Graco 308864C 5.5 HORSEPOWER, GASOLINE POWERED GMAX 5900 Convertible Airless Paint Sprayer Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

First choice when quality counts.

INSTRUCTIONS

308864

Rev. C

5.5 HORSEPOWER, GASOLINE POWERED

GMAX 5900 Convertible

Airless Paint Sprayer

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

Model Series

232624 A

232625 A

232626

232629

232680

232681

232682

240774

240775

A

A

A

A

A

A

A

Description

Sprayer, gas powered

Sprayer, gas powered, with RAC IV tip, gun and hose

Sprayer, gas powered, with electric motor kit

Sprayer, gas powered, with Lo-Boy suction set kit

Sprayer, gas powered, with RAC IV tip, gun and hose and Lo-Boy suction set kit

Sprayer, gas powered, with Lo-Boy suction set kit and electric motor kit

Electric motor kit converts sprayer to electric powered sprayer.

!

Model 232624

Related Manuals

Operator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump . . . . . . . . . . . . . . . . .

308863

308798

Spray Gun

Spray Tip

. . . . . . . . . . . . . . . . . . . . . . . . . 307614

. . . . . . . . . . . . . . . . . . . . . . . . . . . 308644

PC Board . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Motor Kit . . . . . . . . . . . . . . . . . . . .

308919

308920

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

Table of Contents

Component Identification and Function

Maintenance

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

4

Troubleshooting

Repair

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bearing Housing and Connecting Rod

Drive Housing

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

8

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

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

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

11

12

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

Parts

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

Pinion Assembly

Pressure Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring Schematic

Clutch Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

21

Complete Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

21

22

Technical Data

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

23

Graco Phone Number

Graco Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

24

GRACO INC.

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

COPYRIGHT 1998, GRACO INC.

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

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.

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.

308864

Component Identification and Function

202 Main hose

203 Whip end hose

204 Contractor gun with RAC IV

DripLess tip guard and 517 size SwitchTip

C

D

V H

R

S

J

E

G

K

A

P

X

U B

T

203

F

Y

M

L 202

W

N Model 232624

Fig. 1

A Pressure Control Switch

B Pressure Adjusting Knob

C Air Cleaner*

D Fuel Tank*

E Muffler*

F Spark Plug Cable*

G Fuel Shutoff Lever*

H Choke*

J Throttle Lever*

K Engine Switch*

L Secondary Fluid Outlet

M Pressure Control

ON/OFF, enables/disables clutch function

Controls fluid outlet pressure

Filters air entering carburetor

Holds 0.95 gallons (3.6 liter) of 86 octane gasoline

Reduces noise of internal combustion

Routes electrical current to spark plug

On/off lever to regulate fuel flow from gasoline tank to carburetor

Enriches air/gasoline mixture for cold starting

Adjusts engine speed for large or small orifice spray tips

Enables/disables engine operation

Second hose and spray gun is connected here

Controls clutch cycling to maintain fluid pressure

*

U

V

S

T

Drive Housing

Displacement Pump

Fluid Filter

Grounding Clamp and Wire

W Pressure Drain Valve

X

Y

N Primary Fluid Outlet

P Engine*

R Clutch Housing

Hose and spray gun is connected here

5.5 HP gasoline engine

Transfers power from engine to drive assembly

Transfers power from clutch to displacement pump

Provides fluid to be sprayed through spray gun

Filters fluid between source and spray gun

Grounds sprayer system

Relieves fluid pressure when open

Cord

Clamp

Provides electric power from engine alienator to control and clutch

Locks down engine/motor and provides belt tension

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

204

308864

WARNING

INJECTION HAZARD

System pressure must be manually relieved to prevent system from starting or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pressure Relief Procedure whenever you: are instructed to relieve pressure, stop spraying, check or service any system equipment, or install or clean spray tip.

Pressure Relief Procedure

1. Lock gun safety latch.

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

OFF.

3. Unplug power supply cord (electric motor).

4. Move pressure control switch to OFF and turn pressure control knob fully counterclockwise.

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

6.

Unlock gun safety latch. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

7. Lock gun safety latch.

8. Open pressure drain valve. Leave pressure drain valve open until ready to spray again.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above , VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

Maintenance

CAUTION

For detailed engine maintenance and specifications, refer to separate engine manual, supplied.

DAILY: Check engine oil level and fill as necessary.

Manual 308863.

