Graco GMax 233700 Operating instructions

309409E

233705

Related Manuals

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

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

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

Texture Spray Gun 308491. . . . . . . . . . . . . . . . . .

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

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

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All models are not available in all countries

PATENTS PENDING

ti1839a

INSTRUCTIONS-REPAIR

Important Safety Instructions

Read all warnings and instructions in this

manual. Save These instructions.

GMax3900, 5900, 5900HD

Airless Paint Sprayers

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

GMax 3900

Model Series Description

233701 AHi-Boy

233703 AHi-Boy with RACX tip, gun and hose

233700 ALo-Boy

233702 ALo-Boy with RAC X tip, gun and hose

GMax 5900

Model Series Description

233706 AHi-Boy

233708 AHi-Boy with RAC X tip, gun and hose

233705 ALo-Boy

233707 ALo-Boy with RAC X tip, gun and hose

GMax 5900HD

Model Series Description

233716 AHi-Boy

233717 AHi-Boy with RAC X tip, gun and hose

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

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

3094092

Table of Contents

Warnings and Cautions 2. . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair

Bearing Housing & Connecting Rod 8. . . . . . . . . . . . .

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

Pinion Assembly/Rotor/Field/Shaft/Clutch 10. . . . . . .

Clamp 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Housing 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump 17. . . . . . . . . . . . . . . . . . . . . . . . .

Parts

GMax 3900 & GMax 5900 Hi-Boy Sprayers 18. . . . .

Pinion Assembly 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

GMax 3900 & GMax 5900 Lo-Boy Sprayers 22. . . . .

Pressure Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete Sprayers 26. . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

309409 3

WARNING

INJECTION HAZARD

Spray from the spray tip, hose leaks or ruptured components can inject fluid into your body and cause

extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin

can also cause can also cause serious injury.

Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-

cal attention.

Do not point the spray tip at anyone or any part of the body.

Do not put hand or fingers over the spray tip, and do not stop or deflect fluid leaks with your hand,

body, glove or rag.

Do not “blow back” fluid; this is not an air spray system.

Always have the tip guard and the trigger guard on the in-line valve when spraying.

Be sure the trigger safety lever operates before operating the in-line valve.

Lock the trigger safety lever when you stop spraying.

Follow the Pressure Relief Procedure on page 5 when you are instructed to relieve pressure;

stop spraying; check, clean, or service any system equipment; or install or change spray tips.

Tighten all fluid connections before each use.

Check the hoses, tubes and couplings daily. Replace worn or damaged parts immediately. Perma-

nently coupled hoses cannot be repaired.

Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and

hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures

above 150F (65C) or below –40F (–40C).

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause a serious injury or death if the fluid is swallowed or

splashed in the eyes or on the skin or if the fumes are inhaled.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container. Dispose hazardous fluid according to all local,

state and national guidelines.

Dress appropriately for your application. Wear protective eyewear, noise protection for the ears, a

personal respirator, gloves, and clothing.

RECOIL HAZARD

Due to the high pressure fluid emitted, a strong recoil action may occur when you trigger the pole gun.

If you are unprepared, your hand could be forced back toward your body or you could lose your bal-

ance and fall, resulting in serious injury.

3094094

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and

result in fire or explosion and serious injury.

Ground the equipment and the object being sprayed. See Electrical Grounding on page .

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being

sprayed.

Extinguish all the open flames or pilot lights in the spray area.

Electrically disconnect all the equipment in the spray area.

Keep the spray area free of debris, including solvent, rags, and gasoline.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not smoke in the spray area.

Do not operate a gasoline engine in the spray area.

If there is any static sparking while using the equipment, stop spraying immediately. Identify and

correct the problem.

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result

in serious injury.

This equipment is for professional use only.

Read all instruction manuals, tags, and labels before operating the equipment.

Use the equipment only for its intended purpose. If you are uncertain about the usage, call your

distributor.

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Check the equipment daily. Repair or replace worn or damaged parts immediately.

Do not exceed the maximum working pressure of the lowest rated system component. This equip-

ment has a 3600 psi (25 MPa, 248 bar) maximum working pressure.

Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 150F (65C) or below –40F (–40C).

Do not use the hoses to pull the equipment.

Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical

Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or

bends near the couplings.

Comply with all applicable local, state and national fire, electrical and other safety regulations.

Wear hearing protection when operating this equipment.

HAZARD OF USING FLUIDS CONTAINING HALOGENATED HYDROCARBONS

Never use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids

containing such solvents in this equipment. Such use could result in a serious chemical reaction, with

the possibility of explosion, which could cause death, serious injury and/or substantial property dam-

age.

Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc

parts.

309409 5

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:

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 pump 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.

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 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.

Repack connecting rod (22) top needle bearing after

every pump change.

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.

3094096

Troubleshooting

Relieve pressure;page 5.

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 WatchDog

system. EMPTY is displayed.

Pump does not run.

Operating conditions out of WatchDog param-

eters

Low pump output; page 7.

Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.

Operate without WatchDog active; Manual

309408.

Engine operates, but dis-

placement pump does not

operate

Error code displayed? Reference pressure control repair. Page 15.

Pump switch is OFF Turn pump switch ON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

increase pressure.

Fluid filter (318) is dirty Clean filter. Page 24.

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 8.

