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INSTRUCTIONS-REPAIR 308870 Rev. B KEEP FOR REFERENCE. Read this and all related manuals for important warnings and instructions. First choice when quality counts.t INSTRUCTIONS GMaxr 7900 Airless Paint Sprayer 3300 psi (227 bar, 22.7 MPa ) Maximum Working Pressure GMax 7900 Model Series Description 232630 A Hi-Boy 232631 A Hi-Boy with RAC IV tip, gun and hose 232632 A Lo-Boy 232633 A Lo-Boy with RAC IV tip, gun and hose All models are not available in all countries PATENTS PENDING Related Manuals Operation . . . . . . . . . . . . . . . . . . . . . . . . 308867 .. Displacement Pump . . . . . . . . . . . . . . . . 308798 . Spray Gun . . . . . . . . . . . . . . . . . . . . . . . 307614 .. Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . 308644 .. PC Board . . . . . . . . . . . . . . . . . . . . . . . . 308919 .. Drain Valve Kit . . . . . . . . . . . . . . . . . . . . .308961 . 9035A Table of Contents Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . .2. Component Identification and Function . . . . . . . . . . . .3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . Repair Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . Cam Follower Bearings . . . . . . . . . . . . . . . . . . . . . .8. Pinion Assembly/Rotor/Field/Shaft/Clutch . . . . . . . . 9 Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ... Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ... GRACO INC. P.O. BOX 1441 Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 13 .. Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 15 .. Parts Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .. Hi-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 .. Lo-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . 20 .. Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 22 .. Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . 24 .. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 .. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 .. Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 25 .. Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 .. MINNEAPOLIS, MN ECOPYRIGHT 1999, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001 55440–1441 Warnings and Cautions Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. 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: Use outdoors or in an extremely well ventilated area. Do 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. Remove, extinguish or unplug all ignition sources; tape wall switch. Do not smoke in spray area. Never fill fuel tank while the engine is running or hot. Ground Sprayer, object being sprayed, paint and solvent pails. Hold gun firmly to side of a grounded pail when triggering into pail. Use only conductive airless paint hose. Never 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: Engage trigger safety latch when not spraying. Point gun away from yourself or anyone else. Relieve pressure before checking or repairing any leak. Relieve pressure when you turn off the sprayer or stop spraying. Do 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 V 202 Main hose 203 Whip end hose 204 Contractor gun with RAC IV DripLess tip guard and 517 size SwitchTip D C J H E G R K A F P B S U W T Model 232631 202 M L X N 204 203 9034A Fig. 1 A Pressure Control Switch ON/OFF, enables/disables clutch function and pressure control B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner* Filters air entering the carburetor D Fuel Tank* 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 J 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 P Engine* 4–cycle gasoline engine 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 U Fluid Filter Filters fluid between source and spray