Graco Inc. 232630 Paint Sprayer User Manual
Contents
1. REF REF NO PARTNO DESCRIPTION QTY NO PARTNO DESCRIPTION QTY 301 193653 PLATE control 1 318f 192706 BOWL filter 1 302 241093 BOARD PC 1 318g 193710 SEAL valve 1 303 111839 SCREW mch pan 6 32 x 1 2 in 5 318h 193709 SEAT valve 1 304 240776 HARNESS wiring 1 318 194102 HANDLE valve 1 305 193497 GASKET control 2 318k 114688 NUT cap hex hd 1 306 193652 HOUSING control box 1 3181 114708 SPRING compression 1 307 114631 SCREW mch pan hd 0 318m 114797 GASKET 1 308 193052 PLATE instruction 1 318n 245103 VALVE 1 309 114277 SWITCH rocker spst 1 318z 240314 TRANSDUCER pressure control 1 310 241443 POTENTIOMETER pressure control 1 includes 318aa 311 193657 GASKET potentiometer 1 318aa 111457 O RING 1 312 193654 PLATE instruction 1 319 110997 SCREW flange hex 3 313 114273 KNOB potentiometer 1 320 114532 TIE wire twist 1 314 193072 LABEL control 1 321A 189246 LABEL warning 1 315 114629 GROMMET transducer 1 322 241444 COVER pressure control 1 318 FILTER fluid 1 323 193684 LABEL identification 1 318a 193651 HOUSING filter 1 318b 104361 O RING 1 A 318c 186075 SUPPORT filter 1 Drain valve replacement kit 245103 includes 318g through 318d 167025 STRAINER mesh 60 1 318n 318e 171941 SPRING compression 1 A Replacement warning labels may be ordered2. 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 i 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 won t start Engine switch is OFF Turn engine switch ON Engine is out of gas 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 Move
3. 5 193531 CLUTCH HOUSING 1 56A 194126 LABEL warning 7 183401 KEY parallel 1 61 114678 BUSHING strain relief 8 193680 CLAMP 1 62 162485 NIPPLE 3 8 18 npsm m x 3 8 npt m 9 104008 WASHER spring lock 2 64 194178 HOSE drain 0 10 101864 CAPSCREW socket head 65 241718 DEFLECTOR 1 4 20 x 3 4 in 70 110837 SCREW flng hex hd Neea wWH HNHH NYNYNPD 11 239998 CART HANDLE amp HOSE RACK 1 5 16 18 x 1 1 2 in 12 193682 CAP end 2 71 110838 LOCKNUT heavy hex 5 16 18 15 113802 SCREW flange hex hd 1 72 101682 SCREW cap sch 3 8 16 x 5 8 in 73 108842 SCREW cap sch 16 108803 CAPSCREW sch 1 4 2 x 1 in 6 77 100214 WASHER lock spring 17 105510 LOCKWASHER spring 1 4 in 15 78 114687 CLIP retainer 18 241539 GEAR COMBINATION 1 80 HUB armature includes 91 and 92 82 114699 WASHER thrust 19 241116 PINION ASSEMBLY Parts page 17 20 241537 DRIVE HOUSING Parts page 17 21 114967 COUPLING 86 110343 SCREW cap sch 24 241536 COVER housing dr5e kit 87 240997 CONDUCTOR ground 1 83 114672 WASHER thrust 1 1 1 25 100018 WASHER lock spring 1 88 110249 ADAPTER male elbow 90 5 1 85 194118 BRACKET pump 26 100644 SCREW cap 93 108851 WASHER 28 240917 DISPLACEMENT PUMP 94 241540 PAIL HOOK Repair Kit includes 95 Parts manual 308798 95 195377 GROMMET pump 29 194438 TUBE nylon split 1 96 206994 THROAT SEAL LIQUID not shown 30 244823 TUBE intake 1 97 114695 DOWEL PIN includes 21 98 241322 ROLLER assembly
4. Fig 1 4 9026A Installation 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 Fig 13 Connect all necessary wiring Install Pinion Assembly Rotor Field Pinion Clutch Clamp and Clutch Housing as instructed on pages 7 9 and 10 308870 11 On Off Switch Installation Removal ly 1 AN S fF Relieve pressure page 4 2 Fig 15 Remove five screws 307 and cover 322 3 Disconnect two wires A from ON OFF switch 309 4 Press in on two retaining tabs on each side of ON OFF switch 309 and remove switch 12 308870 1 Install new ON OFF switch 309 so tabs of switch snap into place on inside of pressure control housing Connect two wires A to ON OFF switch Install pressure control cover 322 with five screws 307 318a 8711A Pressure Control Control Board Removal 1 In we n Relieve pressure page 4 Installation When installing replacement control board follow instructions with control board to set model type 1 Fig 15 Install green ground wire and control board 302 with five screws 303 2 Fig 22 Connect to control board 302 Two red leads A to ON OFF switch 309 Lead E to transducer Lead D to potentiometer e Four clutch leads two violet and two black 3 Fig 15 Install cover 322 with five screws 307 Pressure Cont