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

Electrical power is not energizing clutch field Check wiring connections. Page 13.

Reference pressure control repair. Page 15.

Reference wiring diagram. Page 25.

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 1.2

±0.2Ω (GMax 3900); 1.7 ±0.2Ω(GMax 5900);

if not, replace pinion housing.

Have pressure control checked by authorized

Graco dealer.

Clutch is worn, damaged, or incorrectly

positioned Replace clutch. Page 10.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 10.

309409 7

PROBLEM CAUSE SOLUTION

Pump output is low Strainer (31) 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 pump is worn or damaged 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. Page 10.

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.

Reprime 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

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

load

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.

Displaced or missing magnet. Check connections. Replace sensor or wire.

Reposition or replace magnet.

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

3094098

Bearing Housing and Connecting Rod

NOTE: The item numbers referenced are for the

Hi-Boy models. The Lo-Boy models may have different

item numbers. Use the Hi-Boy item number and part to

find the corresponding Lo-Boy part and item number.

Removal

1. Relieve pressure;page 5.

2. Fig. 2. Remove screws (14) and front cover (23).

3. For Hi-Boy models; remove spring clip (32) and

drain hose (54). Unscrew suction tube (30) from

pump, hold wrench on pump intake valve (A) to

keep pump from loosening. For Lo-Boy models;

unscrew swivel union (30aa) from pump.

4. Disconnect pump outlet hose (33) from displace-

ment pump outlet nipple (62).

5. Fig. 1. Use screwdriver to push up retaining spring

(26) at top of pump. Push out pin (29).

Fig. 1 7675B

6. Fig. 2. Loosen retaining nut (34). Unscrew and

remove displacement pump (28).

7. Remove four screws (13) and lockwashers (12)

from bearing housing (21).

8. Pull connecting rod (22) and lightly tap lower rear

of bearing housing (21) with plastic mallet to

loosen from drive housing (20). Pull bearing hous-

ing and connecting rod assembly (22) off drive

housing.

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

parts as needed.

Installation

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

bearing housing (21) with high-quality motor oil.

Liberally pack top roller bearing (E), lower bearing

(D) inside connecting rod assembly (22) with

bearing grease.

2. Assemble connecting rod (22) and bearing housing

(21).

3. Clean mating surfaces of bearing and drive hous-

ings.

4. Align connecting rod with crank (B) and carefully

align locating pins (F) in drive housing (20) with

holes in bearing housing (21). Push bearing hous-

ing onto drive housing or tap into place with plastic

mallet.

CAUTION

DO NOT use bearing housing screws (13) to align

or seat bearing housing with drive housing. Align

these parts with locating pins (F), to avoid prema-

ture bearing wear.

5. Install screws (13) and lockwashers (12) on bear-

ing housing. Torque evenly to note 3 value in Fig. 2.

6. Refer to Displacement Pump, Installation, page 17.

8697B

12, 13

GMax 3900: Torque to 200 in-lb (22.6 Nm)

Pack with bearing grease 114819

Oil

Fig. 2 Model 233701 shown

8697A

GMax 5900: Torque to 25 ft-lb (34 Nm)

309409 9

Drive Housing

Removal

1. Relieve pressure;page 5.

2. Fig. 3. Remove bearing housing. Do 1. through 8.

of Bearing Housing and Connecting Rod proce-

dure on page 8.

3. Fig. 4. Disconnect gallon counter sensor at (A).

Cut tie wrap holding gallon counting sensor

wire to clutch wire.

4. Fig. 3. Remove two screws (81) and lockwashers

(17).

5. Remove four screws (10) and lockwashers (17)

from pinion housing (19).

6. 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.

Installation

1. Liberally apply bearing grease (supplied with

replacement gear cluster) to gear cluster (18) and

to areas called out by note 3. Use full 0.62 pint

(0.29 liter) of grease for GMax 3900 and 0.68 pint

(0.32 liter) of grease for GMax 5900.

2. Place bronze colored washer (20g) on shaft pro-

truding from large shaft of drive housing (20).

Place silver colored washer (20h) on pinion hous-

ing. Align gears and push new drive housing

straight onto pinion housing and locating pins (B).

3. Install four screws (10) and lockwashers (17) from

pinion housing (19).

4. Install two screws (81) and lockwashers (17).

5. Fig. 4. Connect gallon counter sensor at (A).

Secure gallon counting sensor wire to clutch

wire with a tie wrap.

6. Fig. 3. Install bearing housing. Do 1. through 6. of

Bearing Housing and Connecting Rod proce-

dure on page 8.

TI0178A

Fig. 3

10 17

20h

20g

92 91

GMax 3900 only

Torque to 125 in-lb – GMax 3900

Torque to 200 in-lb – GMax 5900

Apply remaining grease to these areas

30940910

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.

1. Relieve pressure;page 5.

2. Remove drive housing; page 9.

3. Disconnect field cable (X) from pressure control,

and gallon counter sensor at (A).

8699A

Fig. 4 XBottom View

4. Fig. 5. Remove five screws (10) and lockwashers

(17) and pinion assembly (19).

10 17

Fig. 5 8700A

5. Fig. 6. Place pinion assembly (19) on bench with

rotor side up.

6. Remove four screws (72) and lockwashers (17).

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

Alternately tighten screws until rotor comes off.

8701B

Fig. 6

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