Graco G-Max 7900, 232630, 232631, 232632, 232633 Instructions Manual

Instructions

®

G-Max

7900 Airless

Paint Sprayer

For Portable Airless Spraying of Architectural Coatings and Paints.

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

Models

NOTE: All models are not available in all countries.

Model Series Description

232630 B Hi-Boy

232631
232632 B Lo-Boy

232633
233008 A Hi-Boy with Gauge Kit

B

B

Hi-Boy with RAC 5 tip, gun

and hose

Lo-Boy with RAC 5 tip, gun

and hose

308870G

EN

Important Safety Instructions

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

Related Manuals

Manual Manual Number

Operation

Displacement Pump

Spray Gun

Spray Tip

PC Board

Drain Valve Kit

308867

307898

309091

309055

308919

308961

Table of Contents

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pinion Assembly / Rotor / Field / Shaft / Clutch . 13

Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

On / Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Control Transducer . . . . . . . . . . . . . . 19

Pressure Adjust Potentiometer . . . . . . . . . . . . . 20

Control Board Diagnostics . . . . . . . . . . . . . . . . 21

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 22

Pump Pin Clip . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts List & Drawing - Pinion Assembly . . . . . . . 24

Parts Drawing - Hi-Boy Sprayer . . . . . . . . . . . . . . 25

Model 232630 and 233008 . . . . . . . . . . . . . . . . 25

Parts List - Hi-Boy Sprayers . . . . . . . . . . . . . . . . . 26

Models 232630, 232631 and 233008* . . . . . . . 26

Parts Drawing - Lo-Boy Sprayer . . . . . . . . . . . . . 28

Model 232632, 232633 . . . . . . . . . . . . . . . . . . . 28

Parts List - Lo-Boy Sprayers . . . . . . . . . . . . . . . . 29

Models 232632, 232633 . . . . . . . . . . . . . . . . . . 29

Model 232630 through 232633 . . . . . . . . . . . . . 31

Parts List - Hi-Boy Sprayers . . . . . . . . . . . . . . . . . 32

Models 232630 through 232633 . . . . . . . . . . . . 32

Parts List - Complete Sprayers . . . . . . . . . . . . . . 33

Models 232631, 232633 . . . . . . . . . . . . . . . . . . 33

Displacement Pump Repair Kit . . . . . . . . . . . . . 33

Danger Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Model 232630, 232631, 232008 . . . . . . . . . . . . 35

Model 232632, 232633 . . . . . . . . . . . . . . . . . . . 35

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 308870G

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.

WARNING

FIRE AND EXPLOSION HAZARD

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

• Use equipment only in well ventilated area.

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

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

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

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

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event
that injection occurs, get immediate surgical treatment.

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks
with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Use Graco nozzle tips.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure
before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3000 psi (210 bar/21 MPa). Use Graco replacement parts or
accessories that are rated a minimum of 3000 psi (210 bar/21 MPa).

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

308870G 3

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

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

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. (

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu­facturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

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

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

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

4 308870G

Component Identification

S

U

W
T

X

V

P

A

B

C

E

F

G

H

J

K

202 Main hose
203 Whip end hose
204 Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip

203

204

202

M

N

L

Model 232631

R

D

9034B

Component Identification

A Pressure Control Switch ON/OFF, enables/disables clutch function and pressure control

B Pressure Adjusting Knob Controls fluid outlet pressure

C Air Cleaner*

D Fuel Tank*

E Muffler*

F Spark Plug Cable*

G Fuel Shutoff Lever*

H Choke*

J Throttle Lever*

K Engine Switch*

L Secondary Fluid Outlet

M Pressure Control

N Primary Fluid Outlet

P Engine*

R Clutch Housing

S Drive Housing

T Displacement Pump

U Fluid Filter

V Grounding Clamp and Wire

W Pail Hanger

X Drain Valve

* For more detailed explanations of these controls, refer to the Honda Engines Owner's Manual; supplied.