DAILY: Check that V-belt (60) is centered on pulleys and is not inverted. Replace if worn or damaged.

DAILY: Check and fill gas tank.

DAILY: Check hoses for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check pressure drain valve for proper operation.

AFTER THE FIRST 20 HOURS OF OPERATION

AND EACH 100 HOURS THEREAFTER: Change engine oil.

DAILY: Keep TSL in packing nut to help lubricate pump packings. One full squirt of TSL is usually enough.

WEEKLY: Remove cover of air filter (C) and clean element. Replace element, if necessary. If operating in an unusually dusty environment, check filter daily and replace it, if necessary.

Repack connecting rod (22) top needle bearing after every pump change.

Replacement elements can be purchased from your local HONDA dealer.

SPARK PLUG: Use only an BPR6ES (NGK) or

W20EPR–U (NIPPONDENSO) plug. Gap plug to

0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug wrench when installing and removing plug.

308864

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.

Check everything in chart before disassembling sprayer.

PROBLEM

Engine won’t start

Engine operates, but doesn’t

CAUSE

Engine switch is OFF

Engine is out of gas

Engine oil level low

SOLUTION

Turn engine switch on.

Refill gas tank. Honda Engines Owner’s Manual.

Try to start engine. Replenish oil, if necessary.

Honda Engines Owner’s Manual.

Connect spark plug cable or replace spark plug.

Spark plug cable disconnected or spark plug damaged

Oil seepage into combustion chamber

Pressure control switch turned OFF

Pressure setting too low

Displacement pump outlet filter dirty

Tip or tip filter clogged

Broken drive belt

Displacement pump rod seized by dry paint

Connecting rod worn or damaged

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.

Turn on.

Increase pressure.

Clean filter.

Clean tip or tip filter.

Replace belt.

Service pump. See page 14.

Replace. See page 7.

Drive housing worn or damaged Replace. See page 8.

Electrical power not energizing clutch field " # $ # !$

%& ' #$ # ($

) * +, *

* -./--0 * # " &

' * '$

% '" * & '

* $ !

10

* ' ' ($

*#$

± !$ Ω 2 & 0

Check control board fuse. If blown, replace with equivalent automotive fuse.

3 * " '4 *5 6

$

Clutch worn or damaged Service. See page 9.

Pinion assembly worn or damaged Service. See page 9.

308864

PROBLEM

Pump output low

Pump is difficult to prime

High engine speed at no load

CAUSE

Strainer (31) clogged

Piston ball (25) not seating

Piston packings worn or damaged

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

Intake valve ball not seating properly

Engine speed is too low

V–belt slipping

Clutch worn or damaged

Pressure setting is too low

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

Large pressure drop in hose with heavy materials

SOLUTION

Clean.

Service piston ball check. Manual 308798.

Replace packings. Manual 308798.

Replace o-ring. Manual 308798.

Clean and service. Manual 308798.

Increase throttle setting. See Manual 308863.

Tighten V–belt with clamp (101). Adjust clamp until it takes 15 lb of force to lock clamp down.

Replace. See page 9.

Increase pressure. Manual 308863.

Clean filter. Manual 308863 or 307614.

Excessive paint leakage into throat packing nut

Throat packing nut is loose

Spitting from gun

Throat packings worn or damaged

Displacement rod worn or damaged

Air in fluid pump or hose

Tip partially clogged

Fluid supply is low or empty

Air leak

Intake valve is leaking

Worn packings

Fluid is too thick

Engine speed is too high

Misadjusted throttle setting.

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).

Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.

Replace packings. Manual 308798.

Replace rod. Manual 308798.

Check for loose connections at pump intake and tighten. Then prime pump. See Startup ,

Manual 308863.

Clear.

Refill and prime pump. See Startup , Manual

308863. Check fluid supply often to prevent running pump dry.

" #

$

%* # 4 *

4 ' *# #$

Shut off pump and relieve pressure. Disassemble and clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble.

Repack pump. Manual 308798.

Thin fluid according to supplier’s recommendations.

Decrease throttle setting before priming pump.

Manual 308863.

% # !! 7 !!

Clutch squeaks each time clutch engages

Worn engine governor

Clutch surfaces are not matched to each other when new and may cause noise

Replace or service engine governor

Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time

308864

1.

Removal

Bearing Housing and Connecting Rod

Relieve pressure ; page 4.

3.

Clean mating surfaces of bearing and drive housings (17, 12).

4.

