INSTRUCTIONS-REPAIR
308870
Rev. F
KEEP FOR REFERENCE.
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INSTRUCTIONS
GMaxr 7900
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 7900
Model Series
Description
Hi-Boy
232630
232631
232632
232633
233008
B
B
B
B
A
Hi-Boy with RAC 5 tip, gun and hose
Lo-Boy
Lo-Boy with RAC 5 tip, gun and hose
Hi-Boy with Gauge Kit
All models are not available in all countries
PATENTS PENDING
Related Manuals
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 308867
Displacement Pump . . . . . . . . . . . . . . . . . 308798
Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . 309091
Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 309055
PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . 308919
Drain Valve Kit . . . . . . . . . . . . . . . . . . . . . . 308961
9035B
Table of Contents
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Identification and Function . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Repair
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts
Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hi-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lo-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cam Follower Bearings . . . . . . . . . . . . . . . . . . . . . . . 8
Pinion Assembly/Rotor/Field/Shaft/Clutch . . . . . . . . 9
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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Component Identification and Function
V
D
C
202Main hose
203Whip end hose
204Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip
J
H
E
G
R
K
F
P
S
A
B
U
W
T
Model 232631
202
204
M
L
X
N
203
9034B
Fig. 1
A
B
C
D
E
F
Pressure Control Switch
Pressure Adjusting Knob
Air Cleaner*
ON/OFF, enables/disables clutch function and pressure control
Controls fluid outlet pressure
Filters air entering the carburetor
Fuel Tank*
Uses 86 octane unleaded gasoline
Muffler*
Reduces noise of internal combustion
Spark Plug Cable*
Fuel Shutoff Lever*
Choke*
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
G
H
J
Throttle Lever*
Engine Switch*
Secondary Fluid Outlet
Pressure Control
Primary Fluid Outlet
Engine*
K
L
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
M
N
P
R
S
T
Clutch Housing
Drive Housing
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
Displacement Pump
Fluid Filter
U
V
W
X
*
Grounding Clamp and Wire
Pail Hanger
Provides a hanger for paint pail
Drain Valve
Relieves fluid pressure when open
For more detailed explanations of these controls, refer to the Honda Engines Owner’s Manual; supplied
308870
3
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Maintenance
CAUTION
WARNING
For detailed engine maintenance and specifications,
refer to separate Honda Engines Owner’s Manual,
supplied.
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:
DAILY: Check engine oil level and fill as necessary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
D are instructed to relieve the pressure,
D stop spraying,
DAILY: Check pressure drain valve for proper opera-
tion.
D check or service any of the system equipment,
D or install or clean the spray tip.
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 viscos-
ity.
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
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.
3. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
Replacement elements can be purchased from your
local HONDA dealer.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
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.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
AFTER EACH 100 HOURS OF OPERATION:
Change engine oil. Reference Honda Engines Owner’s
Manual for correct oil viscosity.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY
loosen tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose.
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.
4
308870
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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, adjust-
ing, cleaning or shutting down sprayer.
PROBLEM
CAUSE
SOLUTION
Engine switch is OFF
Engine is out of gas
Turn engine switch ON
Engine won’t start
Refill gas tank. Honda Engines Owner’s Manu-
al.
Engine oil level is low
Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable is disconnected or damaged Connect spark plug cable or replace spark
plug
Cold engine
Use choke
Fuel shutoff lever is OFF
Oil is seeping into combustion chamber
Move lever to ON position
Remove spark plug. Pull starter rope 3 or 4
times. Clean or replace spark plug. Try to start
engine. Keep sprayer upright to avoid oil seep-
age.
Pressure control switch is OFF
Pressure setting is too low
Turn pressure control switch ON.
Engine operates, but dis-
placement pump does not
operate
Turn pressure adjusting knob clockwise to
increase pressure.
Fluid filter (318) is dirty
Tip or tip filter is clogged
Clean filter. Page 22.
Clean tip or tip filter. Manual 309091.
Displacement pump piston rod is stuck due to Repair pump. Manual 308798.
dried paint
Roller bearings are worn or damaged
Drive housing is worn or damaged
Replace connecting rod. Page 7.
Replace drive housing. Page 7.
Electrical power is not energizing clutch field
Check wiring connections. Page 11.
Reference control board diagnostics. Page 14.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check
for power between clutch terminals on control
board.
Remove black clutch wires from control board
and measure resistance across wires. At 70_
F, the resistance must be between 1.7 0.2Ω; if
not, replace clutch coil 241121.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn or damaged
Replace clutch. Page 9.
Pinion assembly is worn or damaged
Repair or replace pinion assembly. Page 9.
308870
5
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PROBLEM
CAUSE
SOLUTION
Strainer (31) is clogged
Piston ball (25) is not seating
Piston packings are worn or damaged
Clean strainer
Pump output is low
Service piston ball. Manual 308798.
Replace packings. Manual 308798.
Replace o-ring. Manual 308798.
O-ring (227) in displacement pump is worn or
damaged
Intake valve ball is not seating properly
Engine speed is too low
Clean intake valve. manual 308798.
Increase throttle setting. Manual 308867.
Replace clutch. Page 9.
Clutch is worn or damaged
Pressure setting is too low
Increase pressure. Manual 308867.
Clean filter. Manual 308867 or 309091.
Fluid filter (318), tip filter or tip is clogged or
dirty
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4
in. hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum perfor-
mance (50 ft minimum).
Throat packing nut is loose
Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Excessive paint leakage into
throat packing nut
Throat packings are worn or damaged
Displacement rod is worn or damaged
Air in pump or hose
Replace packings. Manual 308798.
Replace rod. Manual 308798.
Check and tighten all fluid connections.
Reprime pump. Manual 308867.
Fluid is spitting from gun
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.
Air in pump or hose
Check and tighten all fluid connections.
Pump is difficult to prime
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
Paint is too thick
Replace pump packings. Manual 308798.
Thin the paint according to the supplier’s
recommendations
Engine speed is too high
Decrease throttle setting before priming pump.
Manual 308867.
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other.
when new and may cause noise
Noise will dissipate after a day of run time
Engine speed is to slow
D
D
Increase throttle setting
Engine stalls
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 until pump wears
in
Spark plug wire is loose
Reconnect wire
6
308870
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Rollers
Removal
20
1.
Relieve pressure; page 4.
98
97
9
2. Fig. 2. Remove six cap screws (10) lock washers
(9) and cover assembly (24).
10
Note: A screw driver may be needed to pry off
cover assembly.
3. Remove dowel pins (97) and rollers (98)
Installation
9
1. Install rollers (98) and dowel pins (97)
99
24
2. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
9033A
Fig. 2
Drive Housing
Removal
Installation
1. Liberally apply bearing grease (supplied with
1.
replacement gear cluster) to gear cluster (18),
washers (82) and (83) and to areas called out by
note 1. Use full 0.68 pint (0.32 liter) of grease for
GMax 7900.
Relieve pressure; page 4.
2. Fig. 2. Remove six cap screws (10) lock washers
(9) and cover assembly (24).
3. Fig. 3. Remove two screws (99) and washers (9).
2. Place bronze colored washer (83) and silver
colored washer (82) onto drive housing (20). Install
gear cluster (18) through washers (83) and (82).
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.
3. Place bronze colored washer (20g) and silver
colored washer (20h) on shaft protruding from
large shaft of drive housing (20). Align gears and
push new drive housing straight onto pinion hous-
ing and locating pins (B).
10
9
4. Install two washers (9) and screws (99).
1
20h
5. Install four lock washers (9) and cap screws (10)
into drive housing (20).
20
20g
18
6. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
B
9
99
82
83
1
Apply remaining grease to these areas
Fig. 3
9032A
308870
7
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Cam Follower Bearings
Removal
Installation
1. Install two cam follower bearings (20c).
1.
Relieve pressure; page 4.
2. Fig. 16. Cycle pump piston rod (222) to lowest
position. Turn engine off.
2. Install cam follower plate (20b).
3. Install two retainer rings (20d).
3. Fig. 4. Remove six cap screws (10), lock washers
(9) and cover assembly (24).
Note: A screw driver may be needed to pry off
cover assembly.
4. Drive in pump pin (101) until it engages with pump
pin retaining clip (20a).
4. Remove four dowel pins (97) and rollers (98).
5. From front, drive out pump pin (101) with a screw
driver.
6. Remove two retainer rings (20d).
7. Remove cam follower plate (20b).
5. Install four rollers (98) and dowel
pins (97).
Note: Two 1/2 in. x 13 bolts may be
needed to remove cam follower plates.
6. Install cover assembly (24) with six lock washers
(9) and cap screws (10).
8. Remove two cam follower bearings (20c).
20
98
97
9
10
20a
20c
20b
20d
101
9047A
24
Fig. 4
8
308870
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Pinion Assembly/Rotor/Field/Shaft/Clutch
Removal
If pinion assembly (19) is not removed from clutch
6. Fig. 8. Remove retaining ring (19e).
housing (5), do 1. through 4. Otherwise, start at 5.
7. Tap pinion shaft (19d) out with plastic mallet.
1.
19e
19d
Relieve pressure; page 4.
2. Disconnect field cable (X) from pressure control
and engine lead.
X
9031A
Fig. 8
8. Fig.9. Use an impact wrench or wedge something
between armature (4a) and clutch housing to hold
engine shaft during removal.
Bottom View
9027A
Fig. 5
9. Remove four screws (16) and lockwashers (17).
10. Remove armature (4a).
3. Fig. 6. Remove five screws (26) and lockwashers
(17) and pinion assembly (19).
26
17
4a
17
16
19
9028A
Fig. 9
26
17
9029A
Fig. 6
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.
72
17
E
9030A
Fig. 7
308870
9
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Pinion Assembly/Rotor/Field/Shaft/Clutch
Installation
1. Fig. 10. Lay two stacks of two dimes on smooth
6. Fig. 8. Tap pinion shaft (19d) in with plastic mallet.
bench surface.
7. Install retaining ring (19e) with beveled side facing
field (Y).
2. Lay armature (4a) on two stacks of dimes.
3. Press center of clutch down on bench surface.
8. Fig. 7. Place pinion assembly on bench with rotor
side up.
4a
0.12 .01 in. (3.0 .25 mm)
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
holes to hold rotor.
8705A
Fig. 10
10. Fig. 6. Install pinion assembly (19) with five screws
(10) and lockwashers (9).
4. Install armature (4a) on engine drive shaft.
5. Install four screws (16) and lockwashers (17) with
torque of 125 in-lb.
11. Fig. 5. Connect field cable (X) to pressure control
and engine lead.
Clamp
Removal
1
Face of clutch housing
1. Fig. 11. Loosen two screws (16) on clamp (8),
2
1.812 .010 in. (46.02 .25 mm)
3
Torque to 125 .10 in-lb (14 1.1 Nꢀm)
2. Push screwdriver into slot in clamp (8) and remove
clamp.
4
Chamfer this side
1
5
Installation
1. Fig. 11. Install engine shaft key (7).
2
2. Tap clamp (8) on engine shaft (A) with plastic
mallet.
8
3. Press clamp (8) onto engine shaft (A). Maintain
dimension shown note 2 in Fig. 11. Chamfer side
must face engine.
7
4
B
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
Nꢀm).
16
3
A
03483
Fig. 11
10
308870
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Clutch Housing
Removal
1. Fig. 12. Remove four capscrews (75) and lock-
washers (77) which hold clutch housing (5) to
engine.
5
7
2. Remove screw (15) from under mounting plate (D).
3. Remove engine key (7).
4. Pull off clutch housing (5).
Installation
77
1. Fig. 12. Push on clutch housing (5).
75
2. Install four capscrews (75) and lockwashers (77)
and secure clutch housing (5) to engine. Torque to
200 in-lb (22.6 NSm).
D
15
3. Install capscrew (15) from beneath mounting
9025A
Fig. 12
plate (D). Torque to 26 ft-lb (35.2 NSm).
Engine
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.
70
71
71
87
Green
1
9026A
Fig. 14
Installation
1. Lift engine carefully and place on cart.
2
2. Fig. 14. Install two screws (70) in base of engine
and secure with locknuts (71). Torque to 200 in-lb
(22.6 NSm).
1
To the field
3. Fig. 13. Connect all necessary wiring.
2
To the engine
2
4. Install Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing, as
instructed on pages 7, 9 and 10.
9027A
Fig. 13
308870
11
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On/Off Switch
Removal
Installation
1. Install new ON/OFF switch (309) so tabs of switch
1.
snap into place on inside of pressure control
housing.
Relieve pressure; page 4.
2. Fig. 15. Remove five screws (307) and
cover (322).
2. Connect two wires (A) to ON/OFF switch.
3. Install pressure control cover (322) with five
screws (307).
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.
313
310
1
309
A
315
319
318a
302
303
307
D
E
318z
322
318aa
8711A
1
Locate switch terminals as shown
Fig. 15
12
308870
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Pressure Control
Control Board
Removal
Installation
When installing replacement control board, follow
instructions with control board to set model type.
1.
Relieve pressure; page 4.
2. Fig. 15. Remove five screws (307) and
cover (322).
1. Fig. 15. Install green ground wire and control
board (302) with five screws (303).
3. Fig. 22. Disconnect at control board (302):
D Four clutch leads: two violet and two black.
D Lead (D) from potentiometer.
2. Fig. 22. Connect to control board (302):
D Two red leads (A) to ON/OFF switch (309).
D Lead (E) to transducer.
D Lead (E) from transducer.
D Lead (D) to potentiometer.
D Two red leads (A) to ON/OFF switch (309).
D Four clutch leads: two violet and two black.
3. Fig. 15. Install cover (322) with five screws (307).
4. Fig. 15. Remove five screws (303), green ground
wire and control board (302).
Pressure Control Transducer
Removal
5. Remove pressure control transducer (318z) and
packing o-ring (318aa) from filter housing (318a).
1.
Installation
Relieve pressure; page 4.
1. Fig. 15. Install packing o-ring (318aa) and pres-
sure control transducer (318z) in filter
2. Fig. 15. Remove five screws (307) and
cover (322).
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. 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).
3. Connect lead (E) to motor control board (302).
4. Install cover (322) with five screws (307).
Pressure Adjust Potentiometer
Removal
Installation
1. Install seal (311) on potentiometer (310).
1.
2. Fig. 15. Install pressure adjust potentiometer
(310), shaft nut, lockwasher (310) and potentiome-
ter knob (313).
Relieve pressure; page 4.
a. Turn potentiometer shaft (310) clockwise to
internal stop. Assemble potentiometer knob
(313) to strike pin on plate (312).
2. Fig. 15. Remove five screws (307) and
cover (322).
3. Disconnect lead (D) from control board (302).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
4. Loosen set screws on potentiometer knob (313)
and remove knob, shaft nut, lockwasher (310) and
pressure adjust potentiometer (310).
3. Connect lead (D) to control board (302).
4. Install cover (322) with five screws (307).
5. Remove seal (311) from potentiometer (310).
308870
13
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Pressure Control
Control Board Diagnostics
1. Fig. 15. Remove five screws (307) and
3. Turn ON/OFF switch ON.
cover (322).
2. Start sprayer.
4. Observe LED operation and reference following
table:
LED
SPRAYER OPERATION
INDICATES
WHAT TO DO
BLINKS
Two times Sprayer shuts down and LED contin- Run away pressure.
1. Check pressure transducer con-
nection at control board
2. Replace pressure transducer
3. Replace control board
repeatedly
Pressure greater than
4500 psi (310 bar, 31
MPa).
ues to blink two times repeatedly
Three
times re-
peatedly
Sprayer shuts down and LED contin- Pressure transducer is 1. Check pressure transducer con-
faulty or missing
ues to blink three times repeatedly
nection at control board
2. Replace pressure transducer
3. Replace control board
Four times Sprayer shuts down and LED contin- Generator voltage is
repeatedly
1. Increase engine throttle
2. Check wiring connections
3. Service Honda engine alternator
low
ues to blink four times repeatedly
Five times Sprayer shuts down and LED contin- High clutch current
1. Check clutch 5-pin bulkhead con-
nector. Clean contacts.
repeatedly
ues to blink five times repeatedly
2. Measure 1.7 0.2Ω across clutch
field at 70_F
3. Replace clutch field assembly
Six times
Sprayer shuts down and LED contin- High clutch temperature 1. If clutch is new, let sprayer cool
repeatedly
ues to blink six times repeatedly
down and then restart
2. Inspect clutch. Replace clutch if
there is excessive wear.
3. Remove pump pin, separate pin-
ion housing from clutch housing.
Rotate rotor clockwise to check
for excessive drag.
14
308870
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Displacement Pump
Removal
1. Flush pump.
5. Fig. 17. Use screwdriver to push out pump
pin (101).
2. Fig. 16. Cycle pump with piston rod (222) in lowest
position.
20a
101
3.
Relieve pressure; page 4.
4. Fig. 16. Remove suction tube (30) and hose (33).
Detail A
9019B
Fig. 17
6. Fig. 18. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
222
33
9024C
30
9024B
9022A
Fig. 16
Fig. 18
Repair
See manual 308798 for pump repair instructions.
2. Fig. 17. See Detail A. Push pin (101) into hole
until retaining clip (20a) snaps over pin.
Installation
Fig. 20. Screw jam nut down onto pump until nut
stops. Screw pump up into pump plate until it stops.
Back off pump one full turn and 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 Nꢀm).
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 prop-
erty damage. Make sure pin (101) and retaining
clip (20a) are properly installed. See Detail A. Fig.
17.
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure locknut is properly tightened.
9021A
Fig. 20
1. Fig. 19. Pull piston rod out 1.0 in. Screw in pump
until holes in housing plates and piston rod align.
Fig. 21. Fill packing nut with Graco TSL until fluid flows
onto the top of seal.
1.0 in.
9023A
Fig. 21
9020A
Fig. 19
308870
15
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Displacement Pump
Pump Pin Clip
Removal
Installation
1. Fig. 17. Install clip (230).
1. Remove pump (28).
2. Install shield (95), pail hook (94) and pump bracket
(85) with two washers (25) and bolts (86). Torque
bolts to 40 ft-lb (54 NSm).
2. Remove two bolts (86), washers (25), pump brack-
et (85), pail hook (94) and shield (95).
3. Fig. 17. Remove clip (230).
3. Install pump (28).
16
308870
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Parts List & Drawing – Pinion Assembly
Ref No. 19 and 20
Ref No. 19: Pinion Housing Assembly 241116
Ref No. 20: Drive Housing Assembly 241537
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
19a
19b
19d
19e
241121
105489
241114
112770
PINION HOUSING, COIL
PIN
PINION SHAFT
1
2
20
DRIVE HOUSING
RETAINING CLIP, pump pin
CAM FOLLOWER PLATE
CAM FOLLOWER BEARING
RETAINER CLIP
1
1
1
2
2
1
1
20a
20b
20c
20d
20g
20h
194060
193656
114691
114828
114697
114698
RETAINING RING, large
WASHER
WASHER
101
195523
PIN
1
19e
10 (Ref)
19d
9 (Ref)
19a
20h
20g
83 (Ref)
20
9 (Ref)
99 (Ref)
1
18 (Ref)
82 (Ref)
20c
20b
20d
101
20a
9046A
1
Pinion housing/coil assembly (19a) includes clutch field and all bearings, pins and o-rings
308870
17
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Parts Drawing – Hi-Boy Sprayers
Model 232630
93
78
DETAIL A
1
Label
Ref 11
87
2
3
See page 17 for the parts.
29
40
45
See manual 308798
for the parts.
4
5
See page 22 for the parts.
See page 22 for the parts.
37
8699A
38
39
10
9027A
Bottom View
52
Ref 35
9
61
2
19
2
20h
2
20
2
20g
72
17
98
97
83
24
4b
3
2
9
10
18
9
82
99
56
1
11
103
95
36
26
17
5
94
85
7
8
101
25
DETAIL A
17
49
33
86
16
47
4a
34
70
61
77
73
80
62
71
17
28
21
16
15
35
64
65
30
52
105
31
41
44
71
33(Ref)
42
12
43
62
4
9018D
102
88
104
64(Ref)
18
308870
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Parts List – Hi-Boy Sprayers
Models 232630*
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
1
2
3
4
114530
113084
192014
241113
ENGINE
RIVET, blind
PLATE, indicator
CLUTCH ASSEMBLY,
includes 4a, 4b, 16, 17, 72, 80
.ARMATURE, clutch, 5 in.
.ROTOR, 5 in.
CLUTCH HOUSING
KEY, parallel
1
2
1
1
42
43
44
45
47
49
52
56Y
61
62
64
65
70
101242
104811
154636
112827
237686
112798
114984
194126
114678
162485
194178
241718
110837
RING, retaining
HUBCAP
WASHER
BUTTON, snap
GROUNDING CLAMP & WIRE
SCREW, hex washer hd, No. 8 x 3/8 in 1
SCREW, mch, pn hd;
LABEL, warning
BUSHING, strain relief
NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3
HOSE, drain
2
2
2
2
1
4a
4b
5
7
8
1
1
1
1
1
2
1
1
193531
183401
193680
104008
101864
CLAMP
9
10
WASHER, spring, lock
CAPSCREW, socket head,
1/4–20 x 3/4 in.
CART HANDLE & HOSE RACK
CAP, end
12
10
1
1
2
DEFLECTOR
SCREW, flng, hex hd,
5/16–18 x 1–1/2 in.
LOCKNUT, heavy hex, 5/16–18
SCREW, cap, sch
SCREW, cap, sch
WASHER, lock, spring
CLIP, retainer
HUB, armature
WASHER, thrust
WASHER, thrust
BRACKET, pump
SCREW, cap, sch
CONDUCTOR, ground
ADAPTER, male elbow, 90_
WASHER
PAIL HOOK Repair Kit; includes 95
GROMMET, pump
THROAT SEAL LIQUID; not shown
DOWEL PIN
ROLLER assembly
SCREW, cap, sch
PIN
PLUG, packless, 3/8 in.
LABEL, warning
11
12
15
239998
193682
113802
1
2
1
71
72
73
77
78
80
82
83
85
86
87
88
93
94
95
96
97
98
99
101
102
110838
101682
108842
100214
114687
6
4
4
4
1
1
1
1
1
2
1
1
2
1
1
1
4
4
2
1
1
1
1
1
SCREW, flange, hex hd,
3/8–16 x 5/8 in.
16
17
18
108803
105510
241539
CAPSCREW, sch, 1/4–2 x 1 in.
LOCKWASHER, spring, 1/4 in.
GEAR COMBINATION
includes 91 and 92
PINION ASSEMBLY; Parts, page 17
DRIVE HOUSING; Parts, page 17
COUPLING
COVER, housing, dr5e, kit
WASHER, lock, spring
SCREW, cap
DISPLACEMENT PUMP
Parts, manual 308798
TUBE, nylon, split
TUBE, intake
includes 21
STRAINER
HOSE, coupled
NUT, retaining
CART FRAME
LABEL, identification
WASHER, plain
RING, retaining
SCREW, mch, pn hd, 10–32 x 5/16 in. 4
SLEEVE
WHEEL, semi–pneumatic
6
15
1
114699
114672
194118
110343
240997
110249
108851
241540
195377
206994
114695
241322
114693
195523
240987
19
20
21
24
25
26
28
241116
241537
114967
241536
100018
100644
240917
1
1
1
1
1
5
1
29
30
194438
244823
1
1
31
33
34
35
36
37
38
39
40
41
189920
240795
193394
241324
194068
183350
110243
108795
191084
179811
1
1
1
1
1
2
2
103Y 194317
104Y 195119
105
LABEL, warning; not shown
CLIP, spring.
194194
Y Danger & Warning labels, tags, and cards are free.
2
2
* Model 23308 includes Gauge Kit 241339
308870
19
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Parts Drawing – Lo-Boy Sprayers
Model 232632
78
93
87
5
DETAIL A
1
Label
Ref 11
2
3
See page 17 for the parts.
29
See manual 308798
for the parts.
40
45
4
See page 22 for the parts.
37
39
51
10
9027A
72
9
Bottom View
61
17
2
19
2
20h
Ref 35
2
20g
30b
2
20
30ae
30ad
83
98
4b
97
9
10
30a
101
30c
18
56
1
82
11
103
30e
26
17
95
70
94
85
5
36
99
9
7
24
8
30f
DETAIL A
17
16
25
49
35
86
34
4a
47
71
73
77
80
33
17
62
28
3
16
30ac
30ab
15
71
30aa
52
43 42 44
41
12
33 (Ref)
62
3
2
4
30d
102
104
30b (Ref)
9016A
20
308870
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Parts List – Lo-Boy Sprayers
Model 232632
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
1
2
3
4
114530
113084
192014
241113
ENGINE
RIVET, blind
PLATE, indicator
CLUTCH ASSEMBLY,
includes 4a, 4b, 16, 17, 72, 80
.ARMATURE, clutch, 5 in.
.ROTOR, 5 in.
CLUTCH HOUSING
KEY, parallel
1
2
1
1
36
37
38
39
40
41
42
43
44
45
47
49
52
56Y
61
62
64
65
70
194068
183350
110243
108795
191084
179811
101242
104811
154636
112827
237686
112798
114984
194126
114678
162485
194178
241718
110837
LABEL, identification
WASHER, plain
RING, retaining
SCREW, mch, pn hd, 10–32 x 5/16 in. 4
SLEEVE
WHEEL, semi–pneumatic
RING, retaining
HUBCAP
WASHER
BUTTON, snap
GROUNDING CLAMP & WIRE
SCREW, hex washer hd, No. 8 x 3/8 in 1
SCREW, mch, pn hd;
LABEL, warning
BUSHING, strain relief
NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3
1
2
2
1
1
2
2
2
2
1
4a
4b
5
7
8
1
1
1
1
1
193531
183401
193680
104008
101864
CLAMP
9
10
WASHER, spring, lock
CAPSCREW, socket head,
1/4–20 x 3/4 in.
CART HANDLE & HOSE RACK
CAP, end
12
10
2
1
1
11
12
15
239998
193682
113802
1
2
1
SCREW, flange, hex hd,
3/8–16 x 5/8 in.
HOSE, drain
DEFLECTOR
1
1
2
16
17
18
108803
105510
241539
CAPSCREW, sch, 1/4–2 x 1 in.
LOCKWASHER, spring, 1/4 in.
GEAR COMBINATION
includes 91 and 92
PINION ASSEMBLY; Parts, page 17
DRIVE HOUSING; Parts, page 17
COVER, housing, drive, kit
WASHER, lock, spring
SCREW, cap
DISPLACEMENT PUMP
Parts, manual 308798
TUBE, nylon, split
ASSEMBLY, tube, suction
.TUBE, suction, 30 gallon (120 liter)
. includes 30aa through 30ae
..SWIVEL, tube, inlet
..GUARD, hose
..HOSE, fluid
..CLAMP, hose
..TUBE, suction
.HOSE, drain
.CLIP, spring
.NIPPLE
.DEFLECTOR
.STRAINER
6
15
1
SCREW, flng, hex hd,
5/16–18 x 1–1/2 in.
LOCKNUT, heavy hex, 5/16–18
SCREW, cap, sch
SCREW, cap, sch
WASHER, lock, spring
CLIP, retainer
HUB, armature
WASHER, thrust
WASHER, thrust
BRACKET, pump
SCREW, cap, sch
CONDUCTOR, ground
ADAPTER, male elbow, 90_
WASHER
PAIL HOOK Repair Kit; includes 95
GROMMET, pump
THROAT SEAL LIQUID; not shown
DOWEL PIN
ROLLER assembly
SCREW, cap, sch
PIN
PLUG, packless, 3/8 in.
LABEL, warning
71
72
73
77
78
80
82
83
85
86
87
88
93
94
95
96
97
98
99
101
102
110838
101682
108842
100214
114687
6
4
4
4
1
1
1
1
1
2
1
1
2
1
1
1
4
4
2
1
1
1
1
19
20
24
25
26
28
241116
241537
241536
100018
100644
240917
1
1
1
1
5
1
114699
114672
194118
110343
240997
110249
108851
241540
194681
206994
114695
241322
114693
195523
240987
29
30
30a
194438
241288
241269
1
1
1
30aa 198119
30ab 176450
30ac 194307
30ad 101818
30ae 192633
30b
30c
30d
30e
30f
33
1
1
1
2
1
1
1
1
1
1
1
1
1
194180
194194
162453
241718
112604
240795
193394
241324
103Y 194317
104Y 195119
HOSE, coupled
NUT, retaining
CART FRAME
LABEL, warning
34
35
Y Danger & Warning labels, tags, and cards are free.
308870
21
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Parts Drawing – Sprayer
Models 232630 through 232633
307
301
318f
314
313
304
305
304
310
312
309
318e
319
308
321
302
318d
318c
303
315
318b
320
318z
306
311
310
318aa
323
318a
305
322
318g
307
318h
318m
318n
318l
318j
318k
8716A
22
308870
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Parts List – Sprayer
Models 232630 through 232633
REF
REF
NO. PART NO.
DESCRIPTION
QTY
NO. PART NO.
DESCRIPTION
QTY
301 193653
302 241093
303 111839
304 240776
305 193497
306 193652
307 114631
308 193052
309 114277
310 241443
311 193657
312 193654
313 114273
314 193072
315 114629
318
PLATE, control
BOARD, PC
SCREW, mch pan, 6–32 x 1/2 in.
HARNESS, wiring.
GASKET, control
HOUSING, control box
SCREW, mch, pan hd
PLATE, instruction
SWITCH, rocker, (spst)
POTENTIOMETER, pressure control
GASKET, potentiometer
PLATE, instruction
KNOB, potentiometer
LABEL, control
GROMMET, transducer
FILTER, fluid
HOUSING, filter
O-RING
SUPPORT, filter
STRAINER, mesh, 60
SPRING, compression
1
1
5
1
2
1
10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
318f 192706
318g 193710
318h 193709
318j 194102
318k 114688
318l 114708
318m 114797
318n 245103*
318z 240314
BOWL, filter
SEAL, valve
SEAT, valve
HANDLE, valve
NUT, cap, hex hd
SPRING, compression
GASKET
1
1
1
1
1
1
1
1
1
VALVE
TRANSDUCER, pressure control
includes 318aa
O-RING
SCREW, flange, hex
TIE, wire, twist
LABEL, warning
COVER, pressure control
LABEL, identification
318aa 111457
319 110997
320 114532
321Y 189246
322 241444
323 193684
1
3
1
1
1
1
318a 193651
318b 104361
318c 186075
318d 167025
318e 171941
* Drain valve replacement kit 245103 includes 318g through
318n
Y Replacement warning labels may be ordered free of charge
Wiring Diagram
Green
Black
310
(Ref)
309
(Ref)
D
Red
Potentiometer
E
Pressure
transducer
Red (+)
A
318z
(Ref)
318aa
(Ref)
Violet
304
302
(Ref)
(Ref)
9279
Fig. 22
308870
23
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Parts List & Drawing – Complete Sprayers
Models 232631, 232633
Includes items 201 to 204
204
Ref
No.
Part No.
Description
Qty
203
201
232631
Hi-Boy Sprayer
1
See parts list on page 18
Lo-Boy Sprayer
232633
240797
1
1
See parts list on page 21
HOSE, grounded, nylon; 3/8 in. ID;
cpld 3/8 npsm(fbe); 50 foot (15 m);
spring guards both ends
3300 psi (227 bar, 27.7 MPa)
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
CONTRACTOR SPRAY GUN
202
203
204
238358
220955
0160
202
Includes RAC 5t DripLesst Tip Guard
and 517–size SwitchTipt
See 309091 for parts
1
Accessories
Displacement Pump Repair Kit
DANGER LABELS
Packing repair kit.
An English language DANGER label is on your
sprayer. If you have painters who do not read En-
glish, order one of the following labels to apply to
your sprayer. The drawing shows the best place-
ment of these labels for good visibility.
GMax 7900
240916
Order the labels from your Graco distributor.
French
Spanish 194932
German 194933
194931
Apply other
language here
Greek
Korean
194934
194935
English 194317
9036A
24
308870
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Technical Data
Honda GX160 Engine
Maximum delivery rating . . . . . . 2.1 gpm (7.9 liter/min)
Maximum tip size . . . . . . . . . . 1 gun with 0. 046 in. tip
2 guns with 0.033 in. tip
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)
3 guns with 0. 026 in. tip
4 guns with 0. 022 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,
PTFE,rNylon, polyurethane, UHMW polyethylene,
Vitonr, Delrinr, leather, aluminum, tungsten car-
bide,nickle-plated carbon steel, stainless steel,
chrome plating
Noise Level
Sound power . . . . . . . . . . . . . . . . . . . . . . . . . 105 dBa
per ISO 3744
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . 96 dBa
measured at 3.1 feet (1 m)
Cycles/gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . 69 (18)
NOTE: Delrinr andrVitonr are trademarks of the DuPont
Company.
Dimensions
Model 232630, 233008
Model 232632
Hi-Boy without hose or gun
Lo-Boy Cart without hose or gun
Weight (dry, without packaging) . . . . . 175 lb (79.4 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 in. (96.5 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)
Weight (dry, without packaging) . . . . . 180 lb (82.1 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 in. (96.5 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–690–2894 Toll Free
308870
25
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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 accor-
dance 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 sub-
stitution 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 WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO 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 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 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.
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 reconnais-
sent 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.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN USA 308870 March 1999, Revised 3/2001
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308870
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