gun V Grounding Clamp and Wire Grounds sprayer system W Pail Hanger Provides a hanger for paint pail X Drain Valve Relieves fluid pressure when open * For more detailed explanations of these controls, refer to the Honda Engines Owner ’s Manual; supplied Maintenance CAUTION 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 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: tion. Check pressure drain valve for proper opera- DAILY: Check and fill the gas tank. AFTER THE FIRST 20 HOURS OF OPERA TION: Drain engine oil and refill with clean oil. Reference Honda Engines Owner’s Manual for correct oil viscosity. 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 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, adjusting, 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 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. Pressure control switch is OFF Turn pressure control switch ON. 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 307614. Displacement pump piston rod is stuck due to dried paint Repair pump. Manual 308798. 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. Engine operates, but displacement pump does not operate 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 ±0.2Ω; if not, replace clutch coil 241121. Check control board fuse. If blown, replace with equivalent automotive fuse. 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 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 damaged 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 properly Clean intake valve. manual 308798. Engine speed is too low Increase throttle setting. Manual 308867. Clutch is worn or damaged Replace clutch. Page 9. 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 307614. 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 performance (50 ft minimum). 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 308798. Displacement rod is worn or damaged Replace rod. Manual 308798. Air in pump or hose Check and tighten all fluid connections. Reprime pump. Manual 308867. Tip is partially clogged Clear tip. Manual 307614. Fluid supply is low or empty Refill fluid supply. Prime pump. Manual 308867. Check fluid supply often to prevent running pump dry. Air in pump or hose Check and tighten all fluid connections. Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime 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 supplier’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 6 308870 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 until pump wears in Spark plug wire is loose Reconnect wire Rollers Removal 20 1. Relieve pressure; page 4. 98 97 2. Fig. 2. Remove six cap screws (10) lock washers (9) and cover assembly (24). 9 10 Note: A screw driver may be needed to pry off cover assembly. 3. Remove dowel pins (97) and rollers (98) Installation 9 1. Install rollers (98) and dowel pins (97) 2. Install cover assembly (24) with six lock washers (9) and cap screws (10). Fig. 2 99 24 9033A Drive Housing Removal Installation 1. 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). 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 housing. Be prepared to support gear cluster (18), which may also come out. 10 9 1. 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. 2. Place bronze colored washer (83) and silver colored washer (82) onto drive housing (20). Install gear cluster (18) through washers (83) and (82). 3. 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 housing and locating pins (B). 4. Install two washers (9) and screws (99). 1 20h 20g 20 18 5. Install four lock washers (9) and cap screws (10) into drive housing (20). 6. Install cover assembly (24) with six lock washers (9) and cap screws (10). B 9 82 83 99 1 Apply remaining grease to these areas Fig. 3 9032A Cam Follower Bearings Installation Removal 1. 