Procedure

1. Engage the gun safety latch.

2. Turn the ON/OFF switch to OFF.

3. Unplug the power supply cord.

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

5. Engage the gun safety latch.

6. Open the system pressure drain valve. Leave the pressure drain valve open until you are 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

en the tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

, VERY SLOWLY loos-

Grounding

To reduce the risk of static sparking, ground the sprayer and all other spray equipment used or located in the spray area. Check your local electrical code for detailed grounding instructions for your area and type of equipment.

How to Use the Gun Trigger Safety

1. To engage the gun trigger safety, turn the latch to a right angle with the gun body. See Fig. 1.

2. To disengage the gun trigger safety, push the latch out and turn it parallel with the gun body.

ENGAGED

DISENGAGED



Fig. 1

307-614 5

Page 59

Installation/Operation

How to Use the Gun

1. Connect a grounded fluid hose to the gun inlet. See Fig. 2

2. With no tip installed, start the pump. Flush the pump according to the instructions supplied with it. Prime the system with the fluid.

3. Follow the Pressure Relief Procedure on page 5. Be sure the gun trigger safety is locked. See Fig. 1.

4. Models 217–593 & 235–990: unscrew the tip guard (3) and install the tip (A) and the gasket (2) in the nut of the tip guard. Screw the assembly firmly onto the gun. Tighten the assembly with a wrench. See Fig. 2.

NOTE: If the gasket (2) is not installed, the gun will leak.

5. Models 220–955 and 820–165: install the SwitchTip (40) and the tip guard (41). See manual 307–848, supplied. See Fig. 2.

7. If adjusting the pressure does not give a good spray pattern, follow the Pressure Relief Proce- dure on page 5 and then try another tip size.

8. Use a full-open, full-close triggering action. Hold the gun about 14 in. (350 mm) from and at right angles to the work surface. Don’t swing the gun in an arc. Practice to find the best length and speed of stroke.

How to Adjust the Spray Pattern

1. To adjust the spray pattern direction, follow the Pressure Relief Procedure on page 5. Loosen the tip guard retaining nut (B). Turn the tip guard/ tip groove horizontally (C) for a horizontal pattern and vertically (A) for a vertical pattern. Tighten the nut.

2. The spray tip orifice and spray angle determines the coverage and size of pattern. When more coverage is needed, use a larger spray tip rather than increasing fluid pressure.

Fig. 2

6. Start the pump. Adjust the fluid pressure until the spray is completely atomized. Use the lowest pressure necessary to get the desired results. Higher pressure may not improve the spray pattern and will cause premature tip wear and pump wear.



CAUTION

The openings in the tip guard reduce paint buildup on the tip guard while spraying. Any damage to the sharp edges of the openings causes paint to collect at that area. Never hang the gun by the tip guard.

KEY

A Tip guard shown in position for

vertical spray pattern B Retaining nut C Tip guard shown in position for

horizontal spray pattern

Fig. 3



6 307-614

Page 60

Installation/Operation

How to Clean the Spray Tip and Clear a Spray Tip Obstruction

WARNING

To reduce the risk of fluid injection or splashing in the eyes or on the skin, do not hold a hand, body or rag in front of the spray tip when cleaning or checking a clogged tip. Point the gun toward the ground or into a waste container when checking to see if the spray tip is cleared.

DO NOT try to “blow back” paint; this is NOT an air spray gun.

DO NOT wipe fluid buildup off the gun or spray tip until pressure is relieved.

Cleaning during the day.

1. Follow Pressure Relief Procedure on page 5.

2. Clean the front of the tip frequently during the day to help reduce buildup. Also clean the tip and tip guard at the end of each work day. Use a solventsoaked brush to clean the spray tip.

2. Remove the spray tip and blow out the obstruction by applying air to the front of the spray tip. Or, let the spray tip and gun nozzle soak to dissolve the obstruction. If it won’t dissolve, jar it out by tapping the back of the spray tip against a flat surface.