Align connecting rod (14) with crank (E) and drive housing locating pins (12b) with bearing housing

(17) holes. Push bearing housing onto drive housing or tap into place with plastic mallet.

2.

Stop sprayer at bottom of stroke to get crank (E) in lowest position.To lower crank manually, remove spark plug and carefully rotate crank by pulling starter rope.

3.

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

(108) from pump. Unscrew pump suction tube

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

CAUTION

Do not use bearing housing screws (44) to align or seat bearing housing; this may cause bearing and drive housing misalignment and result in premature bearing wear.

4.

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

19

5.

Install screws and lockwashers (44, 45). Tighten screws evenly to 25 ft-lb (34 N m).

6.

Install pump; page 14.

7.

Fig. 3 . Install remaining parts.

1 B

C 2

D

14

2

45, 44 3

13

18

Fig. 2

5.

Loosen locknut (20). Unscrew displacement pump (21).

89

6.

Remove four screws and lockwashers (44, 45).

7.

Tap lower rear of bearing housing (17) with a plastic mallet to loosen from drive housing (12).

Pull bearing housing and connecting rod assembly

(14) straight off drive housing.

8.

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

9.

Inspect crank (E) for excessive wear and replace parts as needed.

Installation

1.

Evenly lubricate inside of bronze bearing (B) in bearing housing (17) with high-quality motor oil.

Liberally pack top roller bearing (C), lower bearing

(D) inside connecting rod assembly (14) with bearing grease 114819.

2.

Assemble connecting rod (14) and bearing housing (17).

E

12

12b

57

17

18

19

47

1

2

3

108

Oil

Pack with bearing grease 114819

Torque to 25 ft-lb (34 N m)

Fig. 3

20

21

106

107

59

:

308864

1.

Drive Housing

Relieve pressure ; page 4.

Removal

2.

Fig. 4. Remove bearing housing. Do Removal of

Bearing Housing and Connecting Rod procedure on page 7.

3.

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

4.

Remove four screws (9) and lockwashers (10) from pinion housing (8).

2.

Place bronze colored washer (12g) on shaft protruding from large shaft of drive housing (12).

Place silver colored washer (12h) on pins on pinion housing. Assemble washers (15) and (16) onto gear (7). Align gears and push new drive housing straight onto pinion housing and locating pins (A).

3.

Install four screws (9) and lockwashers (10) to pinion housing (8) and drive housing (12).

4.

Install two screws (41) and lockwashers (10) to drive housing (12).

5.

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

Bearing Housing and Connecting Rod procedure on page 7.

5.

Lightly tap around drive housing (12) to loosen drive housing. Pull drive housing straight off pinion housing (8). Be prepared to support gear cluster

(7) which may also come out.

1

9

10

A

8

2

12h

12g

CAUTION

Do not drop gear cluster (7) when removing drive housing (12). Gear cluster is easily damaged. Gear may stay engaged in drive housing or pinion housing.

Installation

1.

Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (18) and to areas called out by note 2. Use full 0.68 pint (0.32

liter) of grease.

12

10

A

15

7

16

15

1 Torque to 200 in-lb

2

Fig. 4

Apply remaining grease to these areas

41 1

8698A

308864

Pinion Assembly/Rotor/Shaft/Clutch/Pulley

Removal

If pinion assembly (8) is not removed from clutch housing (3), do 1. through 4. Otherwise, do 1 and then start at 5.

E

39

6

1.

Relieve pressure ; page 4.

2.

Disconnect field cable (X) from pressure control.

X

Fig. 7

6.

Fig. 8. Remove retaining ring (Z).

7.

Tap pinion shaft (A) out with plastic mallet.

!(

Z

A

Fig. 5

Bottom View :

3.

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

(6) and pinion assembly (8).

5

6

8

Fig. 6

5

6

!

4.

Fig. 7. Place pinion assembly (8) on bench with rotor side up.

5.

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

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

Alternately tighten screws until rotor comes off.

Fig. 8

8.

Fig. 10. Remove drive belt shield (74) and belt (68).

!

9.

Hold pulley (2) and remove four screws (3a) and washers (3h) from hub (3d). Remove armature

(3g) and spacer (3f).

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

Remove three bolts (112b) and three washers

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

Remove pulley and key (1).