1. Install two cam follower bearings (20c). 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). 2. Install cam follower plate (20b). 3. Install two retainer rings (20d). 4. Drive in pump pin (101) until it engages with pump pin retaining clip (20a). 5. Install four rollers (98) and dowel pins (97). 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). 6. Install cover assembly (24) with six lock washers (9) and cap screws (10). 20 98 97 9 10 20a 20c 20b 20d 101 9047A 24 Fig. 4 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. 6. Fig. 8. Remove retaining ring (19e). 7. Tap pinion shaft (19d) out with plastic mallet. 19e Relieve pressure; page 4. 2. Disconnect field cable (X) from pressure control and engine lead. 19d X Fig. 8 8. Fig.9. Use an impact wrench or wedge something between armature (4a) and clutch housing to hold engine shaft during removal. Bottom View Fig. 5 9027A 3. Fig. 6. Remove five screws (26) and lockwashers (17) and pinion assembly (19). 26 9031A 9. Remove four screws (16) and lockwashers (17). 10. Remove armature (4a). 4a 17 19 17 16 Fig. 9 26 17 Fig. 6 9028A 9029A 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 E Fig. 7 9030A 308870 9 Pinion Assembly/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 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. 0.12 ±.01 in. (3.0 ±.25 mm) 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. Fig. 10 8705A 4. Install armature (4a) on engine drive shaft. 10. Fig. 6. Install pinion assembly (19) with five screws (10) and lockwashers (9). 5. Install four screws (16) and lockwashers (17) with torque of 125 in-lb. 11. Fig. 5. Connect field cable (X) to pressure control and engine lead. Clamp Removal 1 1. Fig. 11. Loosen two screws (16) on clamp (8), Face of clutch housing 2 1.812 ±.010 in. (46.02 ±.25 mm) 3 Torque to 125 ±.10 in-lb (14 ±1.1 Nm) 4 Chamfer this side 2. Push screwdriver into slot in clamp (8) and remove clamp. 1 Installation 5 1. Fig. 11. Install engine shaft key (7). 2 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 accurate measuring device to measure distance between bar and face of clamp. Adjust clamp as necessary. Torque two screws (16) to 125 ±10 in-lb (14 ±1.1 Nm). 10 308870 8 7 4 B 16 3 Fig. 11 A 03483 Clutch Housing Removal 1. Fig. 12. Remove four capscrews (75) and lockwashers (77) which hold clutch housing (5) to engine. 5 7 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull off clutch housing (5). Installation 77 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 N m). 3. Install capscrew (15) from beneath mounting plate (D). Torque to 26 ft-lb (35.2 N m). 75 D Fig. 12 15 9025A Engine Removal 1. Remove Pinion Assembly/Rotor/Field/Pinion/ Clutch, Clamp and Clutch Housing, as instructed 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. 70 71 87 Green 71 1 Fig. 14 9026A Installation 1. 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 N m). 2 2 Fig. 13 1 To the field 2 To the engine 9027A 3. Fig. 13. Connect all necessary wiring. 4. Install Pinion Assembly/Rotor/Field/Pinion/ Clutch, Clamp and Clutch Housing, as instructed on pages 7, 9 and 10. 308870 11 On/Off Switch Removal Installation 1. 1. Install new ON/OFF switch (309) so tabs of switch snap into place on inside of pressure control housing. 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. 2. Connect two wires (A) to ON/OFF switch. 3. Install pressure control cover (322) with five screws (307). 313 310 309 303 307 A 315 318z 318aa E Fig. 15 12 308870 318a 302 D 322 319 Locate switch terminals as shown Pressure Control Control Board Installation Removal 1. Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Fig. 22. Disconnect at control board (302): Four clutch leads: two violet and two black. 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): Lead (D) from potentiometer. Two red leads (A) to ON/OFF switch (309). Lead (E) from transducer. Lead (E) to transducer. Two red leads (A) to ON/OFF switch (309). Lead (D) to potentiometer. 4. Fig. 15. Remove five screws (303), green ground wire and control board (302). Four clutch leads: two violet and two black. 3. Fig. 15. Install cover (322) with five screws (307). Pressure Control Transducer Removal 1. 5. Remove pressure control transducer (318z) and packing o-ring (318aa) from filter housing (318a). Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Disconnect lead (E) from control board (302). 4. Remove three screws (319) and fluid filter (318) from control plate (301). Carefully pull transducer connector through rubber grommet (315). Installation 1. Fig. 15. Install packing o-ring (318aa) and pressure control transducer (318z) in filter housing (318a). Torque to 30–35 ft-lb. 2. Carefully feed transducer connector through rubber grommet (315). Install fluid filter (318) on control plate (301) with three screws (319). 3. Connect lead (E) to motor control board (302). 4. Install cover (322) with five screws (307). Pressure Adjust Potentiometer Removal 1. Installation 1. Install seal (311) on potentiometer (310). Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Disconnect lead (D) from control board (302). 2. Fig. 15. Install pressure adjust potentiometer (310), shaft nut, lockwasher (310) and potentiometer knob (313). a. Turn potentiometer shaft (310) 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. 4. Loosen set screws on potentiometer knob (313) and remove knob, shaft nut, lockwasher (310) and pressure adjust potentiometer (310). 3. Connect lead (D) to control board (302). 5. Remove seal (311) from potentiometer (310). 4. Install cover (322) with five screws (307). 308870 13 Pressure Control Control Board Diagnostics 1. Fig. 15. Remove five screws (307) and cover (322). 2. Start sprayer. 3. Turn ON/OFF switch ON. 4. Observe LED operation and reference following table: LED BLINKS SPRAYER OPERATION Two times repeatedly Sprayer shuts down and LED contin- Run away pressure. Pressure greater than ues to blink two times repeatedly 4500 psi (310 bar, 31 MPa). 1. Check pressure transducer connection at control board 2. Replace pressure transducer 3. Replace control board Three times repeatedly Sprayer shuts down and LED contin- Pressure transducer is faulty or missing ues to blink three times repeatedly 1. Check pressure transducer connection at control board 2. Replace pressure transducer 3. Replace control board Four times repeatedly Sprayer shuts down and LED contin- Generator voltage is low ues to blink four times repeatedly 1. Increase engine throttle 2. Check wiring connections 3. Service Honda engine alternator Five times repeatedly Sprayer shuts down and LED contin- High clutch current ues to blink five times repeatedly 1. Check clutch 5-pin bulkhead connector. Clean contacts. 2. Measure 1.7 ±0.2Ω across clutch field at 70 F 3. Replace clutch field assembly Six times repeatedly Sprayer shuts down and LED contin- High clutch temperature 1. If clutch is new, let sprayer cool ues to blink six times repeatedly down and then restart 2. Inspect clutch. Replace clutch if there is excessive wear. 3. Remove pump pin, separate pinion housing from clutch housing. Rotate rotor clockwise to check for excessive drag. 14 308870 INDICATES WHAT TO DO Displacement Pump Removal 1. Flush pump. 2. Fig. 16. Cycle pump with piston rod (222) in lowest position. 5. Fig. 17. Use screwdriver to push out pump pin (101). 230 3. Relieve pressure; page 4. 