Gun 220–955 & 820–165 – with RAC guard

1. Lock the gun trigger safety. Rotate the RAC guard handle 180. See Fig. 4.

2. Unlock the gun trigger safety. Trigger the gun into a pail or onto the ground to remove the clog.

3. Lock the gun trigger safety. Rotate the tip handle to the spraying position.

4. If the tip is still clogged, lock the gun trigger safety, shut off the sprayer and disconnect the power source, and open the pressure drain valve to relieve pressure. Clean the spray tip as shown in manual 307–848, supplied with the RAC guard.

Clearing an obstruction.

If the spray tip clogs while spraying, immediately stop spraying, then:

Gun 217–593 & 235–990 – with standard tip guard

1. Lock the gun trigger safety, open the pressure drain valve.

CAUTION

Never soak the entire gun in solvent. Prolonged exposure to solvent can ruin the packings.

KEY

A Handle shown in spraying

position. Turn handle 180 and trigger gun to clear clog.

Fig. 4

7659A

307-614 7

Page 61

Installation/Operation

How to Check the Gun Diffuser Operation

Check the diffuser operation weekly. The gun diffuser/ seat (A) breaks up spray and reduces the risk of fluid injection when the tip is not installed. Perform the test below. If it fails, replace the entire Needle Kit, Part No. 218–070, as instructed on page 7. Diffuser/seats are not sold separately since the gun will leak if an old needle is used with a new diffuser/seat.

1. Follow Pressure Relief Procedure on page 5.

2. Remove the tip guard and spray tip.

3. Start the sprayer and adjust it to the lowest pressure.

4. Aim the gun into a grounded metal pail while holding it firmly to the pail. Trigger the gun. If the fluid emitted stream, replace the entire needle kit immediately. See Fig. 5.

is not

diffused into an irregular

How to Clean the Filter (See Fig. 6.)

Normal daily system flushing removes most buildup on the filter (17). For a weekly cleaning:

1. Follow Pressure Relief Procedure on page 5.

5. Apply lithium-base grease to the threads of the fluid tube (19) and reassemble the gun.

Fig. 5

2. Remove the screw (14).

3. Push up on the trigger guard (12) and swing it away from the trigger (5).

4. Unscrew the gun handle from the housing (26). Remove the filter and clean it in compatible solvent.

Fig. 6



8 307-614

Page 62

How to Flush the Gun

WARNING

Installation/Operation

Always flush the pump and the gun before the fluid being sprayed can dry in it.

To reduce the risk of serious bodily injury, including splashing fluid in the eyes or on the skin, or static electric

discharge when flushing:  Be sure the entire system, including flushing

pails, are properly grounded.

 Remove the tip guard and spray tip.  Maintain metal to metal contact between the

gun and the flushing pail.

 Use the lowest possible pressure.

NOTE: If it is available, the flushing procedure provided in your pump or sprayer manual should be used instead of this procedure.

1. Follow Pressure Relief Procedure on page 5.

2. Remove the tip guard and spray tip. Soak and clean the parts.

3. Put the pump intake in a grounded pail of water or solvent.

4. Start the pump at its lowest pressure.

5. Trigger the gun into the original pail. When solvent appears, release the trigger.

6. Now trigger the gun into the solvent pail. Circulate the fluid until the system is thoroughly flushed.

7. Follow Pressure Relief Procedure on page 5.

307-614 9

Page 63

Service

Torque to 20-25 ft-lb

(27-34 N.m)

Torque to 80–90 in-lb

01706

(9–10 N.m)

Fig. 7

NOTE: The needle (C), diffuser/seat (A), gasket (B)

and locknut (D) must be replaced together. They are included in Kit 218–070.

Disassembly (See Fig 7 )

1. Follow the Pressure Relief Procedure on page

2. Remove the tip guard assembly. See Fig 2.

3. Squeeze the trigger while unscrewing the diffuser/ seat (A) and gasket (B).

4. If the gun handle (6) was removed, hand tighten it into the fluid housing (26); it should fit easily. Only if necessary, loosen the setscrew (4), align the handle with the fluid housing and torque the setscrew to 80–90 in-lb (9–10 N.m).

5. Adjust the needle before using the gun. Procedure below.

6. Be sure the trigger guard and tip guard are installed before using the gun.

Adjusting the needle (See Fig 8)

1. Engage the gun safety latch.

2. Hold the gun with the nozzle straight up so the trigger falls onto the safety latch.

3. With light pressure, hold the trigger against the latch. Turn the locknut (D) clockwise until there is enough tension for you to feel raise slightly off the latch.