5. Uses 86 octane unleaded gasoline E Muffler Reduces noise of internal combustion F Spark Plug Cable Routes electrical current to spark plug G Fuel Shutoff Lever On off lever to regulate fuel flow from gasoline tank to carburetor H Choke Enriches air gasoline mixture for cold starting Throttle Lever Adjusts engine speed for large or small orifice spray tips K Engine Switch Enables disables engine operation L Secondary Fluid Outlet Second hose and spray gun is connected here M Pressure Control Controls clutch cycling to maintain fluid pressure N Primary Fluid Outlet Hose and spray gun is connected here R Clutch Housing Transfers power from engine to drive assembly S Drive Housing Transfers power from clutch to displacement pump T Displacement Pump Provides fluid to be sprayed through spray gun Fluid Filter Filters fluid between source and spray gun Grounding Clamp and Wire Grounds sprayer system WwW Pail Hanger Provides a hanger for paint pail X Drain Valve Relieves fluid pressure when open Pe For more detailed explanations of these controls refer to the Honda Engines Owner s Manual supplied 308870 3 Maintenance A CAUTION A WARNING INJECTION HAZARD ba 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 injecti
6. 241324 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 42 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 HOSE coupled NUT retaining CART FRAME Qty a Na E Niek aR a au N Anaa e a N a Ref No 103A 104A Part No 194068 183350 110243 108795 191084 179811 101242 104811 154636 112827 237686 112798 114984 194126 114678 162485 194178 241718 110837 110838 101682 108842 100214 114687 114699 114672 194118 110343 240997 110249 108851 241540 194681 206994 114695 241322 114693 195523 240987 194317 195119 Description Qty LABEL identification WASHER plain RING retaining SCREW mch pn hd 10 3
7. 31 189920 STRAINER 33 240795 HOSE coupled 34 193394 NUT retaining 35 241324 CART FRAME 36 194068 LABEL identification 37 183350 WASHER plain 38 110243 RING retaining 39 108795 SCREW mch pn hd 10 32 x 5 16 in 40 191084 SLEEVE 41 179811 WHEEL semi pneumatic 99 114693 SCREW cap sch 101 195523 PIN 102 240987 PLUG packless 3 8 in 1034 194317 LABEL warning 1044 195119 LABEL warning not shown 105 194194 CLIP spring BoA a pH ARBAB aA PHY Ha M t aA A A A AAOD A Danger amp Warning labels tags and cards are free Model 23308 includes Gauge Kit 241339 MMANMNMABAA A 308870 19 Parts Drawing Lo Boy Sprayers Model 232632 DETAIL A Ref 11 a 40 Label See page 17 for the parts See manual 308798 for the parts PPPE See page 22 for the parts ee LZ FEZ SSE SSS 30b won 20 308870 9016A 29 Model 232632 No Part No 1 114530 2 113084 3 192014 4 241113 4a 4b 5 193531 7 183401 8 193680 9 104008 10 101864 11 239998 12 193682 15 113802 16 108803 17 105510 18 241539 19 241116 20 241537 24 241536 25 100018 26 100644 28 240917 29 194438 30 241288 30a 241269 30aa 198119 30ab 176450 30ac 194307 30ad 101818 30ae 192633 30b 194180 30c 194194 30d 162453 30e 241718 30f 112604 33 240795 34 193394 35
8. E TE 41 in 104 1 cm Lengi oreet a ake Pia 38 in 96 5 cm Lengi wae cava in age a a 38 in 96 5 cm Width u adia i a ia 22 in 55 9 cm WIAT sa iaai ara ama araa E metas 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 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
9. 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
