Graco 309412F Setup guide

Repair Instructions

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

GMaxR7900

Airless Paint Sprayer

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

See page 2 for models numbers.

Related Manuals

Operation 309408...............................

Displacement Pump 309277......................

Spray Gun 309639..............................

Spray Tip 309640................................

PC Board 309459...............................

Drain Valve Kit 308961...........................

Clutch Replacement Kit 309890...................

309412F

ti1833a

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

3094122

Models

Model Series Description

233718 ALo--Boy

233719 AHi--Boy

233720 ALo--Boy with RACRX tip, gun and hose

233721 AHi--Boy with RAC X tip, gun and hose

Table of Contents

Warnings and Cautions 3.........................

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

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

Repair

Rollers 8......................................

Drive Housing 9................................

Cam Follower Bearings 10......................

Engine 11.....................................

Pressure Control 13............................

Displacement Pump 15.........................

Parts

Pinion Assembly 17............................

Sprayers 18...................................

Pressure Control 21............................

Tip, Gun, Hose 22..............................

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

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

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

Graco Phone Number 24..........................

309412 3

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 and high pressure hazard: High pressure spray or

leaks can inject fluid into the body.

To help prevent injection, always:

DEngage trigger safety latch when not spraying.

DKeep clear of nozzle and leaks.

DNever spray without a tip guard.

DDo PRESSURE RELIEF if you stop spraying or begin servicing

sprayer.

DDo not use components rated less than sprayer Maximum

Working Pressure.

DNever allow children to use this unit.

If high pressure fluid pierces your skin, the injury might look like

“just a cut”, but it is a serious wound! Get immediate medical atten-

tion.

Fire and explosion: Solvent and paint fumes can ignite or

explode.

To help prevent a fire and explosion:

DUse only in an extremely well ventilated area.

DEliminate all ignition sources; such as pilot lights, cigarettes and

plastic drop cloths (static arc hazard). Do not plug or unplug

power cords or turn lights on or off in spray area.

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

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

DUse only conductive airless paint hose.

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.

DDo not fill fuel tank while engine is running or hot.

DDo not flush with gasoline.

WARNING

3094124

Maintenance

WARNING

INJECTION HAZARD

The system pressure must be manually

relieved to prevent the system from

starting or spraying accidentally. Fluid

under high pressure can be injected through the

skin and cause serious injury. To reduce the risk of

an injury from injection, splashing fluid, or moving

parts, follow the Pressure Relief Procedure

whenever you:

Dareinstructedtorelievethepressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor 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.

UTION

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.

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.

309412 5

Troubleshooting

Relieve pressure;page 4.

PROBLEM CAUSE SOLUTION

E=XX is displayed Fault condition exists Determine fault correction from table, page 14.

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

Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.

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

Honda Engines Owner’s Manual.

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 lever to ON position

Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times.

Clean or replace spark plug. Start engine.

Keep sprayer upright to avoid oil seepage.

False tripping of Watch-

Dog system. EMPTY is

displayed. Pump does

not run.

Operating conditions out of WatchDog parameters Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.

Operate without WatchDog active; Manual

309408.

Low pump output. See Troubleshooting Table, Pump Outlet Low,

page 6.

Engine operates, but

displacement pump

does not operate

Error code displayed? Determine fault correction from table, page 14.

Pump switch is OFF TurnpumpswitchON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

increase pressure.

Fluid filter (318) is dirty Clean filter. Page 20.

Tip or tip filter is clogged Clean tip or tip filter. Manual 309091.

Displacement pump piston rod is stuck due to dried

paint

Repair pump. Manual 309277.

Connecting rod is worn or damaged Replace connecting rod. Page 15.

Drive housing is worn or damaged Replace drive housing. Page 9.

Electrical power is not energizing clutch field Check wiring connections. Page 11.

Reference pressure control repair. Page 13.

Reference wiring diagram. Page 21.

With pump switch ON and pressure turned to

MAXIMUM, use a test light to check for power

between clutch test points on control board.

Remove 7--pin connector from control board

and measure resistance across clutch coil. At

70_F, the resistance must be between 1.7

±0.2Ω; if not, replace pinion housing.

Have pressure control checked by authorized

Graco dealer.

3094126

Troubleshooting

PROBLEM CAUSE SOLUTION

Clutch is worn, damaged, or incorrectly positioned Replace clutch. Manual 309890.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Manual

309890.

Pump output is low. Strainer (89) is clogged Clean strainer. Sprayer 233716 strainer is for

use in paint only.

Piston ball (206) is not seating Service piston ball. Manual 309277.

Piston packings are worn or damaged Replace packings. Manual 309277.