101 4. Fig. 16. Remove suction tube (30) and hose (33). 9019A Fig. 17 6. Fig. 18. Loosen locknut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump. 222 33 30 Fig. 16 9024A 9022A Fig. 18 Repair See manual 308798 for pump repair instructions. 2. Fig. 17. Push pin (101) into hole until retaining clip (230) engages pump pin groove. Installation 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 property damage. Make sure pin (101) and retaining clip (230) are properly installed. Clip must engage groove in 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 Nm). CAUTION If the pump locknut loosens during operation, the threads of the bearing housing will be damaged. 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. Fig. 20 9021A Fig. 21. Fill packing nut with Graco TSL until fluid flows onto the top of seal. 1.0 in. Fig. 19 9020A 9023A Fig. 21 308870 15 Displacement Pump Pump Pin Clip Removal Installation 1. Remove pump (28). 1. Fig. 17. Install clip (230). 2. Remove two bolts (86), washers (25), pump bracket (85), pail hook (94) and shield (95). 2. Install shield (95), pail hook (94) and pump bracket (85) with two washers (25) and bolts (86). Torque bolts to 40 ft-lb (54 N m). 3. Fig. 17. Remove clip (230). 3. Install pump (28). 16 308870 Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241116 Ref No. Part No. Description 19a 19b 19d 19e 241121 105489 241114 112770 PINION HOUSING, COIL PIN PINION SHAFT RETAINING RING, large 19e 19d Ref No. 20: Drive Housing Assembly 241537 Qty 10 (Ref) 9 (Ref) 19a 1 2 Ref No. Part No. Description 20 20a 20b 20c 20d 20g 20h 101 194060 193656 114691 114828 114697 114698 194117 DRIVE HOUSING RETAINING CLIP, pump pin CAM FOLLOWER PLATE CAM FOLLOWER BEARING RETAINER CLIP WASHER WASHER PIN Qty 1 1 1 2 2 1 1 1 20h 20g 83 (Ref) 20 9 (Ref) 99 (Ref) 1 18 (Ref) 82 (Ref) 20c 20b 20d 101 20a 9046A 1 Pinion housing/coil assembly (19a) includes clutch field and all bearings, pins and o-rings 308870 17 Parts Drawing – Hi-Boy Sprayers Model 232630 DETAIL A Ref 11 Label 40 45 37 87 See page 17 for the parts. See manual 308798 for the parts. See page 22 for the parts. See page 22 for the parts. 93 78 29 8699A 38 39 10 52 Ref 35 9 19 20h 72 17 20g 20 98 83 4b 3 9027A Bottom View 61 97 24 2 9 56 11 18 1 95 94 85 5 7 DETAIL A 33 8 101 86 17 49 25 16 47 4a 70 61 77 73 71 44 42 80 17 16 28 22 15 23 35 64 21 66 105 30 65 31 41 71 33(Ref) 12 62 88 104 308870 34 62 52 18 99 103 26 17 43 9 82 102 64(Ref) 9018A 10 Parts List – Hi-Boy Sprayers Models 232630 Ref No. Part No. Description 1 2 3 4 114530 113084 192014 241113 4a 4b 5 7 8 9 10 193531 183401 193680 104008 101864 11 12 15 239998 193682 113802 16 17 18 108803 105510 241539 19 20 21 22 23 24 25 26 28 241116 241537 194189 103413 111603 241536 100018 100644 240917 29 30 194438 241541 31 33 34 35 37 38 39 40 189920 240795 193394 241324 183350 110243 108795 191084 ENGINE 1 RIVET, blind 2 PLATE, indicator 1 CLUTCH ASSEMBLY, 1 includes 4a, 4b, 16, 17, 72, 80 .ARMATURE, clutch, 5 in. 1 .ROTOR, 5 in. 1 CLUTCH HOUSING 1 KEY, parallel 1 CLAMP 1 WASHER, spring, lock 12 CAPSCREW, socket head, 10 1/4–20 x 3/4 in. CART HANDLE & HOSE RACK 1 CAP, end 2 SCREW, flange, hex hd, 1 3/8–16 x 5/8 in. CAPSCREW, sch, 1/4–2 x 1 in. 6 LOCKWASHER, spring, 1/4 in. 15 GEAR COMBINATION 1 includes 91 and 92 PINION ASSEMBLY; Parts, page 17 1 DRIVE HOUSING; Parts, page 17 1 SWIVEL, male, QD 1 O-RING 1 O-RING 1 COVER, housing, drive, kit 1 WASHER, lock, spring 1 SCREW, cap 5 DISPLACEMENT PUMP 1 Parts, manual 308798 TUBE, nylon, split 1 TUBE, intake 1 includes 22, 23, and 66 STRAINER 1 HOSE, coupled 1 NUT, retaining 1 CART FRAME 1 WASHER, plain 2 RING, retaining 2 SCREW, mch, pn hd, 10–32 x 5/16 in. 4 SLEEVE 2 Qty Ref No. Part No. Description 41 42 43 44 45 47 