10. down and LED contin ues to blink six times repeatedly High clutch temperature Check pressure transducer con nection at control board Replace pressure transducer Replace control board Check pressure transducer con nection at control board Replace pressure transducer Replace control board Increase engine throttle Check wiring connections Service Honda engine alternator Check clutch 5 pin bulkhead con nector Clean contacts Measure 1 7 0 2Q across clutch field at 70 F Replace clutch field assembly If clutch is new let sprayer cool 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 Displacement Pump Removal 1 Flush pump 2 Fig 16 Cycle pump with piston rod 222 in lowest position Relieve pressure page 4 A 4 Fig 16 Remove suction tube 30 and hose 33 222 9024C lt __ 30 9024B See manual 308798 for pump repair instructions Fig 16 Repair 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 20a are properly installed See Detail A Fig 17 A CAUTION If the pump locknut loosens during operation the threads of the bearing housing will be da
11. eee 22 Cam Follower Bearings 20 0055 8 Complete Sprayers 000e eee ee eee 24 Pinion Assembly Rotor Field Shaft Clutch 9 DIMENSIONS aaea rau ati a a a eee 25 Clamp ie tee rane daa E EE 10 Technical Data eese mocinno AS 25 Clutch Housing 2 00ce cece eee eee 11 Graco Phone Number 00000 eee 25 Enge tii athe Sen Scie snot rho int ae Ea inde 11 Graco Warranty 00 ccc eee eee nes 26 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1999 GRACO INC Graco Inc is registered to I S EN ISO 9001 Warnings and Cautions Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Caution Symbol A CAUTION This symbol alerts you to the possibility of damage to 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 eDo 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 eRemove extinguis
12. free of charge ane 9 Wiring Diagram r aa NY 310 309 ac N D Ref H a Ref alo a Red O 2 CLUTCH 14 i l 3 e H 3 Potentiometer o LI H Dn C mms E 55 DY l HI Red 711 T ay Pressure A cs L transducer CC g SAE vot O 318z 318aa Ref Ref JG 304 Violet 302 Ref S Ref lt A 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 232631 Hi Boy Sprayer 1 See parts list on page 18 232633 Lo Boy Sprayer 1 See parts list on page 21 202 240797 HOSE 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 nosm m x 1 4 npsm f swivel 3 foot 0 9 m spring guards both ends 1 202 0180 204 220955 CONTRACTOR SPRAY GUN Includes RAC 5 DripLess Tip Guard and 517 size SwitchTip See 309091 for parts 1 Accessories Displacement Pump Repair Kit Packing repair kit 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 French 194931 NORA Apply other Spanish 194932 sy language here German 194933 i Greek 19
13. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s 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 availa
14. 2 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 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 N 2 20424M4242pNNMNMAH ANN SHB 3 a pH ARBAB aA pH Ha pABaB ao A A A AAO 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
15. 4934 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 ANS eniten 5 5 Horsepower 2 guns with 0 033 in tip DIN 6270B DIN 6271 3 guns with 0 026 in tip NTa O E E 2 9 Kw 4 0 Ps 4 guns with 0 022 in tip NB oo cece cece ee eececcees 3 6 Kw 4 9 Ps Inlet paint strainer 16 mesh 1190 micron Maxi king pressure stainless steel screen reusable ee gene ere a 227 bar 227 Mpa Outlet paint filter 60 mesh 250 micron Noise Level i stainless steel screen reusable Sound power 105 dBa Pump inlet size uaau 3 4 in npt m oa a per ISO 3744 Fluid outlet size 1 4 npsm from fluid filter Sound pressure 96 dBa Wetted parts zinc plated carbon steel Se measured at 3 1 feet 1 m PTFE Nylon polyurethane UHMW polyethylene l Viton Delrine leather aluminum tungsten car Cycles gallon liter 0 00 eee eee 69 18 bide nickle plated carbon steel stainless steel chrome plating NOTE Delrin and Viton are trademarks of the DuPont Company 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 Weight dry without packaging 180 Ib 82 1 kg HeD s eeaeee ea ewan SEENE 41 in 104 1 cm FIGIQN EE E EE E