11. Remove three screws (27) from beneath mounting plate (D).

12. Lift off clutch housing (3).

($ % # # ;'<$ =* >" &

'4 ;< *$

308864

Pinion Assembly/Rotor/Shaft/Clutch/Pulley

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

Installation

($ 1#$ (!$ / >" & '4 ;<$ /

# # ;'<$

2.

Fig. 9. Lay two stacks of two dimes on smooth bench surface.

3.

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

4.

Press center of clutch down on bench surface.

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

13. Install retaining ring (Z).

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

4a

0.12 ± .01 in. (3.0 ± .25 mm)

15. Apply locktite to screws. Install four screws (39) and lockwashers (6). Alternately torque screws to

125 in-lb until rotor is secure.

16. Install pinion assembly with five screws (5) and lockwashers (6).

Fig. 9

5.

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

!8

6.

Install three screws (27) through mounting plate

(D) and into clutch housing (3).

7.

Insta to ll key (1) in bushing (112). Apply Locktite to three bolts (112).

Install bushing in pulley (2) with three bolts (112b). Install set screw (112a) in bushing. End of jackshaft (3c) must be 0.090 in.

below flush with end of bushing.

8.

Hold pulley (2) and install four screws (3a) and washers (3h) in hub (3d). Torque to 125 in-lb

(14 N m).

9.

Install drive belt shield (74).

10. Push drive housing (12) and pinion housing (8) assembly onto clutch housing (3). Tap lightly on front of bearing housing (17) with a plastic mallet to push drive housing and pinion housing assembly onto clutch housing.

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

71

74

3b

3c

112b

112a

1

68

Fig. 10

2 112

3e

3f

3g

3d

3h

D

3a

27

(

308864

On/Off Switch

Removal

1.

Relieve pressure ; page 4.

2.

Fig. 11. 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.

(

Installation

1.

Install new ON/OFF switch (309) so tabs of switch snap into place on inside of pressure control housing.

2.

Connect two wires (A) to ON/OFF switch.

3.

Install pressure control cover (322) with five screws (307).

313

310

307

303

302

309 A

301

315 319 318a

322

Fig. 11

D

318z

318aa

(

E

Locate switch terminals as shown

((

308864

1.

Pressure Control

Control Board

Two red leads (A) to ON/OFF switch (80).

Relieve pressure ; page 4.

4.

Remove five screws (303), green ground wire and circuit board (302).

2.

Fig. 11. Remove five screws (307) and cover (322).

3.

Fig. 18. Disconnect at control board (302):

Four clutch leads: two violet and two black.

Lead (D) from potentiometer.

Lead (E) from transducer.

1.

Fig. 11. Install control board (302) and green ground wire with five screws (303).

2.

Connect to control board (302):

Two red leads (A) to ON/OFF switch (309).

Lead (E) to transducer.

Lead (D) to potentiometer.

Four clutch leads: two violet and two black.

3.

Install cover (322) with five screws (307).

Pressure Control Transducer

1.

Relieve pressure ; page 4.

1.

Fig. 11. Install packing o-ring (318aa) and pressure control transducer (318z) in filter housing (318a).

Torque to 30–35 ft-lb.

2.

Fig. 11. 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).

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 control board (302).

4.

Install cover (322) with five screws (307).

5.

Remove pressure control transducer (318z) and packing o-ring (318aa) from filter housing (318a).

Pressure Adjust Potentiometer

1.

Relieve pressure ; page 4.

2.

Fig. 11. Remove five screws (307) and cover (322).

3.

Disconnect lead (D) from control board (302).

4.

Loosen set screws on potentiometer knob (313) and remove knob, shaft nut, lockwasher (310) and pressure adjust potentiometer (310).

5.

Remove seal (311) from potentiometer (310).

1.

Install seal (311) on potentiometer (310).

2.

Fig. 11. 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.

3.

Connect lead (D) to control board (302).

4.

Install cover (322) with five screws (307).

308864

Pressure Control

Control Board Diagnostics

1.

Fig. 11. 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

Two times repeatedly

Three times repeatedly

Four times repeatedly

Five times repeatedly

Six times repeatedly

SPRAYER OPERATION

Sprayer shuts down and LED continues to blink two times repeatedly

Sprayer shuts down and LED continues to blink three times repeatedly

Sprayer shuts down and LED continues to blink four times repeatedly

Sprayer shuts down and LED continues to blink five times repeatedly

Sprayer shuts down and LED continues to blink six times repeatedly

INDICATES

Run away pressure.

Pressure greater than

4500 psi (310 bar, 31

MPa).

