Graco 232624 Operation manual

308864G

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Model 232624 8737A

INSTRUCTIONS-PARTS LIST

INSTRUCTIONS

This manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

5.5 HORSEPOWER, GASOLINE POWERED

GMAX 5900 Convertible

Airless Paint Sprayer

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

Model Series Description

232624 ASprayer, gas powered

232625 ASprayer, gas powered, with RACt5tip,

gun and hose

232626 ASprayer, gas powered, with electric mo-

tor kit

232629 ASame as 232626 except with ETL ap-

proval to CSA and UL standards

232680 ASprayer, gas powered, with Lo-Boy

suction set kit

232681 ASprayer, gas powered, with RAC 5 tip,

gun and hose and Lo-Boy suction set kit

232682 ASprayer, gas powered, with Lo-Boy suc-

tion set kit and electric motor kit

240774 AElectric motor kit converts sprayer to

electric powered sprayer.

240775 ASame as 240774 except with ETL ap-

proval to CSA and UL standards

Table of Contents

Component Identification and Function 3............

Maintenance 4...................................

Troubleshooting 5................................

Repair

Bearing Housing and Connecting Rod 7...........

Drive Housing 8................................

Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley 9..

ON/OFF Switch 11.............................

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

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

Parts

Basic Sprayer 16...............................

Pinion Assembly 18............................

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

Wiring Schematic 20............................

Clutch Assembly 21............................

Complete Sprayer 21...........................

Lo-Boy Suction Set Kit 22.......................

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

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

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

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

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

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

2308864

Warnings and Cautions

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

Fluid injection is a serious injury! If high pressure fluid pierces

your skin, the injury might look like “just a cut”. But it is a serious

wound! Get immediate medical attention.

To help prevent injection, always:

DEngage trigger safety latch when not spraying.

DPoint gun away from yourself or anyone else.

DRelieve pressure before checking or repairing any leak.

DRelieve pressure when you turn off the sprayer or stop spraying.

DDo 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.

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:

DUse outdoors or in an extremely well ventilated area.

DDo 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.

DRemove, extinguish or unplug all ignition sources;

tape wall switch. Do not smoke in spray area.

DNever fill fuel tank while the engine is running or hot.

DGround Sprayer, object being sprayed, paint and solvent pails.

DHold gun firmly to side of a grounded pail when triggering into pail.

DUse only conductive airless paint hose.

DNever run engine in inclosed area.

WARNING

3308864

Component Identification and Function

Fig. 1

203

204

202

202 Main hose

203 Whip end hose

204 Contractor gun with RAC 5

DripLess tip guard and 517 size SwitchTip

NModel 232624

8738A

APressure Control Switch ON/OFF, enables/disables clutch function

BPressure Adjusting Knob Controls fluid outlet pressure

CAir Cleaner* Filters air entering carburetor

DFuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline

EMuffler* Reduces noise of internal combustion

FSpark Plug Cable* Routes electrical current to spark plug

GFuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor

HChoke* Enriches air/gasoline mixture for cold starting

JThrottle Lever* Adjusts engine speed for large or small orifice spray tips

KEngine Switch* Enables/disables engine operation

LSecondary Fluid Outlet Second hose and spray gun is connected here

MPressure Control Controls clutch cycling to maintain fluid pressure

NPrimary Fluid Outlet Hose and spray gun is connected here

PEngine* 5.5 HP gasoline engine

RClutch Housing Transfers power from engine to drive assembly

SDrive Housing Transfers power from clutch to displacement pump

TDisplacement Pump Provides fluid to be sprayed through spray gun

UFluid Filter Filters fluid between source and spray gun

VGrounding Clamp and Wire Grounds sprayer system

WPressure Drain Valve Relieves fluid pressure when open

XCord Provides electric power from engine alienator to control and clutch

YClamp Locks down engine/motor and provides belt tension

*For more detailed explanations of these controls, refer to Honda engine manual; supplied

4308864

Maintenance

WARNING

INJECTION HAZARD

System pressure must be manually

relieved to prevent system from starting

or spraying accidentally. Fluid under high

pressure can be injected through skin and cause

serious injury. To reduce risk of injury from injec-

tion, splashing fluid, or moving parts, follow Pres-

sure Relief Procedure whenever you:

Dare instructed to relieve pressure,

Dstop spraying,

Dcheck or service any system equipment,

Dor install or clean spray tip.