16. INSTRUCTIONS REPAIR N RA 308870 KEEP FOR REFERENCE Rev F Read this and all related manuals for important warnings and instructions INSTRUCTIONS GMax 7900 gt Airless Paint Sprayer 3300 psi 227 bar 22 7 MPa Maximum Working Pressure GMax 7900 Model Series Description 232630 Hi Boy 232631 ET Hi Boy with RAC 5 tip gun and hose Lo Boy GRACO First choice when quality counts 232633 B Lo Boy with RAC 5 tip gun and hose 233008 Hi Boy with Gauge Kit All models are not available in all countries PATENTS PENDING Related Manuals Operation 0 eee eee 308867 Displacement Pump 308798 Spray Gun 2 4026 cs eS aee idacomicye bbax 309091 ee Spray Tip 2 cece eee eee 309055 PC BOard s ceived baciter tier unnie 308919 Drain Valve Kit 2 000 308961 Table of Contents Warnings and Cautions 0 cece ee eee 2 Pressure Control 0 cece eee een ees 13 Component Identification and Function 3 Displacement Pump 000 15 Maintenance 0 cece eee ees 4 Parts Troubleshooting 0 0 c cece eee eee eee 5 Pinion Assembly 0 0 ce ee eee eee 17 Repair Hi Boy Sprayers 000 eee cece eee eee 18 Rollei Sei sisal e ves fe hae woe eee eed ed 7 Lo Boy Sprayers sassuanaaanna nenen 20 Drive HOUSING cece eee eee 7 Pressure Control 00 00 e cece ee
17. ON SHAFT RETAINING RING large Parts List amp Drawing Pinion Assembly Ref No 20 Drive Housing Assembly 241537 Ref No 20 20a 20b 20c 20d 20g 20h 101 Part No 194060 193656 114691 114828 114697 114698 195523 20d Description DRIVE HOUSING RETAINING CLIP pump pin CAM FOLLOWER PLATE CAM FOLLOWER BEARING RETAINER CLIP WASHER WASHER PIN A Pinion housing coil assembly 19a includes clutch field and all bearings pins and o rings 9046A 308870 Qty 424 pp 4 17 Parts Drawing Hi Boy Sprayers Model 232630 Label DETAIL A Ref 11 f See page 17 for the parts See manual 308798 for the parts See page 22 for the parts b gt PPP See page 22 for the parts W 8699A HH 62 88 gt Q 102 s0180 104 D e 64 Ref 18 308870 Parts List Hi Boy Sprayers Models 232630 Ref Ref No Part No Description Qty No PartNo Description Qty 1 114530 ENGINE 1 42 101242 RING retaining 2 113084 RIVET blind 2 43 104811 HUBCAP 3 192014 PLATE indicator 1 44 154636 WASHER 4 241113 CLUTCH ASSEMBLY 1 45 112827 BUTTON snap includes 4a 4b 16 17 72 80 47 237686 GROUNDING CLAMP amp WIRE 4a ARMATURE clutch 5 in 1 49 112798 SCREW hex washer hd No 8 x 3 8 in 4b ROTOR 5 in 1 52 114984 SCREW mch pn hd
18. ble 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 http www graco com PRINTED IN USA 308870 March 1999 Revised 3 2001 26 308870
19. e measuring device to measure distance between bar and face of clamp Adjust clamp as necessary Torque two screws 16 to 125 10 in Ib 14 1 1 N m 10 308870 A Face of clutch housing 1 812 010 in 46 02 25 mm A Torque to 125 10 in lb 14 1 1 N m A Cham fer this side A 03483 Fig 11 Clutch Housing Removal 1 Fig 12 Remove four capscrews 75 and lock washers 77 which hold clutch housing 5 to engine Fig 12 9025A Engine 2 Remove screw 15 from under mounting plate D 3 Remove engine key 7 4 Pull off clutch housing 5 Installation 1 Fig 12 Push on clutch housing 5 2 Install four capscrews 75 and lockwashers 77 and secure clutch housing 5 to engine Torque to 200 in lb 22 6 Nem 3 Install capscrew 15 from beneath mounting plate D Torque to 26 ft lb 35 2 Nem 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 71 2 H A To the field A To the engine A 9027A Fig 13