4. Turn the adjusting nut 3/4 turn

5. Connect the fluid hose. Install the tip guard and prime the system. Trigger the gun and release it. The fluid flow should stop immediately. Engage the safety latch and try to trigger the gun. No fluid should flow. If the gun fails either test, relieve pressure, disconnect the hose and readjust the needle.

and

see the trigger

counterclockwise.

4. Remove the locknut (D) and end cap (23).

5. Tap the rear of the gun with a plastic mallet to push the needle assembly out the front.

Reassembly (See Fig 7)

1. Guide the threaded end of the needle assembly into the front of the gun.

2. Install the end cap, aligning its guides with the holes in the rear of the gun. Install the locknut (D) loosely.

3. Squeeze the trigger while installing the gasket (B) and diffuser/seat (A). Torque the diffuser seat to 20–25 ft-lb (27–34 N.m).

Engage trigger

safety latch Arrows indicate

clockwise turn

Fig 8

01705

10 307-614

Page 64

Notes

307-614 11

Page 65

Model 220–955, Series D

Includes items 1 and 4 to 41

Model 235–990, Series C

Includes items 1 to 39

Model 217–593, Series E

Includes items 1 to 39

Model 820–165, Series D

Includes items 1 to 39

Parts Drawing

Included with 1

31 22

40

41

2



Purchase separately





12 307-614

Page 66

Parts List

Model 220–955, Series D; Model 235–990, Series C; Model 217–593, Series E; Model 820–165, Series D

Ref. No. Part No. Description Qty .

1 218–070 NEEDLE–DIFFUSER/SEAT KIT 1 2 166–969 GASKET, 3 220–251 TIP GUARD 1 4 100–421 SETSCREW , soc hd, 5/16–18 x 3/8” 1 5 179–734 2 FINGER TRIGGER (standard) 1 5a 179–943 4 FINGER TRIGGER

(Model 235–990 only) 1

6 218–643 GUN HANDLE ASSEMBL Y

includes replaceable items 4, 13, 14 1

10 172–479 INSTRUCTION TAG 1 11 179–761 WARNING TAG 1 12 190–972 TRIGGER GUARD 1 13 179–730 GUARD RETAINER 1 14 109–575 SCREW 15 218–021 SWIVEL 1 16 179–750 SPRING RETAINER 1 17 218–131 FLUID FIL TER ASSEMBLY

(standard 50 mesh) includes replaceable items 16, 18, 20, 21 1

17a 218–133 FLUID FIL TER ASSEMBLY

(optional 100 mesh) includes replaceable items 16, 18a, 20, 21a 1

18 179–731 STRAINER ELEMENT

(standard 50 mesh) 1

18a 179–732 STRAINER ELEMENT

(optional 100 mesh) 1

tip (used with flat tips only) 1

, 8–32 x 5/16” 1

Ref. No. Part No. Description Qty.

19 179–721 FLUID TUBE 1 20 179–763 SPRING 1 21 179–722 SPRING RETAINER

(for standard 50 mesh filter) 1

21a 179–957 SPRING RET AINER (color coded orange)

(for optional 100 mesh filter) 1

22 179–733 GASKET 1 23 191–244 END CAP 1 26 179–718 FLUID HOUSING 1 31 105–334 LOCKNUT; M4 x 0.7 thread 1 32 177–538 TRIGGER STUD 1 33 179–737 ACTUATOR PIN 2 37 179–729 NEEDLE HOUSING 1 39 222–385 WARNING CARD (not shown) 1 40 221–517 SWITCHTIP SPRA Y TIP, 41 237–859 RAC DripLess GUARD

See manual 307–644 for parts 1



Replacement Danger and Warning labels, tags and

(color coded blue)

SZ 517 1

cards are available at no cost.



Keep these spare parts on hand to reduce down time.

307-614 13

Page 67

Accessories

FILTERS

3000 psi (210 bar, 21 MPa) Maximum Working Pressure.