49 52 56 61 62 64 65 66 70 179811 101242 104811 154636 112827 237686 112798 114984 194126 114678 162485 194178 241718 241719 110837 71 72 73 77 78 80 82 83 85 86 87 88 93 94 95 96 97 98 99 101 102 103 104 105 110838 101682 108842 100214 114687 WHEEL, semi–pneumatic 2 RING, retaining 2 HUBCAP 2 WASHER 2 BUTTON, snap 2 GROUNDING CLAMP & WIRE 1 SCREW, hex washer hd, No. 8 x 3/8 in 1 SCREW, mch, pn hd; 2 LABEL, warning 1 BUSHING, strain relief 1 NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3 HOSE, drain 1 DEFLECTOR 1 CLIP, spring 1 SCREW, flng, hex hd, 2 5/16–18 x 1–1/2 in. LOCKNUT, heavy hex, 5/16–18 6 SCREW, cap, sch 4 SCREW, cap, sch 4 WASHER, lock, spring 4 CLIP, retainer 1 HUB, armature 1 WASHER, thrust 1 WASHER, thrust 1 BRACKET, pump 1 SCREW, cap, sch 2 CONDUCTOR, ground 1 ADAPTER, male elbow, 90 1 WASHER 2 PAIL HOOK Repair Kit; includes 95 1 GROMMET, pump 1 THROAT SEAL LIQUID; not shown 1 DOWEL PIN 4 ROLLER assembly 4 SCREW, cap, sch 2 PIN 1 PLUG, packless, 3/8 in. 1 LABEL, warning 1 LABEL, warning; not shown 1 CLIP, spring. 1 114699 114672 194118 110343 240997 110249 108851 241540 195377 206994 114695 241322 114693 194117 240987 194317 195119 194194 Qty Danger & Warning labels, tags, and cards are free. 308870 19 Parts Drawing – Lo-Boy Sprayers Model 232632 DETAIL A Ref 11 40 Label See page 17 for the parts. See manual 308798 for the parts. See page 22 for the parts. 45 5 87 78 93 29 37 39 51 10 72 17 9 19 Ref 35 30ae 61 20h 20g 30b 83 30ad 9027A Bottom View 20 98 4b 97 30a 9 30aea 56 1 11 30aec 18 30e 30c 82 103 95 26 17 70 101 94 5 30aeb 30f 7 85 9 86 17 49 16 34 4a 35 33 47 77 71 73 80 17 28 62 15 22 23 30ab 66 71 52 41 44 42 3 2 30aa 12 33 (Ref) 104 62 30d 30b (Ref) 20 308870 21 16 30ac 43 24 25 8 DETAIL A 99 102 9016A 10 Parts List – Lo-Boy Sprayers Model 232632 Ref No. Part No. Description 1 2 3 4 114530 113084 192014 241113 4a 4b 5 7 8 9 10 193531 183401 193680 104008 101864 11 12 15 239998 193682 113802 16 17 18 108803 105510 241539 19 20 21 22 23 24 25 26 28 241116 241537 194189 103413 111603 241536 100018 100644 240917 29 30 30a 194438 241288 241269 30aa 241542 30ab 30ac 30ad 30ae 176450 194307 101818 241720 30aea 30aeb 30aec 30b 30c 30d 30e 170957 195151 114967 194180 194194 162453 241718 ENGINE 1 RIVET, blind 2 PLATE, indicator 1 CLUTCH ASSEMBLY, 1 includes 4a, 4b, 16, 17, 72, 80 .ARMATURE, clutch, 5 in. 1 .ROTOR, 5 in. 1 CLUTCH HOUSING 1 KEY, parallel 1 CLAMP 1 WASHER, spring, lock 12 CAPSCREW, socket head, 10 1/4–20 x 3/4 in. CART HANDLE & HOSE RACK 1 CAP, end 2 SCREW, flange, hex hd, 1 3/8–16 x 5/8 in. CAPSCREW, sch, 1/4–2 x 1 in. 6 LOCKWASHER, spring, 1/4 in. 15 GEAR COMBINATION 1 includes 91 and 92 PINION ASSEMBLY; Parts, page 17 1 DRIVE HOUSING; Parts, page 17 1 SWIVEL, male, QD 1 O-RING 1 O-RING 1 COVER, housing, drive, kit 1 WASHER, lock, spring 1 SCREW, cap 5 DISPLACEMENT PUMP 1 Parts, manual 308798 TUBE, nylon, split 1 ASSEMBLY, tube, suction 1 .TUBE, suction, 30 gallon (120 liter) 1 . includes 30aa through 30ae ..SWIVEL, tube, inlet 1 includes 22, 23 and 66 ..GUARD, hose 1 ..HOSE, fluid 1 ..CLAMP, hose 2 ..TUBE, suction 1 includes 30aea, 30aeb and 30aec ...TUBE, suction, lower 1 ...TUBE, intake. 