Graco Gmax 7900 User manual

Instructions

G-Max®7900 Airless

Paint Sprayer 308870G

For Portable Airless Spraying of Architectural Coatings and Paints.

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

Models

NOTE: All models are not available in all countries.

Related Manuals

Model Series Description

232630 B Hi-Boy

232631 BHi-Boy with RAC 5 tip, gun

and hose

232632 B Lo-Boy

232633 BLo-Boy with RAC 5 tip, gun

and hose

233008 A Hi-Boy with Gauge Kit

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Manual Manual Number

Operation 308867

Displacement Pump 307898

Spray Gun 309091

Spray Tip 309055

PC Board 308919

Drain Valve Kit 308961

Table of Contents

2308870G

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pinion Assembly / Rotor / Field / Shaft / Clutch . 13

Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

On / Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

Pressure Adjust Potentiometer . . . . . . . . . . . . . 20

Control Board Diagnostics . . . . . . . . . . . . . . . . 21

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 22

Pump Pin Clip . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts List & Drawing - Pinion Assembly . . . . . . . 24

Parts Drawing - Hi-Boy Sprayer . . . . . . . . . . . . . . 25

Model 232630 and 233008 . . . . . . . . . . . . . . . . 25

Parts List - Hi-Boy Sprayers . . . . . . . . . . . . . . . . . 26

Models 232630, 232631 and 233008* . . . . . . . 26

Parts Drawing - Lo-Boy Sprayer . . . . . . . . . . . . . 28

Model 232632, 232633 . . . . . . . . . . . . . . . . . . . 28

Parts List - Lo-Boy Sprayers . . . . . . . . . . . . . . . . 29

Models 232632, 232633 . . . . . . . . . . . . . . . . . . 29

Model 232630 through 232633 . . . . . . . . . . . . . 31

Parts List - Hi-Boy Sprayers . . . . . . . . . . . . . . . . . 32

Models 232630 through 232633 . . . . . . . . . . . . 32

Parts List - Complete Sprayers . . . . . . . . . . . . . . 33

Models 232631, 232633 . . . . . . . . . . . . . . . . . . 33

Displacement Pump Repair Kit . . . . . . . . . . . . . 33

Danger Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Model 232630, 232631, 232008 . . . . . . . . . . . . 35

Model 232632, 232633 . . . . . . . . . . . . . . . . . . . 35

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Warnings

308870G 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific

hazard symbols and warnings not covered in this section may appear throughout the body of this manual where

applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent

fire and explosion:

• Use equipment only in well ventilated area.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable

and can ignite or explode if spilled on hot surface.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are antistatic or conductive.

•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event

that injection occurs, get immediate surgical treatment.

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks

with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Use Graco nozzle tips.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while

spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure

before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn

off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3000 psi (210 bar/21 MPa). Use Graco replacement parts or

accessories that are rated a minimum of 3000 psi (210 bar/21 MPa).

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

Warnings

4308870G

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. (

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-

facturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including

eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is

not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

WARNING

Component Identification

308870G 5

Component Identification

*For more detailed explanations of these controls, refer to the Honda Engines Owner's Manual; supplied.

APressure Control Switch ON/OFF, enables/disables clutch function and pressure control

BPressure Adjusting Knob Controls fluid outlet pressure

CAir Cleaner* Filters air entering the carburetor

DFuel Tank* Uses 86 octane unleaded 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* 4-cycle 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

WPail Hanger Provides a hanger for paint pail

XDrain Valve Relieves fluid pressure when open

202 Main hose

203 Whip end hose

204 Contractor gun with RAC 5

DripLess tip guard and 517 size SwitchTip

203

204

202

Model 232631

9034B

Maintenance

6308870G

Maintenance

NOTE: For detailed engine maintenance and specifica-

tions, refer to separate Honda Engines Owner's Manual,

supplied.

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage trigger lock.

2. Turn ON/OFF switch to OFF.

3. Move pressure control switch to OFF and turn pres-

sure 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 the pressure drain valve. Leave the pressure

drain valve open until you are ready to spray again.