Adequate filtering is important for a good surface finish and to minimize tip clogging. These filters provide secondary filtering. Elements are available in various mesh sizes.

Mounts in hose 213–068 Includes filter body, spring and one

100 mesh screen.

213–069 Includes filter spring and one

60 mesh screen. Use with above filter body.

210–742 Includes filter spring and one

100 mesh screen. Use with above filter body.

210–729 Includes assembly 213–068 plus a

3 ft (0.9 m) whip hose for more flexible gun movement.

Standard filter elements

224–455 Two, 50 mesh filters (179–731) 224–456 Two, 100 mesh filters (179–732)

Mounts between hose and gun 210–500 Includes swivel, adapter and one

60 mesh screen

Replacement elements for above filters

SWIVELS and WHIP HOSES

Swivels and whip hoses provide more flexible gun movement for easier handling and less fatigue. Working pressures are listed in the descriptions.

214–925 Swivel, 1/4 npsm x 3/8 npt(f)

5000 psi (350 bar, 35 MPa) Max. Working Pressure

207–946 Swivel, 1/2 npsm x 3/8 npt(f)

5000 psi (350 bar, 35 MPa) Max. Working Pressure

204–940 Swivel, 1/4 npt x 1/4 npsm

3000 psi (210 bar, 21 MPa) Max. Working Pressure

214–701 Whip hose, nylon, coupled 1/4 npsm(f)

x 3/8 npt(m), spring guards both ends.

3000 psi (210 bar, 21 MPa) Max. Working Pressure

TIP GUARDS

These tip guards fit all Graco airless spray guns. Choose the one that’s right for your application. One of these tip guards is included with every Graco airless gun.

237–859 Performance Series Reverse–A–Clean

DripLesst Guard. Order SwitchTip separately. See your distributor for available sizes.

210–731 Three 60 mesh (250 micron) screens 210–732 Three 100 mesh (149 micron) screens 210–733 Three 200 mesh (74 micron) screens

TOOLS

Nylon Brushes

Use to thoroughly clean the gun’s fluid passages.

101–891 0.375” (9 mm) dia. 101–892 0.625” (16 mm) dia.

Wrench 171–147

Fits all hexes on the gun.

14 307-614

220–251 Standard DripLesst Tip Guard. Order

flat tip separately. See your distributor for available sizes.

222–674 Heavy Duty RACR DripLesst Tip Guard.

Order SwitchTip separately. See your distributor for available sizes.

Page 68

Technical Data

PTFE

Graco Phone

Maximum Working Pressure 3600 psi . . . . . . . . . . . . . .

(252 bar, 25.2 MPa)

Fluid Orifice Size 0.125 in. (3.18 mm). . . . . . . . . . . . . . .

Wetted Parts Stainless steel, Polyethylene,. . . . . . . . .

Polyurethane, Nylon, 

Weight 18 oz. (510 g). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inlet 1/4 npsm(m)swivel. . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Material Temperature 120F(50C). . . . . . .

Sound Data

Sound Pressure Level 78 dB(A)*. . . . . . . . . . . . . . . .

Sound Power Level 87 dB(A)*. . . . . . . . . . . . . . . . . . .

* Measured while spraying waterbase paint – gravity

1.36 through a 517 tip at 3,000 psi (207 bar). Per ISO 3744

 is a registered trademark

Number

TO PLACE AN ORDER

utor, or call this number to identify the distributor closest to you: 1–800–328–0211 Toll Free.

, contact your Graco distrib-

Manual Change

Summary

Changed Revision level of manual from N to P.

307-614 15

Page 69

Graco Warranty

Graco warrants all equipment listed in this manual which is 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 or structures, accessories, equipment or materials not supplied by Graco.

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 , or any 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 MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT , MA TERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,

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.

LIMITATION OF LIABILITY

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”.

All information, illustrations and specifications in this document are based on the latest product information available at the time

of publication. The right is reserved to make changes at any time without notice.

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany , Hong Kong, Japan

Sales Offices: Atlanta, Chicago, Detroit, Los Angeles

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

http://www.graco.com

PRINTED IN U.S.A. 307–614 May 1983, Revised August 1997

16 307-614

Page 70

INSTRUCTIONS-PARTS LIST

308–644

Rev. B

INSTRUCTIONS

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

First choice when

quality counts.