Filters air entering the carburetor

Uses 86 octane unleaded gasoline

Reduces noise of internal combustion

Routes electrical current to spark plug

On/off lever to regulate fuel flow from gasoline tank to carburetor

Enriches air/gasoline mixture for cold starting

Adjusts engine speed for large or small orifice spray tips

Enables/disables engine operation

Second hose and spray gun is connected here

Controls clutch cycling to maintain fluid pressure

Hose and spray gun is connected here

4-cycle gasoline engine

Transfers power from engine to drive assembly

Transfers power from clutch to displacement pump

Provides fluid to be sprayed through spray gun

Filters fluid between source and spray gun

Grounds sprayer system

Provides a hanger for paint pail

Relieves fluid pressure when open

308870G 5

Maintenance

Maintenance

NOTE: For detailed engine maintenance and specifica-

tions, refer to separate Honda Engines Owner's Manual,
supplied.

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever
you see this symbol.

This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.

1. Engage trigger lock.

2. Turn ON/OFF switch to OFF.

3. Move pressure control switch to OFF and turn pres­sure control knob fully counterclockwise.

4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.

5. Lock gun trigger safety.

6. Open the pressure drain valve. Leave the pressure
drain valve open until you are ready to spray again.

Maintenance Checklist

• 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 oper-

ation.

• 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.

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.

7. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow­ing the steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.

6 308870G

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.

Troubleshooting

Problem Cause Solution

Engine won't start Engine switch is OFF Turn engine switch ON

Engine is out of gas Refill gas tank. Honda Engines

Owner's Manual.

Engine oil level is low Try to start engine. Replenish oil, if

necessary. Honda Engines Owner's
Manual.

Troubleshooting

Engine operates, but displacement
pump does not operate

Spark plug cable is disconnected or
damaged

Cold engine Use choke

Fuel shutoff lever is OFF Move lever to ON position

Oil is seeping into combustion
chamber

Pressure control switch is OFF Turn pressure control switch ON.

Pressure setting is too low Turn pressure adjusting knob clock-

Fluid filter (318) is dirty Clean filter. Page 31.

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

Displacement pump piston rod is
stuck due to dried paint

Roller bearings are worn or dam­aged

Drive housing is worn or damaged Replace drive housing. Page 10.

Connect spark plug cable or replace
spark plug

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

wise to increase pressure

309091.

Repair pump. Manual 308798.

Replace connecting rod. Page 10.

308870G 7

Troubleshooting

Problem Cause Solution

Engine operates, but displacement
pump does not operate (continued)

Electrical power is not energizing
clutch field

Check wiring connections. Page 15.

Reference control board diagnos­tics. Page 21.

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 1.7
+0.2W; if not, replace clutch coil

241121.

Have pressure control checked by
authorized Graco dealer.

Clutch is worn or damaged Replace clutch. Page 13.

Pinion assembly is worn or dam­aged

Repair or replace pinion assembly.
Page 13.

Pump output is low Strainer (31) is clogged Clean strainer

Piston ball (25) is not seating Service piston ball. Manual 308798.

Piston packings are worn or dam-

Replace packings. Manual 308798.

aged

O-ring (227) in displacement pump

Replace o-ring. Manual 308798.

is worn or damaged

Intake valve ball is not seating prop-

Clean intake valve. manual 308798.

erly

Engine speed is too low Increase throttle setting. Manual

308867.

Clutch is worn or damaged Replace clutch. Page 13.

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

Clean filter. Manual 308867 or

309091.

Use larger diameter hose and/or
reduce overall length of hose. Use
of more than 100 ft of 1/4 in. hose
significantly reduces performance of
sprayer. Use 3/8 in. hose for opti­mum performance (50 ft minimum).

8 308870G

Problem Cause Solution

Troubleshooting

Excessive paint leakage into throat
packing nut

Throat packing nut is loose Remove throat packing nut spacer.

Tighten throat packing nut just
enough to stop leakage.