Pressure Relief Procedure

1. Lock gun safety latch.

2. Turn engine or electric motor ON/OFF switch to

OFF.

3. Unplug power supply cord (electric motor).

4. Move pressure control switch to OFF and turn

pressure control knob fully counterclockwise.

5. Rotate RAC 5 tip, if used, to reverse position.

6. Unlock gun safety latch. Hold metal part of gun

firmly to grounded metal pail. Trigger gun to relieve

pressure.

7. Lock gun safety latch.

8. Open pressure drain valve. Leave pressure drain

valve open until ready to spray again.

If suspected that spray tip or hose is completely

clogged, or that pressure has not been fully relieved

after following 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 obstruction.

UTION

For detailed engine maintenance and specifications,

refer to separate engine manual, supplied.

DAILY: Check engine oil level and fill as necessary.

Manual 308863.

DAILY: Check that V-belt (60) is centered on pulleys

and is not inverted. Replace if worn or damaged.

DAILY: Check and fill gas tank.

DAILY: Check hoses for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check pressure drain valve for proper opera-

tion.

AFTER THE FIRST 20 HOURS OF OPERATION

AND EACH 100 HOURS THEREAFTER: Change

engine oil.

DAILY: Keep TSL in packing nut to help lubricate

pump packings. One full squirt of TSL is usually

enough.

WEEKLY: Remove cover of air filter (C) and clean

element. Replace element, if necessary. If operating in

an unusually dusty environment, check filter daily and

replace it, if necessary.

Repack connecting rod (22) top needle bearing after

every pump change.

Replacement elements can be purchased from your

local HONDA dealer.

SPARK PLUG: Use only an BPR6ES (NGK) or

W20EPR--U (NIPPONDENSO) plug. Gap plug to

0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug

wrench when installing and removing plug.

5308864

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.

Check everything in chart before disassembling 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 Manual.

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

Honda Engines Owner’s Manual.

Spark plug cable disconnected or

spark plug damaged

Connect spark plug cable or replace spark plug.

Oil seepage 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 seepage.

Engine operates, but

Pressure control switch turned OFF Turn on.

displacement pump

doesn’t Pressure setting too low Increase pressure.

Displacement pump outlet filter dirty Clean filter.

Tip or tip filter clogged Clean tip or tip filter.

Broken drive belt Replace belt.

Displacement pump rod seized by

dry paint

Service pump. See page 14.

Connecting rod worn or damaged Replace. See page 7.

Drive housing worn or damaged Replace. See page 8.

Electrical power not energizing clutch field Check wiring connections. See page 20.

Reference control board diagnostics. See page 13.

With pressure control switch ON and pressure

turned to MAXIMUM, use a test light to check for

power between clutch terminals on control board.

Remove black clutch wires from control board and

measure resistance across wires. At 70_F, the

resistance must be between 1.7 ±0.2Ω;ifnot,re-

place pinion housing.

Have pressure control checked by authorized Gra-

co dealer.

Clutch worn or damaged Service. See page 9.

Pinion assembly worn or damaged Service. See page 9.

6308864

PROBLEM CAUSE SOLUTION

Pump output low Strainer (31) clogged Clean.

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

Piston packings worn or damaged Replace packings. Manual 308798.

O-ring (227) in displacement pump is worn or

damaged

Replace o-ring. Manual 308798.

Intake valve ball not seating properly Clean and service. Manual 308798.

Engine speed is too low Increase throttle setting. See Manual 308863.

V--belt slipping Tighten V--belt with clamp (101). Adjust clamp

until it takes 15 lb of force to lock clamp down.

Clutch worn or damaged Replace. See page 9.

Pressure setting is too low Increase pressure. Manual 308863.

Fluid filter (318), tip filter or tip is clogged or

dirty

Clean filter. Manual 308863 or 309091.