Pressure transducer is faulty or missing

Generator voltage is low

WHAT TO DO

1.

Check pressure transducer connection at control board

2.

Replace pressure transducer

3.

Replace control board

1.

Check pressure transducer connection at control board

2.

Replace pressure transducer

3.

Replace control board

1.

Increase engine throttle

2.

Check wiring connections

3.

Service Honda engine alternator

High clutch current 1.

Check clutch 5-pin bulkhead connector. Clean contacts.

2.

Measure 1.7

±

0.2

Ω

across clutch field at 70 F

3.

Replace clutch field assembly

High clutch temperature 1.

If clutch is new, let sprayer cool 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.

308864

Displacement Pump

19

1.

Flush pump.

2.

Relieve pressure ; page 4.

3.

Fig. 12. Cycle pump with piston rod (222) in its lowest position.

4.

Fig. 12. Remove suction tube (107) and hose (47).

Fig. 13

6.

Fig. 14. Loosen locknut by hitting firmly with a

20 oz (maximum) hammer. Unscrew pump.

89

222

47

107

Fig. 12 9

5.

Fig. 13. Use screwdriver: push retaining spring up and push out pin (19).

Repair

See manual 308798 for pump repair instructions.

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 and retaining spring are properly installed.

CAUTION

If the pump jamnut loosens during operation, the threads of the bearing housing will be damaged.

Make sure jamnut is properly tightened.

1.

Fig. 15. Pull piston rod out 1.5 in. Screw in pump until holes in bearing cross link and piston rod align.

Fig. 14

9

2.

Fig. 13. Push pin (19) into hole. And push retaining spring into groove all the way around connecting rod.

3.

Fig. 16. Screw jam nut down onto pump until stops. Screw pump up into bearing housing until it is stopped by jam nut. Back off pump and jam nut to 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

N m).

Fig. 16 9

4.

Fig. 17. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal.

1.5 in.

Fig. 15

308864

9 Fig. 17

9

308864

Parts – Basic Sprayer

71

Model 232624, Series A

74

79 68 112b

72

85 84 2 112

79

90

112a

1

65

5

6

3

5

1

2

See exploded view on page 18

See parts in manual 308798

3 See engine detail on page 17

4 See parts on page 19

5 See parts on page 21

6 Label

9

10

8

1

12h

12g

83

7

16

131

10

41

76

39

6

4

89 DETAIL A

15

40

6

11

1 12 57

18

19

62

117

43

27

52

47

61

108

105

3

51

50

49

DETAIL A

76 Ref

75

81

64

63

62

14

45

44

13

17

20 59

56

21

2

106

107

104

102

8(Ref) 82

101 103

122

48

4

42

42(Ref)

26 25

Bottom View 87

308864

8739A

88

109

108(Ref)

86

46

47(Ref)

60

58

8742A

91 92

73

95

1 69 66

94 93

112a

112

70

54

96

130

2

25

26

27

39

40

41

42

43

44

45

46

47

16

17

18

19

20

21

10

11

12

13

14

15

48

49

97

53

6

7

8

3

4

1

2

5

9

Ref.

No.

99

98

53

8743A

104008

194125

241011

241308

241012

114672

114673

241015

183169

183210

193031

240291

Part No.

Description

183401

193548

241306

193553

100644

105510

241440

241112

101864

114425

114794

112395

101682

237686

114686

112798

114666

106115

155699

222516

193682

154636

Qty.

KEY, parallel

PULLEY

CLUTCH HOUSING ASSY

ROTOR, clutch, 5 in.

CAPSCREW, sckt hd,, 1/4–20 x 3/4 in.

4

2

2

1

1

LOCKWASHER, spring, 1/4 in.

GEAR, combination

PINION ASSEMBLY; Parts, page 18

11

1

1

4 CAPSCREW, socket head,

1/4–20 x 3/4 in.

WASHER, lock, spring

LABEL, danger

DRIVE HOUSING

COVER, HOUSING, DRIVE

CONNECTING ROD KIT

WASHER, thrust

1

1

2

4

1

1

WASHER

BEARING HOUSING

SPRING, retaining

PIN, straight, 3/8 x1/8 in.

NUT, retaining

PUMP, displacement ; 1

Parts, Manual 308798

BUSHING, strain relief

CORD, power, convertible

1

1

1

1

1

1

1

SCREW, 3/8–16 x 3/4 in.