Throat packings are worn or dam-

Replace packings. Manual 308798.

aged

Displacement rod is worn or dam-

Replace rod. Manual 308798.

aged

Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connec-

tions. Reprime pump. Manual

308867.

Tip is partially clogged Clear tip. Manual 309091.

Fluid supply is low or empty Refill fluid supply. Prime pump.

Manual 308867. Check fluid supply
often to prevent running pump dry.

Pump is difficult to prime Air in pump or hose Check and tighten all fluid connec-

tions.
Reduce engine speed and cycle
pump as slowly as possible during
priming.

Intake valve is leaking Clean intake valve. Be sure ball

seat is not nicked or worn and that
ball seats well. Reassemble valve.

Pump packings are worn Replace pump packings. Manual

308798.

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

plier's recommendations.

Engine speed is too high Decrease throttle setting before

priming pump. Manual 308867.

Clutch squeaks each time clutch
engages

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

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

Engine stalls Engine speed is to slow - Increase throttle setting.

- Adjust engine speed at no load to
3750 - 3850 rpm

Fluid filter is clogged Relieve pressure and clean filter

Too much pump friction (new pump) Reduce pressure to 3000 psi (20.68

MPa, 206.8 bar) until pump wears in

Spark plug wire is loose Reconnect wire

308870G 9

Rollers

9033A

10

9

97

98

20

9

99

24

20

9

99

9

10

20h

20g

18

82

83

B

1

1

Apply remaining grease to these areas

Rollers

Removal

1. Relieve pressure, page 6.

2. Remove six cap screws (10) lock washers (9) and
cover assembly (24) (F

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

IG. 1).

Drive Housing

Removal

1. Relieve pressure, page 6.

2. Remove six cap screws (10) lock washers (9) and
cover assembly (24) (F

3. Remove two screws (99) and washers (9).

4. Remove four cap screws (10) lock washers (9) from
drive housing (20).

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.

IG. 1).

FIG. 1

3. Remove dowel pins (97) and rollers (98).

Installation

1. Install rollers (98) and dowel pins (97).

2. Install cover assembly (24) with six lock washers (9)
and cap screws (10).

10 308870G

FIG. 2

Rollers

222

33

Installation

1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (18),
washers (82) and (83) (F
areas called out by note 1. Use full 0.68 pint (0.32
liter) of grease for GMax 7900.

2. Place bronze colored washer (83) and silver colored
washer (82) (F

IG. 2, page 10) onto drive housing

(20). Install gear cluster (18) through washers (83)
and (82).

3. Place bronze colored washer (20g) and silver col­ored washer (20h) on shaft protruding from large
shaft of drive housing (20) (F
gears and push new drive housing straight onto pin­ion housing and locating pins (B).

4. Install two washers (9) and screws (99) (F
page 10).

5. Install four lock washers (9) and cap screws (10)
into drive housing (20) (F

6. Install cover assembly (24) with six lock washers (9)
and cap screws (10) (F

IG. 2, page 10) and to

IG. 2, page 10). Align

IG. 2,

IG. 2, page 10).

IG. 2, page 10).

Cam Follower Bearings

Removal

1. Relieve pressure, page 6.

2. Cycle pump piston rod (222) to lowest position (F

3). Turn engine off.

FIG. 3

NOTE: All Steps refer to F

IG. 4.

IG.

3. Remove six cap screws (10), lock washers (9) and
cover assembly (24) (F

IG. 4, page 12).

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

4. Remove four dowel pins (97) and rollers (98) (F

IG.

4, page 12).

5. From front, drive out pump pin (101) with a screw
driver (F

6. Remove two retainer rings (20d) (F

7. Remove cam follower plate (20b) (F

IG. 4, page 12).

IG. 4, page 12).

IG. 4. page 12).

NOTE: Two 1/2 in. x 13 bolts may be needed to
remove cam follower plates.

8. Remove two cam follower bearings (20c) (F

IG. 4,

page 12).

308870G 11