7. If you suspect the spray tip or hose is clogged or

that pressure has not been fully relieved after follow-

ing the steps above, VERY SLOWLY loosen tip

guard retaining nut or hose end coupling to relieve

pressure gradually, then loosen completely. Clear

hose or tip obstruction.

Maintenance Checklist

•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 oper-

ation.

•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 vis-

cosity.

•WEEKLY: Remove air filter cover and clean ele-

ment. 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 (NIPPON-

DENSO) plug. Gap plug to 0.028 to 0.031 in. (0.7 to

0.8 mm).

• Use spark plug wrench when installing and remov-

ing plug.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury

from pressurized fluid, such as skin injection,

splashing fluid and moving parts, follow the Pressure

Relief Procedure when you stop spraying and before

cleaning, checking, or servicing the equipment.

Troubleshooting

308870G 7

Troubleshooting

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 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

rope 3 or 4 times. Clean or replace

spark plug. Try to start engine.

Keep sprayer upright to avoid oil

seepage.

Engine operates, but displacement

pump does not operate

Pressure control switch is OFF Turn pressure control switch ON.

Pressure setting is too low Turn pressure adjusting knob clock-

wise to increase pressure

Fluid filter (318) is dirty Clean filter. Page 31.

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 308798.

Roller bearings are worn or dam-

aged

Replace connecting rod. Page 10.

Drive housing is worn or damaged Replace drive housing. Page 10.

Troubleshooting

8308870G

Engine operates, but displacement

pump does not operate (continued)

Electrical power is not energizing

clutch field

Check wiring connections. Page 15.

Reference control board diagnos-

tics. Page 21.

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 resis-

tance across wires. At 70_ F, the

resistance must be between 1.7

+0.2W; if not, replace clutch coil

241121.

Have pressure control checked by

authorized Graco dealer.

Clutch is worn or damaged Replace clutch. Page 13.

Pinion assembly is worn or dam-

aged

Repair or replace pinion assembly.

Page 13.

Pump output is low Strainer (31) is clogged Clean strainer

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

Piston packings are worn or dam-

aged

Replace packings. Manual 308798.

O-ring (227) in displacement pump

is worn or damaged

Replace o-ring. Manual 308798.

Intake valve ball is not seating prop-

erly

Clean intake valve. manual 308798.

Engine speed is too low Increase throttle setting. Manual

308867.

Clutch is worn or damaged Replace clutch. Page 13.

Pressure setting is too low Increase pressure. Manual 308867.

Fluid filter (318), tip filter or tip is

clogged or dirty

Clean filter. Manual 308867 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 opti-

mum performance (50 ft minimum).

Problem Cause Solution

Troubleshooting

308870G 9

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 dam-

aged

Replace packings. Manual 308798.

Displacement rod is worn or dam-

aged

Replace rod. Manual 308798.

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

tions. Reprime pump. Manual

308867.

Tip is partially clogged Clear tip. Manual 309091.

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 connec-

tions.

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. Reassemble valve.

Pump packings are worn Replace pump packings. Manual

308798.

Paint is too thick Thin the paint according to the sup-

plier's recommendations.

Engine speed is too high Decrease throttle setting before

priming pump. Manual 308867.

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 - Increase throttle setting.

- 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 (20.68

MPa, 206.8 bar) until pump wears in

Spark plug wire is loose Reconnect wire

Problem Cause Solution

Rollers

10 308870G

Rollers

Removal

1. Relieve pressure, page 6.

2. Remove six cap screws (10) lock washers (9) and

cover assembly (24) (FIG. 1).

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).

Drive Housing

Removal

1. Relieve pressure, page 6.

2. Remove six cap screws (10) lock washers (9) and

cover assembly (24) (FIG. 1).

3. Remove two screws (99) and washers (9).

4. Remove four cap screws (10) lock washers (9) from

drive housing (20).

5. Lightly tap around drive housing (20) to loosen drive

housing. Pull drive housing straight off pinion hous-

ing. Be prepared to support gear cluster (18), which

may also come out.

FIG. 1

9033A

FIG. 2

20h

20g

1Apply remaining grease to these areas

This manual suits for next models

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