20. h or unplug all ignition sources tape wall switch Do not smoke in spray area eNever 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 eNever run engine in inclosed area 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 ePoint gun away from yourself or anyone else eRelieve pressure before checking or repairing any leak eRelieve pressure when you turn off the sprayer or stop spraying eDo not use components rated less than system Maximum Working Pressure Never allow children to use this unit If you are injured using this equipment get immediate medical treatment 2 308870 Component Identification and Function Minimum Operating Speed 3 2ni LSL o ll Aow Slower Cycles 202 Main hose V D 203 Whip end hose 204 Contractor gun with RAC 5 DripLess tip guard and 517 size SwitchTip Fig 1 A Pressure Control Switch ON OFF enables disables clutch function and pressure control B Pressure Adjusting Knob Controls fluid outlet pressure Filters air entering the carburetor D Fuel Tank
21. ig 3 Installation 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 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 n 1 W N 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 Insta
22. lever to ON position 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 Engine operates but dis Pressure control switch is OFF Turn pressure control switch ON placement pump does not 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 309091 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 20 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 PROBLEM CAUSE SOLUTION Pi
23. ll 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 Ne 1 aN Ra F Relieve pressure page 4 2 Disconnect field cable X from pressure control and engine lead Bottom View Fig 5 9027A 3 Fig 6 Remove five screws 26 and lockwashers 17 and pinion assembly 19 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 9030A Fig 7 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 ae AY Fig 9 9028A 308870 9 Pinion A
24. maged 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 9020A Fig 19 5 Fig 17 Use screwdriver to push out pump pin 101 20a 101 Detail A hes Fig 17 6 Fig 18 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump 9022A Fig 18 2 Fig 17 See Detail A Push pin 101 into hole until retaining clip 20a snaps over pin 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 9023A Fig 21 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 Ref No 19 and 20 Ref No 19 Pinion Housing Assembly 241116 Ref No 19a 19b 19d 19e Part No 241121 105489 241114 112770 Description Qty PINION HOUSING COIL 1 PIN 2 PINI
25. on 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 For detailed engine maintenance and specifications refer to separate Honda Engines Owner s Manual supplied DAILY Check engine oil level and fill as necessary DAILY Check hose for wear and damage DAILY Check gun safety for proper operation DAILY Check pressure drain valve for proper opera tion DAILY Check and fill the gas tank AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscos ity
26. rol Transducer 5 Remove pressure control transducer 318z and packing o ring 318aa from filter housing 318a Installation 1 Fig 15 Install packing o ring 818aa and pres sure control transducer 31 82 in filter housing 318a Torque to 30 35 ft lb 2 Carefully feed transducer connector through rubber grommet 315 Install fluid filter 818 on control plate 301 with three screws 319 Connect lead E to motor control board 302 4 Install cover 322 with five screws 307 Pressure Adjust Potentiometer 2 Fig 15 Remove five screws 307 and cover 322 3 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 4 Fig 15 Remove five screws 303 green ground wire and control board 302 Removal 1 i In A w ai 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 Removal 1 k Ins k w AE Relieve pressure page 4 2 Fig 15 Remove five screws 307 and cover 322 3 Disconnect lead D from control board 302 4 Loosen set screws on potentiometer knob 313 and remove knob shaft nut lockwasher 310 and pressure adjust potentiome