Supercedes Rev. A



Reverse-A-Clean Dripless Guard

4050 psi (279 bar) Maximum Working Pressure

Model 237–859, Series A

 Patented aerodynamic design virtually eliminates paint buildup,

dipping, and spitting.

 Fits all Graco Airless Spray Guns.  Must purchase Switch Tip spray tip separately.

WARNING

Pressure Relief Procedure

To reduce the risk of fluid injection or splashing in the eyes or on the skin, completely relieve air and fluid pressure before installing, cleaning or changing tips. To relieve pressure:

Shut off power to pump, hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure. ENGAGE TRIGGER SAFETY LATCH. Open any fluid drain valves. If you susĆ pect pressure is not fully relieved, slowly loosen tip guard retaining nut and relieve pressure gradually.

Failure to install or use the PS RAC tip guard assembly correctly may result in an undirected spray of paint into the eyes or on the skin of the operator. Be sure you:

 Use the appropriate gasket for the solvent

used (see the other side of this sheet).

 Fully insert the SwitchTip spray tip into the guard.  Fully tighten the guard onto the gun nozzle

using a wrench.

 Turn the SwitchTip handle so it is parallel to

the gun nozzle. See Fig. 24.

 When replacing a worn spray tip, always

install a new gasket and seat.

WARNING

RAC

TIP GUARD

Fig. 24

GUN NOZZLE

SwitchTip HANDLE

FULL CLEAN POSITIONFULL SPRAY POSITION

YES YES NO

ac237–859

Page 71

RAC TIP GUARD ASSEMBLY

WARNING

To reduce the risk of fluid splashback into the eyes or on the skin:

USE THE BLACK RUBBER GASKET ONL Y with latex and oil-based paints, stoddard solvents, mineral spirits, turpentine and water. NEVER use it with any other solvents.

USE THE YELLOW PLASTIC GASKET with the same solvents as the black rubber gasket and with lacquer thinner, trichloroethylene, MEK, acetone, brush cleaner, xylol and any unknown solvents.

A black and a yellow gasket are supplied with each SwitchTip. The solvent you use determines which gasket to use with the PS RAC. The new flat-backed seat accepts either gasket. See Fig 26.

Fig.

OPERATION

WARNING

Keep clear of nozzle! High pressure fluid from leaks or spray can penetrate the skin and cause extremely serious bodily injury , including the need for amputation. The tip guard provides extra protection against injection,

but does not prevent it!

NEVER cut off the tip guard!

When to Use the Black Rubber Gasket

The black rubber gasket is for use ONL Y with latex and oil-based paints, stoddard solvents, mineral spirits, turpentine and water. When using this gasket, the SwitchT ip can be removed and replaced without using tools.

When to Use the Yellow Plastic Gasket

The yellow plastic gasket can be used with the same fluids as the rubber gasket AND most solvents. When using this gasket, you must loosen the PS RAC retaining nut to remove the SwitchTip.

INSTALLATION

W ARNING

Always follow the Pressure Relief Procedure Warning on the front cover of this form before installing, cleaning or changing spray tips.

Install a SwitchTip spray tip in the tip guard. The flange on the cylinder fits into the slots at the base of the tip guard.

Place the seat on the end of a pencil, curved side out. Guide the seat into the retaining nut and turn until it straddles the cylinder. See Fig 2. Drop in the appropriate gasket and press it down. If using the yellow gasket, be sure the flat side faces out. See Fig 1.

Screw the PS RAC snugly onto the gun, holding the tip guard in the desired position while tightening the nut.

CAUTION

The openings in the tip guard are designed to reduce paint buildup on the guard while sparaying. Any damage to the sharp edges of the tip guard openings causes paint to collect at that area, To reduce the risk of damage, do not hang the gun by the tip guard.

Be sure the SwitchTip handle is in the FULL SPRAY position before operating the gun.

If the spray tip clogs while spraying, engage the gun safety latch. Turn the arrow handle to the FULL CLEAN position. Disengage the safety latch and trigger the gun into a grounded metal pail. Fluid pressure should force out the clog. Engage the safety latch and return the arrow handle to the full spray position. Relief Procedure Warning on the front of this form and remove the SwitchTip for cleaning.