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).

Excessive paint leakage into

throat packing nut

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

throat packing nut just enough to stop leakage.

Throat packings worn or damaged Replace packings. Manual 308798.

Displacement rod worn or damaged Replace rod. Manual 308798.

Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake

and tighten. Then prime pump. See Startup,

Manual 308863.

Tip partially clogged Clear.

Fluid supply is low or empty Refill and prime pump. See Startup, Manual

308863. Check fluid supply often to prevent

running pump dry.

Pump is difficult to prime Air leak Check all hose connections and tighten as

needed.

Reduce engine speed and cycle pump as

slowly as possible during priming.

Intake valve is leaking Shut off pump and relieve pressure. Disas-

semble and clean intake valve. Be sure ball

seat is not nicked or worn and that ball seats

well. Reassemble.

Worn packings Repack pump. Manual 308798.

Fluid is too thick Thin fluid according to supplier’s recommenda-

tions.

Engine speed is too high Decrease throttle setting before priming pump.

Manual 308863.

High engine speed at no

load

Misadjusted throttle setting. Reset engine throttle to 3600 -- 3800 rpm at no

load

Worn engine governor Replace or service engine governor

Clutch squeaks each time

clutch engages

Clutch surfaces are not matched to each other

when new and may cause noise

Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time

7308864

Bearing Housing and Connecting Rod

Removal

1. Relieve pressure;page 4.

2. Stop sprayer at bottom of stroke to get crank (E) in

lowest position.To lower crank manually, remove

spark plug and carefully rotate crank by pulling

starter rope.

3. Fig. 3. Remove front cover (13). Unclip drain hose

(108) from pump. Unscrew pump suction tube

(107) from pump. Disconnect pump hose (47).

4. Push up retaining spring (18). Push pin (19) out

rear.

Fig. 2 7675B

5. Loosen locknut (20). Unscrew displacement

pump (21).

6. Remove four screws and lockwashers (44, 45).

7. Tap lower rear of bearing housing (17) with a

plastic mallet to loosen from drive housing (12).

Pull bearing housing and connecting rod assembly

(14) straight off drive housing.

8. Remove pail hanger (59) and install it on new

bearing housing.

9. Inspect crank (E) for excessive wear and replace

parts as needed.

Installation

1. Evenly lubricate inside of bronze bearing (B) in

bearing housing (17) with high-quality motor oil.

Liberally pack top roller bearing (C), lower bearing

(D) inside connecting rod assembly (14) with

bearing grease 114819.

2. Assemble connecting rod (14) and bearing

housing (17).

3. Clean mating surfaces of bearing and drive hous-

ings (17, 12).

4. Align connecting rod (14) with crank (E) and drive

housing locating pins (12b) with bearing housing

(17) holes. Push bearing housing onto drive hous-

ing or tap into place with plastic mallet.

UTION

Do not use bearing housing screws (44) to align or

seat bearing housing; this may cause bearing and

drive housing misalignment and result in premature

bearing wear.

5. Install screws and lockwashers (44, 45). Tighten

screws evenly to 25 ft-lb (34 N¡m).

6. Install pump; page 14.

7. Fig. 3.Install remaining parts.

Fig. 3

45, 44

Pack with bearing grease 114819

Oil

108

107

106

8697A

12b

Torque to 25 ft-lb (34 N¡m)

8308864

Drive Housing

1. Relieve pressure;page 4.

Removal

2. Fig. 4. Remove bearing housing. Do Removal of

Bearing Housing and Connecting Rod proce-

dure on page 7.

3. Remove two screws (41) and lockwashers (10).

4. Remove four screws (9) and lockwashers (10)

from pinion housing (8).

5. Lightly tap around drive housing (12) to loosen

drive housing. Pull drive housing straight off pinion

housing (8). Be prepared to support gear cluster

(7) which may also come out.

UTION

Do not drop gear cluster (7) when removing drive

housing (12). Gear cluster is easily damaged. Gear

may stay engaged in drive housing or pinion housing.

Installation

1. Liberally apply bearing grease (supplied with re-

placement gear cluster) to gear cluster (18) and to

areas called out by note 2. Use full 0.68 pint (0.32

liter) of grease.