27. ssembly 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 1 Wo Pet et Pee i Fig 10 disa 4 Install armature 4a on engine drive shaft 5 Install four screws 16 and lockwashers 17 with torque of 125 in lb 6 Fig 8 Tap pinion shaft 19d in with plastic mallet 7 Install retaining ring 19e with beveled side facing field Y 8 Fig 7 Place pinion assembly on bench with rotor side up 9 Apply locktite to screws Install four screws 16 and lockwashers 17 Alternately torque screws to 125 in lb until rotor is secure Use threaded holes to hold rotor 10 Fig 6 Install pinion assembly 19 with five screws 10 and lockwashers 9 11 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 accurat
28. ston ball 25 is not seating Service piston ball Manual 308798 Piston packings are worn or damaged Replace packings Manual 308798 O ring 227 in displacement pump is worn or damaged Pressure setting is too low Fluid filter 318 tip filter or tip is clogged or Clean filter Manual 308867 or 309091 dirty Large pressure drop in hose with heavy Use larger diameter hose and or reduce overall 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 mance 50 ft minimum 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 Reprime pump Manual 308867 Tip is partially clogged 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 connections Reduce engine speed and cycle pump as slowly as possible during priming Intake valve is leaking Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reas semble valve Pump packings are worn Replace pump packings Manual 308798 Paint is too thick Thin the paint according to the supplier s recommendations Engine speed is too high Decrease throttle setting before priming pump Manual 308867 Cl
29. ter 310 5 Remove seal 311 from potentiometer 310 Installation 1 Install seal 311 on potentiometer 310 2 Fig 15 Install pressure adjust potentiometer 310 shaft nut lockwasher 310 and potentiome ter knob 313 a Turn potentiometer shaft 810 clockwise to 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 3 Connect lead D to control board 302 Install cover 322 with five screws 307 gt A 308870 13 Pressure Control Control Board Diagnostics 3 Turn ON OFF switch ON 4 Observe LED operation and reference following 1 Fig 15 Remove five screws 307 and cover 322 2 Start sprayer table LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times repeatedly Three times re peatedly Four times repeatedly Five times repeatedly Six times repeatedly 14 308870 Sprayer shuts down and LED contin ues to blink two times repeatedly Run away pressure Pressure greater than 4500 psi 310 bar 31 MPa Pressure transducer is faulty or missing Sprayer shuts down and LED contin ues to blink three times repeatedly Sprayer shuts down and LED contin ues to blink four times repeatedly Generator voltage is low Sprayer shuts down and LED contin ues to blink five times repeatedly High clutch current Sprayer shuts
30. utch 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 Spark plug wire is loose Reconnect wire 6 308870 Rollers Removal In 1 AI M amp F Relieve pressure page 4 2 Fig 2 Remove six cap screws 10 lock washers 9 and cover assembly 24 Note A screw driver 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 1 In 1 W A 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 Remove four cap screws 10 lock washers 9 from drive housing 20 5 Lightly tap around drive housing 20 to loosen 3 drive housing Pull drive housing straight off pinion housing Be prepared to support gear cluster 18 which may also come out AN Apply remaining grease to these areas F
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