1 ...COUPLING, pipe, 1in. 1 .HOSE, drain 1 .CLIP, spring 1 .NIPPLE 1 .DEFLECTOR 1 Qty Ref No. Part No. Description 30f 33 34 35 37 38 39 40 41 42 43 44 45 47 49 52 56 61 62 64 65 66 70 112604 240795 193394 241324 183350 110243 108795 191084 179811 101242 104811 154636 112827 237686 112798 114984 194126 114678 162485 194178 241718 241719 110837 71 72 73 77 78 80 82 83 85 86 87 88 93 94 95 96 97 98 99 101 102 103 104 110838 101682 108842 100214 114687 .STRAINER 1 HOSE, coupled 1 NUT, retaining 1 CART FRAME 1 WASHER, plain 2 RING, retaining 2 SCREW, mch, pn hd, 10–32 x 5/16 in. 4 SLEEVE 1 WHEEL, semi–pneumatic 1 RING, retaining 2 HUBCAP 2 WASHER 2 BUTTON, snap 2 GROUNDING CLAMP & WIRE 1 SCREW, hex washer hd, No. 8 x 3/8 in 1 SCREW, mch, pn hd; 2 LABEL, warning 1 BUSHING, strain relief 1 NIPPLE, 3/8–18 npsm(m) x 3/8 npt(m) 3 HOSE, drain 1 DEFLECTOR 1 CLIP, spring 1 SCREW, flng, hex hd, 2 5/16–18 x 1–1/2 in. LOCKNUT, heavy hex, 5/16–18 6 SCREW, cap, sch 4 SCREW, cap, sch 4 WASHER, lock, spring 4 CLIP, retainer 1 HUB, armature 1 WASHER, thrust 1 WASHER, thrust 1 BRACKET, pump 1 SCREW, cap, sch 2 CONDUCTOR, ground 1 ADAPTER, male elbow, 90 1 WASHER 2 PAIL HOOK Repair Kit; includes 95 1 GROMMET, pump 1 THROAT SEAL LIQUID; not shown 1 DOWEL PIN 4 ROLLER assembly 4 SCREW, cap, sch 2 PIN 1 PLUG, packless, 3/8 in. 1 LABEL, warning 1 LABEL, warning 1 114699 114672 194118 110343 240997 110249 108851 241540 194681 206994 114695 241322 114693 194117 240987 194317 195119 Qty Danger & Warning labels, tags, and cards are free. 308870 21 Parts Drawing – Sprayer Models 232630 through 232633 307 301 314 318f 313 304 305 310 309 308 318e 312 304 319 321 302 318d 303 320 318b 315 318c 318z 306 311 318aa 310 318a 305 322 318g 307 318h 318m 318n 318k 318j 318l 8716A 22 308870 Parts List – Sprayer Models 232630 through 232633 REF NO. PART NO. DESCRIPTION QTY 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 318 318a 318b 318c 318d 193653 PLA TE, control 241093 BOARD, PC 111839 SCREW, mch pan, 6–32 x 1/2 in. 240776 HARNESS, wiring. 193497 GASKET , control 193652 HOUSING, control box 114631 SCREW, mch, pan hd 193052 PLATE, instruction 114277 SWITCH, rocker, (spst) 241443 POTENTIOMETER, pressure control 193657 GASKET , potentiometer 193654 PLATE, instruction 114273 KNOB, potentiometer 193072 LABEL, control 114629 GROMMET, transducer FILTER, fluid 193651 HOUSING, filter 104361 O-RING 186075 SUPPOR T, filter 167025 STRAINER, mesh, 60 NO. PART NO. DESCRIPTION QTY 318e 318f 318g 318h 318j 318k 318l 318m 318n 318z 171941 SPRING, compression 192706 BOWL, filter 193710* SEAL, valve 193709* SEA T, valve 194102* HANDLE, valve 114688* NUT, cap, hex hd 114708* SPRING, compression 114797* GASKET 240914* V ALVE 240314 TRANSDUCER, pressure control includes 318aa 318aa 111457 O-RING 319 110997 SCREW, flange, hex 320 114532 TIE, wire, twist 321 189246 LABEL, warning 322 241444 COVER, pressure control 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 * Drain valve replacement kit 241276 available; includes 318g through 318n Replacement warning labels may be ordered free of charge Wiring Diagram Green 309 (Ref) 1 1 5 1 2 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 REF Black 310 (Ref) D Red Potentiometer E Red (+) 304 (Ref) Violet A 318z (Ref) Pressure transducer 318aa (Ref) 302 (Ref) 9279 Fig. 22 308870 23 Parts List & Drawing – Complete Sprayers Models 232631, 232633 Includes items 201 to 204 204 Ref No. Part No. Description 201 232631 Hi-Boy Sprayer 1 See parts list on page 18 Lo-Boy Sprayer 1 See parts list on page 21 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) HOSE, grounded, nylon; 3/16 in. ID; cpld 1/4 npsm(m) x 1/4 npsm(f) swivel; 3 foot (0.9 m); spring guards both ends 1 CONTRACTOR SPRAY GUN Includes RAC IV DripLess Tip Guard and 517–size SwitchTip See 307614 for parts 1 232633 202 240797 203 238358 204 220955 Qty 203 202 0160 Accessories DANGER LABELS An English language DANGER label is on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing shows the best placement of these labels for good visibility. Order the labels from your Graco distributor. French Spanish German Greek Korean English 24 194931 194932 194933 194934 194935 194317 308870 Apply other language here 9036A Displacement Pump Repair Kit Packing repair kit. GMax 7900 240916 Technical Data Honda GX160 Engine Power Rating @ 3700 rpm ANSI . . . . . . . . . . . . . . . . . . . . . .5.5 . Horsepower DIN 6270B/DIN 6271 NA . . . . . . . . . . . . . . . . . . . . .2.9 . Kw – 4.0 Ps NB . . . . . . . . . . . . . . . . . . . . .3.6 . Kw – 4.9 Ps Maximum working pressure . . . . . . . . . . . . . . .3300 psi (227 bar, 22.7 MPa ) Noise Level Sound power . . . . . . . . . . . . . . . . . . . . . . . 