MAINTENANCE

Change the seat and gasket whenever a SwitchTip wears out. These parts wear at about the same rate.

If it is still clogged

Retaining Nut

, follow the Pressure

FlatĆBacked Seat

Yellow Plastic Gasket

Seat

Black Rubber Gasket

CAUTION

NEVER use a wrench to turn the plastic tip guard, to avoid damage to the guard.

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

Graco Inc. is registered to I.S. EN ISO 9001

18308-644

221-XXX SwitchTip Spray Tip

Fig. 26

Page 72

AV AILABLE TIPS

Switch Tip use only in the RAC IV Dripless Guard and Performance Series RAC Dripless Guard.

Orifice Size

Inch gpm (lpm) 2.0–4.0

0.007 .053 (.20) 221–207 221–307

0.009 .087 (.33) 221–209 221–309 221–409 221–509 221–609

0.01 1 .13 (.49) 221–1 1 1 221–21 1 221–31 1 221–41 1 221–51 1 221–61 1

0.013 .18 (.69) 221–203 221–213 221–313 221–413 221–513 221–613

0.015 .24 (.91) 221–1 15 221–215 221–315 221–415 221–515 221–615 221–815

0.017 .31 (1.17) 221–217 221–317 221–417 221–517 221–617 221–817 221–917

0.019 .39 (1.47) 221–201 221–219 221–319 221–419 221–519 221–619 221–819

0.021 .47 (1.79) 221–221 221–321 221–421 221–521 221–621 221–721 221–821

0.023 .57 (2.15) 221–223 221–323 221–423 221–523 221–623 221–723

0.025 .67 (2.54) 221–225 221–325 221–425 221–525 221–625 221–725

0.027 .78 (2.96) 221–327 221–427 221–527 221–627 221–827

0.029 .90 (3.42) 221–429 221–529 221–629 221–729

0.031 1.03 (3.90) 221–331 221–431 221–531 221–631 221–831

0.033 1.17 (4.42) 221–433 221–533 221–633 221–833

0.035 1.31 (4.96) 221–235 221–435 221–535 221–635 221–735 221–835 221–935

0.037 1.47 (5.56)

0.039 1.63 (6.18) 221–439

0.041 1.80 (6.83)

0.043 1.99 (7.51) 221–443 221–543

0.045 2.17 (8.23) 221–645

0.047 2.37 (8.98)

0.049 2.58 (9.75)

0.051 2.79 (10.57) 221–451 221–551

0.053 3.01 (11.41)

0.055 3.21 (12.29) 221–455 221–555 221–655

0.057 3.49 (13.2)

0.059 3.74 (14.14)

0.061 3.99 (15.12)

0.063 4.26 (16.13) 221–563

0.065 4.53 (17.17) 221–665 Note:

* Flow rate established with water at 2000 psi (138 bar) at the tip. ** Pattern length (Fan Width) established by spraying the solvent base enamel with viscosity set at 20 seconds. Zahn #4 and pressure set at 1600

psi (110 bar) at the tip. The distance between the tip and the target surface is 12.0 inch (305 mm).

Flow Rate* Fan Width** Inch (mm)

(51–102)

4.0–6.0 (102–152)

6.0–8.0 (152–203)

8.0–10.0 (203–254)

10.0–12.0 (254–305)

12.0–14.0 (305–356)

14.0–16.0 (356–406)

16.0–18.0 (406–457)

18.0–20.0 (457–508)

308-644

Page 73

Graco Warranty

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 or structures, accessories, equipment or materials not supplied by Graco.

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 , or any 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.

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.

FOR GRACO CANADA CUSTOMERS

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: 1-800-367-4023 Toll Free

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.

Sales Offices: Minneapolis, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, France, Germany , Hong Kong, Japan

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

PRINTED IN U.S.A. 308–644 January 1996, Revised August 1997

20308-644

http://www.graco.com

Graco GMax 3900, GMaxu0001 5900HD, GMaxu0001 5900, GMaxu0001 7900 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual