Graco Inc. 308870 Paint Sprayer User Manual
Contents
1. Bottom View Fig 5 9027A 3 Fig 6 Remove five screws 26 and lockwashers 17 and pinion assembly 19 19 Fig 6 l 9029A 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 9030A 6 Fig 8 Remove retaining ring 19e 7 Tap pinion shaft 19d out with plastic mallet Fig 8 9031A 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 9 9028A 308870 9 Pinion Assembly Rotor Field Shaft Clutch Installation 1 Fig 10 Lay two stacks of two dimes on smooth bench surface 2 Lay armature 4a on two stacks of dimes 3 Press center of clutch down on bench surface 4a 0 12 01 in 3 0 25 mm iS E E E S A E R HATIS Pe TT f eS Ea WH H EA ET PE PY W Fig 10 oe 4 Install armature 4a on engine drive shaft 5 Install four screws 16 and lockwashers 17 with torque of 125 in lb 10 11 Fig 8 Tap pinion shaft 19d in with plastic mallet Install2. ANN AS a3 anana AO BR BR P Nanananananana HR HB BR O A Danger amp Warning labels tags and cards are free 308870 21 Parts Drawing Sprayer Models 232630 through 232633 8716A 22 308870 Parts List Sprayer Models 232630 through 232633 REF REF NO PART NO DESCRIPTION QTY NO PART NO DESCRIPTION QTY 301 193653 PLA TE control 1 318e 171941 SPRING compression 1 302 241093 BOARD PC 1 318f 192706 BOWL filter 1 303 111839 SCREW mch pan 6 32 x 1 2 in 5 318g 193710 SEAL valve 1 304 240776 HARNESS wiring 1 318h 193709 SEA T valve 1 305 193497 GASKET control 2 318j 194102 HANDLE valve 1 306 193652 HOUSING control box 1 318k 11
3. 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 Nem 3 Install capscrew 15 from beneath mounting plate D Torque to 26 ft lb 35 2 Nem Removal 1 Fig 12 Remove four capscrews 75 and lock washers 77 which hold clutch housing 5 to engine Fig 12 9025A Engine Remove Pinion Assembly Rotor Field Pinion Clutch Clamp and Clutch Housing as in structed on pages 7 9 and 10 Fig 13 Disconnect all necessary wiring Fig 14 Remove two locknuts 71 and screws 70 from base of engine Lift engine carefully and place on work bench NOTE All service to the engine must be performed by an authorized HONDA dealer an A To the field To the engine 9027A Fig 14 9026A Installation 1 Lift engine carefully and place on cart 2 Fig 14 Install two screws 70 in base of engine and secure with locknuts 71 Torque to 200 in lb 22 6 Nem 3 Fig 13 Connect all necessary wiring 4 Install Pinion Assembly Rotor Field Pinion Clutch Clamp and Clutch Housing
4. ja Ae S ee NO Q Ss 9019A Fig 17 6 Fig 18 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump 9022A Fig 18 2 Fig 17 Push pin 101 into hole until retaining clip 230 engages pump pin groove 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 N m 9021A Fig 20 Fig 21 Fill packing nut with Graco TSL until fluid flows onto the top of seal Fig 1 9023A 308870 15 Displacement Pump Pump Pin Clip Removal Installation Install shield 95 pail hook 94 and pump bracket 85 with two washers 25 and bolts 86 Torque bolts to 40 ft lb 54 Nem 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 Parts List amp 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 241121 PINION HOUSING COIL 1 20 DRIVE HOUSING 19b 105489 PIN 2 20a 194060 RETAINING CLIP pump pin 19d 241114 PINION SHAFT 20b 193656 CAM FOLLOWER PLATE 19e 112770 RETAINING RING large 20c 114691 C
5. Cam Follower Bearings na nanana anaana 8 Complete Sprayers n anana nananana 24 Pinion Assembly Rotor Field Shaft Clutch 9 Dimensions 4222226556445 aaea 25 CAAMD 26 66 iaeia ka od r a eek eee ee hoe oe 10 Technical Data 0 0 0 cee eee 25 Clutch HOUSING ss amp eces 7 oy os rriar ete AiR 11 Graco Phone Number 005 25 Engine 140252456 oas0ndmon onan Ped ooow 2 11 Graco Warranty occ d db bbs On eae aetna owes 26 GRACO INC P O BOX 1441 COPYRIGHT 1999 GRACO INC MINNEAPOLIS MN 55440 1441 Graco Inc is registered to l S EN ISO 9001 Warnings and Cautions Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A 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 eUse 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 e Remove extinguish or unplug all ignition
6. a eis 60 mesh 250 micron Noise Level stainless steel screen reusable Sound power 2 0 22 ccc eee ee Daa ZUR NN See sega anne a asa a H per ISO 3744 Fluid outlet size 1 4 npsm from fluid filter Wetted parts zinc plated carbon steel Sound pressure 000 eee eee 96 dBa PTFE N Nylon polyurethane UHMW polyethylene MASU abe iee Viton Delrin leather aluminum tungsten car Cycles gallon liter 85 69 18 bide nickle plated erin steel EE al chrome plating NOTE Delrin PTFE Viton are trademarks of the DuPont Company Model 232630 Model 232632 Hi Boy without hose or gun Lo Boy Cart without hose or gun Weight dry without packaging 175 Ib 79 4 kg Weight dry without packaging 180 Ib 82 1 kg Height 2 00 ee eee ee 41 in 104 1 cm Height 2 0 0 c ee eee ee 41 in 104 1 cm Lengt gn yates 2 sarri Se oe Soe ae 38 in 96 5 cm LENGI 2 4 gue 6 x accu ners ey eo 38 in 96 5 cm WVIGUM ao ete nh ase Grae eee aA 22 in 55 9 cm YVO co ore nn ee ae Base e a oo ee 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 Graco Warranty Graco warrants all equipment manufactured by Graco and bearing its nart be free from defects in material and workmanship onthe date of sale byan authorized Gr
7. 0 2Q across clutch field at 70 F Replace clutch field assembly Six times Sprayer shuts down and LED contin High clutch temperature f1 If clutch is new let sprayer cool repeatedly ues to blink six times repeatedly down and then restart Inspect clutch Replace clutch if there is excessive wear Remove pump pin separate pin ion housing from clutch housing Rotate rotor clockwise to check for excessive drag 14 308870 Displacement Pump Removal 1 Flush pump 2 Fig 16 Cycle pump with piston rod 222 in lowest position 3 IA W ai Relieve pressure page 4 4 Fig 16 Remove suction tube 30 and hose 33 222 OG gr Dg p Q a pen an Q Fig 16 Repair See manual 308798 for pump repair instructions Installation A 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 230 are properly installed Clip must engage groove in pin A 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 0 in Screw in pump until holes in housing plates and piston rod align Fig 19 A _ 30 9024A 9020A 5 Fig 17 Use screwdriver to push out pump pin 101 lt 72 W ae z BAL F O
8. Oil is seeping into combustion chamber 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 Spark plug cable is disconnected or damaged Engine operates but dis Pressure control switch is OFF Turn pressure control switch ON lacement pump does not p operate Pressure setting is too low Turn pressure adjusting knob clockwise to increase pressure Fluid filter 318 is dirty Clean filter Page 22 Tip or tip filter is clogged Clean tip or tip filter Manual 307614 Displacement pump piston rod is stuck due to Repair pump Manual 308798 dried paint Roller bearings are worn or damaged Replace connecting rod Page 7 Drive housing is worn or damaged 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 2Q if not replace clutch coil 241121 Check control board fuse If blown replace with equivalent automotive fuse Have pressure control checked by authorized Graco dealer Clutch is worn or damaged Replace clutch Pag
9. Use larger diameter hose and or reduce overall mance 50 ft minimum Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Reprime pump Manual 308867 running pump dry Fluid supply is low or empty Air in pump or hose Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming Pump is difficult to prime 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 Intake valve is leaking Paint is too thick Thin the paint according to the suppliers recommendations Engine speed is too high Decrease throttle setting before priming pump Manual 308867 Clutch squeaks each time Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other clutch engages when new and may cause noise Noise will dissipate after a day of run time Engine stalls Engine speed is to slow e Increase throttle setting e 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 6 308870 Rollers Removal lh 4 Ba Relieve pressure page 4 2 Fig 2 Remove six cap screws 10 lock washers 9 and cover assembly 24 Note A screw driv
10. as instructed on pages 7 9 and 10 308870 11 On Off Switch Removal Installation h 1 Install new ON OFF switch 309 so tabs of switch l v amp Relieve pressure page 4 snap into place on inside of pressure control housing 2 Fig 15 Remove five screws 307 and 2 Connect two wires A to ON OFF switch OVER AA 3 Install pressure control cover 322 with five 3 Disconnect two wires A from ON OFF screws 307 switch 309 4 Press in on two retaining tabs on each side of ON OFF switch 309 and remove switch 8711A 12 308870 Pressure Control Control Board Removal 1 lh Ww Relieve pressure page 4 Fig 15 Remove five screws 307 and cover 322 Fig 22 Disconnect at control board 302 e Four clutch leads two violet and two black e Lead D from potentiometer e Lead E from transducer e Two red leads A to ON OFF switch 309 Fig 15 Remove five screws 303 green ground wire and control board 302 Installation When installing replacement control board follow instructions with control board to set model type 1 2 3 Fig 15 Install green ground wire and control board 302 with five screws 303 Fig 22 Connect to control board 302 e Two red leads A to ON OFF switch 309 e Lead E to transducer e Lead D to potentiometer Four clutch leads two violet and two black Fig 15 Install c
11. correct oil viscos ity 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 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 A WARNING INJECTION HAZARD moving parts always follow Pressure Relief Procedure Warning page 4 before checking adjust fi To reduce risk of serious injury including fluid injection or splashing in eyes or on skin or injury from ing cleaning or shutting down sprayer SOLUTION PROBLEM CAUSE Engine won t start Engine switch is OFF Engine is out of gas Turn engine switch ON Refill gas tank Honda Engines Owners Manu a Engine oil level is low Try to start engine Replenish oil if necessary Honda Engines Owner s Manual Connect spark plug cable or replace spark plug Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position
12. grounded nylon 3 8 in ID 1 cpld 3 8 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 1 202 204 220955 CONTRACTOR SPRAY GUN Includes RAC IV DripLess Tip Guard and 517 size SwitchTip See 307614 for parts 1 Accessories Displacement Pump Repair Kit 0160 DANGER LABELS An English language DANGER label is on your sprayer If you have painters who do not read En GMax 7900 240916 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 Order the labels from your Graco distributor Packing repair kit French 194931 OMe Apply other Spanish 194932 lt 2 VW language here German 194933 Greek 194934 Korean 194935 English 194317 24 308870 Technical Data Honda GX160 Engine Maximum delivery rating 2 1 gpm 7 9 liter min Power Rating 3700 rpm Maximum tip size 1 gun with 0 046 in tip ANSI so et big ea pt oo ee wa 5 5 Horsepower 2 guns with 0 033 in tip DIN 6270B DIN 6271 3 guns with 0 026 in tip eer 2 9 Kw 4 0 Ps 4 guns with 0 022 in tip A ee 26Kw 49Ps Inlet paint strainer 16 mesh 1190 micron Maxi kina pressure 3300 psi stainless steel screen reusable A E a 227 bar 22 7 MPa Outlet paint filter
13. 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 4 Unlock trigger safety Hold metal part of gun firmly to side of grounded metal pail and trigger gun to relieve pressure 5 Lock gun trigger safety 6 Open pressure drain valve Leave valve open until ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose 4 308870 A 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
14. screws 10 into drive housing 20 Install cover assembly 24 with six lock washers 9 and cap screws 10 308870 7 Cam Follower Bearings Removal lh Ww Relieve pressure page 4 2 Fig 16 Cycle pump piston rod 222 to lowest position Turn engine off 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 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 Note Two 1 2 in x 13 bolts may be needed to remove cam follower plates 8 Remove two cam follower bearings 20c Fig 4 8 308870 Installation Install two cam follower bearings 20c Install cam follower plate 20b Install two retainer rings 20d Drive in pump pin 101 until it engages with pump pin retaining clip 20a Install four rollers 98 and dowel pins 97 Install cover assembly 24 with six lock washers 9 and cap screws 10 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 lh fa Relieve pressure page 4 2 Disconnect field cable X from pressure control and engine lead
15. 4688 NUT cap hex hd 1 307 114631 SCREW mch pan hd 10 318 114708 SPRING compression 1 308 193052 PLATE instruction 1 318m 114797 GASKET 1 309 114277 SWITCH rocker spst 1 318n 240914 V ALVE 1 310 241443 POTENTIOMETER pressure control 1 318z 240314 TRANSDUCER pressure control 1 311 193657 GASKET potentiometer 1 includes 318aa 312 193654 PLATE instruction 1 318aa 111457 O RING 1 313 114273 KNOB potentiometer 1 319 110997 SCREW flange hex 3 314 193072 LABEL control 1 320 114532 TIE wire twist 1 315 114629 GROMMET transducer 1 3214 189246 LABEL warning 1 318 FILTER fluid 1 322 241444 COVER pressure control 1 318a 193651 HOUSING filter 1 318b 104361 O RING 1 Drain valve replacement kit 241276 available includes 318c 186075 SUPPOR T filter 1 318g through 318n 318d 167025 STRAINER mesh 60 1 A Replacement warning labels may be ordered free of charge T E O Oo 5 Wiring Diagram ree 7 n a gt 310 ac 309 OO H D Ref Ref Red O 2 Gack ry Oz i Potentiometer o y 5 a E a E L a Red J e 7 Pressure J A transducer O m O 318z 318aa SN Ref Ref a O ial 304 Violet 302 Ref ce J Ref S 9279 Fig 22 308870 23 Parts List amp Drawing Complete Sprayers Models 232631 232633 Includes items 201 to 204 Ref No PartNo Description Qty 201 232031 Hi Boy Sprayer 1 See parts list on page 18 232633 Lo Boy Sprayer 1 See parts list on page 21 202 240797 HOSE
16. AM FOLLOWER BEARING 20d 114828 RETAINER CLIP 20g 114697 WASHER 20h 114698 WASHER 101 194117 PIN AQ NYO 20d 101 20a 9046A J Pinion housing coil assembly 19a includes clutch field and all bearings pins and o rings 308870 17 Parts Drawing Hi Boy Sprayers Model 232630 Label See page 17 for the parts See manual 308798 for the parts See page 22 for the parts gt gt b gt See page 22 for the parts L EF SS an ARS SANS Wh NNN N S J Ca a LH ine Lei LZ a ISLE a 3 lt F SLA EA L LASSE ES SSS SSS SSS SSS KL SSS 9018A 18 308870 Models 232630 Ref No Part No 1 114530 2 113084 3 192014 4 241113 4a 4b 9 193531 T 183401 8 193680 9 104008 10 101864 11 239998 12 193682 15 113802 16 108803 17 105510 18 241539 19 241116 20 241537 21 194189 22 103413 23 111603 24 241536 25 100018 26 100644 28 240917 29 194438 30 241541 31 189920 33 240795 34 193394 39 241324 37 183350 38 110243 39 108795 40 191084 Parts List Hi Boy Sprayers Description Qty ENGINE RIVET blind PLATE indicator CLUTCH ASSEMBLY inclu
17. CREW 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 LABEL warning not shown CLIP spring Nh Dh PAY P O PD PD PO a a nanana AO BR BR na PA Nanananana AARO A Danger amp Warning labels tags and cards are free 308870 19 Parts Drawing Lo Boy Sprayers Model 232632 Label See page 17 for the parts See manual 308798 for the parts gt b gt gt See page 22 for the parts 9 99 NX oa 25 DQ iZ 3 AZ LZ T SENN T SSNRNNNN con RASS GY a GE E eZ aa iF ee FEZ SE Sa SOF SEZ eZ lt Ses LLL LSA SSE PSS SSS SSS SSS SSS SSS SS SS L SS SS N NNI 30b Ref gt 20 308870 9027A 24 9016A Model 232632 R
18. INSTRUC TIONS REPAIR 9 KEEP FOR REFERENCE RI Read this and all related manuals for INSTRUCTIONS important warnings and instructions GMax 7900 CE Airless Paint Sprayer 3300 psi 227 bar 22 7 MPa Maximum Working Pressure GMax 7900 Model Series Description 232630 A Hi Boy 232631 A Hi Boy with RAC IV tip gun and hose 232632 A Lo Boy 232633 A Lo Boy with RAC IV tip gun and hose All models are not available in all countries PATENTS PENDING Related Manuals Operation 244 ccc eseaadaw eves wanes 308867 Displacement Pump 308798 Spray Gun 2 2012 od dae eonietkemarn ne 307614 Spray TIP easa ee ee eae 308644 PG Board 5 ohebc kab aaa cok w hee eh ores 308919 Drain Valve Kit 85 308961 308870 Rev B GRACO First choice when quality counts Table of Contents Warnings and Cautions 00000 ee 2 Pressure Control 0 00 00 0c eee eee 13 Component Identification and Function 3 Displacement PUMP ssrarsisirisicreres 15 Maintenance nananana naaa 4 Parts Troubleshooting nanana on Pinion Assembly 0 0000 cee ee eee 17 Repair Hi Boy Sprayers 0 0 0 0 ccc ee eee 18 RONGTG iiaia 2408 bet bee eee ds cel goes eee E Lo Boy Sprayers nnna anaana 20 Drive Housing ca 2 diced a ake naaa aaaea foa Pressure Control nananana aaan ce eee eee 22
19. LE EFLECTOR Qty AQ On gt a gt Na ok a Nana em e IM Ref No 102 Part No 112604 240795 193394 241324 183350 110243 108795 191084 179811 101242 104811 154636 112827 237686 112798 114984 194126 114678 162485 194178 241718 241719 110837 110838 101682 108842 100214 114687 114699 114672 194118 110343 240997 110249 108851 241540 194681 206994 114695 241322 114693 194117 240987 1034 194317 1044 195119 Description Qty STRAINER HOSE coupled NUT retaining CART FRAME WASHER plain RING retaining SCREW mch pn hd 10 32 x 5 16 in SLEEVE WHEEL semi pneumatic RING retaining HUBCAP WASHER BUTTON snap GROUNDING CLAMP amp WIRE SCREW hex washer hd No 8 x 3 8 in SCREW mch pn hd LABEL warning BUSHING strain relief NIPPLE 3 8 18 npsm m x 3 8 npt m HOSE drain DEFLECTOR CLIP spring 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 LABEL warning Nanana VPN AD VP NO PO
20. aco distributor to the original purchaser for use With the exception of any special extendwadimited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part efthement determined by Graco to be defective This warranty applies only when the equipmens 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 teaior any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tamperirag sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibiltof 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 distributcfor verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defeetparts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disdagedefect in material or workmanship repairs will be ma
21. de 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 VARRANTIES 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 tlaabther remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person operty or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two ajyyof the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connetion with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactdire by Graco such as electric motors switches hose etc are subject to the warrantyif 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 eqament hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contrat breach of warranty t
22. des 4a 4b 16 17 72 80 ARMATURE clutch 5 in ROTOR 5 in CLUTCH HOUSING KEY parallel CLAMP WASHER spring lock CAPSCREW socket head 1 4 20 x 3 4 in AQ On gt CART HANDLE amp HOSE RACK 1 CAP end 2 SCREW flange hex hd 1 3 8 16 x 5 8 in CAPSCREW sch 1 4 2 x 1 in 6 LOCKWASHER spring 1 4 in 15 GEAR COMBINATION 1 includes 91 and 92 PINION ASSEMBLY Parts page 17 1 DRIVE HOUSING Parts page 17 1 SWIVEL male QD 1 O RING 1 O RING 1 COVER housing drive kit 1 WASHER lock spring 1 SCREW cap 5 DISPLACEMENT PUMP 1 Parts manual 308798 TUBE nylon split TUBE intake includes 22 23 and 66 STRAINER HOSE coupled NUT retaining CART FRAME WASHER plain RING retaining SCREW mch pn hd 10 32 x 5 16 in SLEEVE hoods NO NOS ee Ref No Part No 179811 101242 104811 154636 112827 237686 112798 114984 194126 114678 162485 194178 241718 241719 110837 110838 101682 108842 100214 114687 114699 114672 194118 110343 240997 110249 108851 241540 195377 206994 114695 241322 114693 194117 240987 194317 195119 194194 Description Qty WHEEL semi pneumatic RING retaining HUBCAP WASHER BUTTON snap GROUNDING CLAMP amp WIRE SCREW hex washer hd No 8 x 3 8 in SCREW mch pn hd LABEL warning BUSHING strain relief NIPPLE 3 8 18 npsm m x 3 8 npt m HOSE drain DEFLECTOR CLIP spring S
23. e 9 Pinion assembly is worn or damaged Repair or replace pinion assembly Page 9 308870 5 PROBLEM CAUSE SOLUTION 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 damaged Replace packings Manual 308798 O ring 227 in displacement pump is worn or Replace o ring Manual 308798 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 Clean filter Manual 308867 or 307614 dirty materials 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 Excessive paint leakage into Throat packing nut is loose Remove throat packing nut spacer Tighten throat packing nut throat packing nut just enough to stop leakage Throat packings are worn or damaged Replace packings Manual 308798 Displacement rod is worn or damaged Replace rod Manual 308798 Tip is partially clogged Clear tip Manual 307614 Refill fluid supply Prime pump Manual 308867 Check fluid supply often to prevent Large pressure drop in hose with heavy
24. ef No AUN 30aa 30ab 30ac 30ad 30ae 30aea 30aeb 30aec 30b 30c 30d 30e Part No 114530 113084 192014 241113 193531 183401 193680 104008 101864 239998 193682 113802 108803 105510 241539 241116 241537 194189 103413 111603 241536 100018 100644 240917 194438 241288 241269 241542 176450 194307 101818 241720 170957 195151 114967 194180 194194 162453 241718 Parts List Lo Boy Sprayers Description 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 CLAMP WASHER spring lock CAPSCREW socket head 1 4 20 x 3 4 in CART HANDLE amp HOSE RACK CAP end SCREW flange hex hd 3 8 16 x 5 8 in 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 SWIVEL male QD O RING O RING 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 includes 22 23 and 66 GUARD hose HOSE fluid CLAMP hose TUBE suction includes 30aea 30aeb and 30aec TUBE suction lower TUBE intake COUPLING pipe in HOSE drain CLIP spring NIPP
25. er may be needed to pry off cover assembly 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 Fig 2 Drive Housing Removal Installation lh i Na Relieve pressure page 4 2 Fig 2 Remove six cap screws 10 lock washers 9 and cover assembly 24 Fig 3 Remove two screws 99 and washers 9 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 A Apply remaining grease to these areas Fig 3 9032A 1 Liberally apply bearing grease supplied with 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 Place bronze colored washer 83 and silver colored washer 82 onto drive housing 20 Install gear cluster 18 through washers 83 and 82 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 Install two washers 9 and screws 99 Install four lock washers 9 and cap
26. he 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 process entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les esrteconnais sent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiresi executes donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es 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 publicdion Graco reserves the right to make changes at any time without notice Sales Offices Minneapolis Detroit Foreign Offices Belgium England Korea France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com PRINTED IN USA 308870 March 1999 Revised May 1999 26 308870
27. internal stop Assemble potentiometer knob 313 to strike pin on plate 312 b After adjustment of step a tighten both set screws in knob 1 4 to 3 8 turn after contact with shaft Connect lead D to control board 302 Install cover 322 with five screws 307 308870 13 Pressure Control Control Board Diagnostics 1 Fig 15 Remove five screws 307 and 3 Turn ON OFF switch ON cover 322 4 Observe LED operation and reference following 2 Start sprayer table LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times Sprayer shuts down and LED contin Run away pressure Check pressure transducer con repeatedly ues to blink two times repeatedly Pressure greater than nection at control board 4500 psi 310 bar 31 Replace pressure transducer MPa Replace control board Three Sprayer shuts down and LED contin Pressure transducer is Check pressure transducer con times re ues to blink three times repeatedly faulty or missing nection at control board peatedly Replace pressure transducer Replace control board Four times Sprayer shuts down and LED contin Generator voltage is Increase engine throttle repeatedly ues to blink four times repeatedly low Check wiring connections Service Honda engine alternator Five times Sprayer shuts down and LED contin High clutch current Check clutch 5 pin bulkhead con repeatedly ues to blink five times repeatedly nector Clean contacts Measure 1 7
28. over 322 with five screws 307 Pressure Control Transducer Removal lh i Na Relieve pressure page 4 2 Fig 15 Remove five screws 307 and cover 322 Disconnect lead E from control board 302 Remove three screws 319 and fluid filter 318 from control plate 301 Carefully pull transducer connector through rubber grommet 315 5 Remove pressure control transducer 318z and packing o ring 318aa from filter housing 318a Installation 1 4 Fig 15 Install packing o ring 318aa and pres sure control transducer 318z in filter housing 318a Torque to 30 35 ft lb Carefully feed transducer connector through rubber grommet 315 Install fluid filter 318 on control plate 301 with three screws 319 Connect lead E to motor control board 302 Install cover 322 with five screws 307 Pressure Adjust Potentiometer Removal 1 lh Na Relieve pressure page 4 Fig 15 Remove five screws 307 and cover 322 Disconnect lead D from control board 302 Loosen set screws on potentiometer knob 313 and remove knob shaft nut lockwasher 310 and pressure adjust potentiometer 310 Remove seal 311 from potentiometer 310 Installation 1 2 Install seal 311 on potentiometer 310 Fig 15 Install pressure adjust potentiometer 310 shaft nut lockwasher 310 and potentiome ter knob 313 a Turn potentiometer shaft 310 clockwise to
29. retaining ring 19e with beveled side facing field Y Fig 7 Place pinion assembly on bench with rotor side up 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 Fig 6 Install pinion assembly 19 with five screws 10 and lockwashers 9 Fig 5 Connect field cable X to pressure control and engine lead 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 Chamfer side must face engine 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 10 308870 AN Face of clutch housing 1 812 010 in 46 02 25 mm AN Torque to 125 10 in lb 14 1 1 N m An Chamfer this side N5 A AG lr 7 B ia os S SNS BD JA gt 16A A 03483 i Fig 11 Clutch Housing Removal 1 2 Remove screw 15 from under mounting plate D
30. sources tape wall switch Do not smoke in spray area Never fill fuel tank while the engine is running or hot eGround Sprayer object being sprayed paint and solvent pails Hold gun firmly to side of a grounded pail when triggering into pail eUse only conductive airless paint hose Never run engine in inclosed area NS 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 eEngage 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 Maximum Working Pressure MPa bar PSI Never allow children to use this unit If you are injured using this equipment get immediate medical treatment 2 308870 Component Identification and Function 202 Main hose V D C i Mininura Opersing Speed 203 Whip end hose lanenino 204 Contractor gun with RAC IV DripLess tip guard and 517 size SwitchTp Full Flow Slower Cycles 3 2 1 0 J SA TII NS WS K 202 Fig 1 A Pressure Control Switch ON OFF enables disables clutch function and press
31. ure control B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleane Filters air entering the carburetor D Fuel Tankt Uses 86 octane unleaded gasoline n E Muffler Reduces noise of internal combustion sd F Spark Plug Cable Routes electricalcurrenttosparkplug sid G Fuel Shutoff Lever On off lever to regulate fuel flow from gasoline tank to carburetor J Throttle Leve Adjusts engine speed for large or small orifice spray tips L Secondary Fluid Outlet Second hose and spray gunisconnectedhere e M Pressure Control Controls clutch cycling to maintain fluid pressure N Primary Fluid Outlet Hose and spray gun is connected here Csi R Clutch Housing Transfers power from engine to drive assembly sid S Drive Housing Transfers power from clutch to displacement pump i T Displacement Pump Provides fluid to be sprayed through spraygun e w Pail Hanger Provides a hanger for paint pail X Drain Valve Relieves fluid pressure when open s For more detailed explanations of these controls refer to the Honda Engines Owner s Manual supplied 308870 3 Maintenance A WARNING INJECTION HAZARD Ea 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
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