2. Place bronze colored washer (12g) on shaft pro-

truding from large shaft of drive housing (12).

Note: If replacing a washer with pin holes with a

washer without pin holes, remove guide pins from

housing. Place silver colored washer (12h) on pin-

ion housing. Assemble washers (15) and (16) onto

gear (7). Align gears and push new drive housing

straight onto pinion housing and locating pins (A).

3. Install four screws (9) and lockwashers (10) to

pinion housing (8) and drive housing (12).

4. Install two screws (41) and lockwashers (10) to

drive housing (12).

5. Fig. 4. Install bearing housing. Do 1. through 6. of

Bearing Housing and Connecting Rod proce-

dure on page 7.

910

12h

12g

Fig. 4

Apply remaining grease to these areas

1Torque to 200 in-lb

16 15

TI0178B

9308864

Pinion Assembly/Rotor/Shaft/Clutch/Pulley

Removal

If pinion assembly (8) is not removed from clutch

housing (3), do 1. through 4. Otherwise, do 1 and then

startat5.

1. Relieve pressure;page 4.

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

Fig. 5

8739A

Bottom View

3. Fig. 6. Remove five screws (5) and lockwashers

(6) and pinion assembly (8).

Fig. 6 8740A

4. Fig. 7. Place pinion assembly (8) on bench with

rotor side up.

5. Remove four screws (39) and lockwashers (6).

Install two screws in threaded holes (E) in rotor.

Alternately tighten screws until rotor comes off.

Fig. 7

8701A

6. Fig. 8. Remove retaining ring (Z).

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

Fig. 8

8703A

8. Fig. 10. Remove drive belt shield (74) and

belt (68).

9. Hold pulley (2) and remove four screws (3a) and

washers (3h) from hub (3d). Remove armature

(3g) and spacer (3f).

10. Remove set screw (112a) from bushing (112).

Remove three bolts (112b) and three washers

(112c). Use bolts to remove pulley from bushing.

Remove pulley and key (1).

11. Remove three screws (27) from beneath mounting

plate (D).

12. Lift off clutch housing (3).

13. Remove retaining ring (3b). Pull jack shaft assem-

bly (3c) out.

10 308864

Pinion Assembly/Rotor/Shaft/Clutch/Pulley

Installation

1. Fig. 10. Install jack shaft assembly (3c). Install

retaining ring (3b).

2. Fig. 9. Lay two stacks of two dimes on smooth

bench surface.

3. Lay armature (4a) on two stacks of dimes.

4. Press center of clutch down on bench surface.

Fig. 9

8705A

0.12 ±.01 in. (3.0 ±.25 mm)

5. Place spacer (3f) and armature (3d, 3g) on jack

shaft assembly.

6. Install three screws (27) through mounting plate

(D) and into clutch housing (3).

7. Insta toll key (1) in bushing (112). Apply LocktiteE

to three bolts (112). Install bushing in pulley (2)

with three bolts (112b). Install set screw (112a) in

bushing. End of jackshaft (3c) must be 0.090 in.

below flush with end of bushing.

8. Hold pulley (2) and install four screws (3a) and

washers (3h) in hub (3d). Torque to 125 in-lb

(14 N¡m).

9. Install drive belt shield (74).

10. Push drive housing (12) and pinion housing (8)

assembly onto clutch housing (3). Tap lightly on

front of bearing housing (17) with a plastic mallet

to push drive housing and pinion housing assem-

bly onto clutch housing.

11. Install five screws (5) and lockwashers (6).

12. Fig. 8. Tap pinion shaft (A) in with plastic mallet.

13. Install retaining ring (Z).

14. Fig. 7. Place pinion assembly on bench with rotor

side up.

15. Apply locktite to screws. Install four screws (39)

and lockwashers (6). Alternately torque screws to

125 in-lb until rotor is secure.

16. Install pinion assembly with five screws (5) and

lockwashers (6).

17. Fig. 5. Connect field cable (X) to pressure control.

Fig. 10

8741A

71 112a

68 112 27

112b

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