105 . . dBa per ISO 3744 Sound pressure . . . . . . . . . . . . . . . . . . . . . . 96 . . dBa measured at 3.1 feet (1 m) Cycles/gallon (liter) . . . . . . . . . . . . . . . . . . . . . . 69 . . (18) Maximum delivery rating . . . . . .2.1 gpm (7.9 liter/min) Maximum tip size . . . . . . . . . . 1 gun with 0. 046 in. tip 2 guns with 0.033 in. tip 3 guns with 0. 026 in. tip 4 guns with 0. 022 in. tip Inlet paint strainer . . . . . . . . . . .16 mesh (1190 micron) stainless steel screen, reusable Outlet paint filter . . . . . . . . . . . . 60 . mesh (250 micron) stainless steel screen, reusable Pump inlet size . . . . . . . . . . . . . . . . . . . . .3/4 . in. npt (m) Fluid outlet size . . . . . . . . . . . .1/4 npsm from fluid filter Wetted parts . . . . . . . . . . . . . . zinc-plated carbon steel, PTFE , Nylon, polyurethane, UHMW polyethylene, Viton , Delrin , leather , aluminum, tungsten carbide,nickle-plated carbon steel, stainless steel, chrome plating NOTE: Delrin ,PTFE , Viton are trademarks of the DuPont Company. Dimensions Model 232630 Model 232632 Weight (dry, without packaging) . . . . . 175 lb (79.4 kg) Height . . . . . . . . . . . . . . . . . . . . . . . . .41 . in. (104.1 cm) Length . . . . . . . . . . . . . . . . . . . . . . . . . .38 . in. (96.5 cm) Width . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . in. (55.9 cm) Weight (dry, without packaging) . . . . . 180 lb (82.1 kg) Height . . . . . . . . . . . . . . . . . . . . . . . . .41 . in. (104.1 cm) Length . . . . . . . . . . . . . . . . . . . . . . . . . .38 . in. (96.5 cm) Width . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . in. (55.9 cm) Hi-Boy without hose or gun Lo-Boy Cart without hose or gun 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 byan 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 equipment of the determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance 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 substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibilit y of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper 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 distributo r for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defecti ve 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 W ARRANTIES, 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 no thatother remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person operty, or pr or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two ears (2) yof 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, materials or components sold but not manufactured by Graco. These items sold, but not manufacture d 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 equi pment 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 proceedi ngs entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parti es reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciai res exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty Program”. All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Sales Offices: Minneapolis, Detroit Foreign Offices: Belgium, England, Korea, France, Germany, Hong Kong, Japan GRACO INC. 26 308870 P.O. BOX 1441 MINNEAPOLIS, MN http://www.graco.com PRINTED IN USA 308870 March 1999, Revised May 1999 55440–1441
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