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

aged

Replace o-ring. Manual 309277.

Intake valve ball is not seating properly Clean intake valve. Manual 309277.

Intake valve ball is packed with material Clean intake valve. Manual 309277. Do not

leave 233716 sprayer under pressure for more

than 5 minutes when spraying texture and not

actively spraying.

Engine speed is too low Increase throttle setting. Manual 309408.

Clutch is worn or damaged Replace clutch. Manual 309890.

Pressure setting is too low Increase pressure. Manual 309408.

Fluid filter (318), tip filter or tip is clogged or dirty Clean filter. Manual 309408 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 are worn or damaged Replace packings. Manual 309277.

Displacement rod is worn or damaged Replace rod. Manual 309277.

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

prime pump. Manual 309408.

Tip is partially clogged Clear tip. Manual 309091.

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

309408. 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 309277.

Paint is too thick Thin the paint according to the supplier’s

recommendations

309412 7

Troubleshooting

PROBLEM CAUSE SOLUTION

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

Manual 309408.

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.

High engine speed at no

Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load

Worn engine governor Replace or service engine governor

Gallon counter not working Bad sensor, broken or disconnected wire Check connections. Replace sensor or wire.

No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.

Clutch squeaks each time

clutch engages

Clutch surfaces are not matched to each other

when new and may cause noise

Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time

Engine stalls Engine speed is to slow DIncrease throttle setting

DAdjust 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

Spark plug wire is loose Reconnect wire

3094128

Rollers

Removal

1. Relieve pressure;page 4.

2. Fig. 1. Remove six cap screws (56) lock washers

(87), clip (35), and cover assembly (13).

Fig. 1

ti1860a

108

109

77 59

Note: A screw driver may be needed to pry off cover

assembly.

3. Remove dowel pins (108) and rollers (109)

Installation

1. Install rollers (109) and dowel pins (108)

2. Install cover assembly (13) with six lock washers

(87), clip (35), and cap screws (56).

309412 9

Drive Housing

Removal

1. Relieve pressure;page 4.

2. Fig. 2. Disconnect gallon counting sensor.

Fig. 2

ti1835a

3. Fig. 1. Remove six cap screws (56) lock washers

(87) and cover assembly (13).

4. Fig. 3. Remove two screws (59) and washers (87).

5. Remove four cap screws (56) lock washers (87)

from drive housing (71).

6. Lightly tap around drive housing (71) to loosen

drive housing. Pull drive housing straight off pinion

housing. Be prepared to support gear cluster

(102), which may also come out.

9046C

87 59

71h

71g

102 104 105

1Apply remaining grease to these areas

Fig. 3

71b

71c

71d

101

71a

Installation

1. Liberally apply bearing grease (supplied with

replacement gear cluster) to gear cluster (102),

washers (104) and (105) and to areas called out

by note 1. Use full 0.68 pint (0.32 liter) of grease

for GMax 7900.

2. Place bronze colored washer (105) and silver

colored washer (104) onto drive housing (71).

Install gear cluster (102) through washers (105)

and (104).

3. Place bronze colored washer (71g) and silver

colored washer (71h) on shaft protruding from

large shaft of drive housing (71). Align gears and

push new drive housing straight onto pinion hous-

ing and locating pins (B).

4. Install two washers (87) and screws (59).

5. Install four lock washers (87) and cap screws (56)

into drive housing (71).

6. Install cover assembly (13) with six lock washers

(87) and cap screws (56).

7. Fig. 4. Reconnect gallon counting sensor.

Fig. 4 ti1835a

30941210

Cam Follower Bearings

Removal

1. Relieve pressure;page 4.

2. Fig. 9. Cycle pump piston rod (222) to lowest

position. Turn engine off.

3. Fig. 5. Remove six cap screws (56), lock washers

(87) and cover assembly (13).

Note: A screw driver may be needed to pry off

cover assembly.

4. Remove four dowel pins (108) and rollers (109).

5. From front, drive out pump pin (77) with a screw

driver.

6. Remove two retainer rings (71d).

7. Remove cam follower plate (71b).

Note: Two 1/2 in. x 13 bolts may be

needed to remove cam follower plates.

8. Remove two cam follower bearings (71c).

Installation

1. Install two cam follower bearings (71c).

2. Install cam follower plate (71b).

3. Install two retainer rings (71d).

4. Drive in pump pin (77) until it engages with pump

pin retaining clip (71a).

5. Install four rollers (109) and dowel

pins (108).

6. Install cover assembly (13) with six lock washers

(87) and cap screws (56).

Fig. 5

109

71c

71b

71d

108

9046c

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