SCREW, cap, sch

GROUNDING CLAMP & WIRE

SCREW, cap, sch

PRESSURE CONTROL

Parts, page 19

SCREW, thread forming

CAPSCREW, socket head,

LOCKWASHER, spring, 3/8 in.

3

4

1

2

1

ELBOW, street

FLUID HOSE, 3/8 in. ID, 3/8 npt couplings, 2.5 ft long, spring guards

CAP, end;

WASHER, 5/8 in.

1

1

1

2

2

1

4

4

Parts – Basic Sprayer

121

Ref.

No.

96

97

98

99

91

92

93

94

95

83

84

85

86

87

88

89

90

101

102

103

104

105

106

107

108

109

111

72

73

74

75

76

79

81

82

64

65

66

68

69

70

71

50

51

52

53

54

56

57

58

59

60

61

62

63

Part No.

101242

104811

179811

110996

114653

108795

192014

113084

110838

114391

114687

194126

114806

114805

194181

114816

114813

109099

112586

241313

194130

111800

241935

110885

108947

187147

241718

194194

193097

194178

110249

206994

112746

240131

192719

164672

162485

240712

110243

183350

241003

112406

193547

194198

194087

111801

114827

114530

194099

191084

239998

114810

112827

114809

112

117

121

122

130

131

114959

114271

194414

114984

194925

290228

Description Qty.

RING, retaining

HUBCAP

WHEEL, semi–pneumatic

NUT, flng hd, hex

SCREW, cap, flng hd

LOCKNUT, 5/16–18

PLUG, packless

HANGER, pail

ADAPTER 2

NIPPLE, 3/8–18 npsm(m) x 1/4 npt(m) 1

1

1

FRAME, cart

RING, retaining

1

2

4

4

2

2

8

2

2

WASHER

GUARD, back

CAPSCREW, hex hd

BELT, 4V

GUARD, lower engine

HANDLE, slide

SCREW, cap, flng hd

SPACER, hex

ENGINE, 5.5 HP

GUARD, belt front

SLEEVE, cart

CART HANDLE

EXTRUSION, trim

BUTTON, snap

BUSHING, strain relief

2

2

1

1

2

2

1

1

1

4

1

1

2

1

2

SCREW, cap, sch

PLATE, indicator

RIVET, blind (not shown) 2

LOCKNUT, w/nylon insert, 5/16–18 4

SCREW, grounding

4

1

1

CLIP, retainer

LABEL, warning

EXTRUSION, gasket

1

1

1

JACK, 1/4, motor

BOX, junction, engine

NUT, hex

SCREW, mach, hex washer hd

BUSHING, snap

SCREW, cap, hex hd, flanged

PLATE, mount motor

BRACKET, clamp

SCREW, cap, flanged hd

1

2

2

1

1

1

1

1

1

LATCH, adjustable

SCREW, mach, pnhd, thrd forming

NUT, square

STRAINER

.DEFLECTOR

CLIP, spring

TUBE, intake

HOSE, coupled

ADAPTER, male elbow, 90

THROAT SEAL LIQUID,

8 oz (0.27 liter) (not shown)

BUSHING, 3/4 in. (3 bolts, 3 washers)

STRAP, retaining

BRACKET, J-box

SCREW, tapping, pnhd, #10 x 1/2 in.

BRACKET, tension

LABEL, caution

1

1

1

1

1

2

1

1

2

1

1

2

1

2

1

1

Replacement Danger and Warning labels, tags and cards are available at no cost.

308864

Parts List & Drawing – Pinion Assembly

Ref No. 8 and 12

Ref No. 8: Pinion Housing Assembly 241112

Ref

No.

Part No.

Description Qty

Ref No. 12: Drive Housing Assembly 241011

Ref

No.

Part No.

Description Qty

8

8b 105489

PINION HOUSING

PIN

8d*

8e*

193358

112770

PINION SHAFT

RETAINING RING, large

*Must be ordered separately

8e

8d

8b

9 (Ref.)

10 (Ref.)

8

12h

1

1

1

2

12

12g* 194173

12h* 194172

HOUSING, drive

WASHER

WASHER

*Must be ordered separately

1

1

1

12g

15 (Ref)

12

10 (Ref.)

9 (Ref.)

7(Ref.)

16 (Ref)

8715A

308864

Parts Drawing – Sprayer

Ref No. 42

307

301

314

313

304

305

309 310

312

308

304

318f

318a

319

320

307

322

305

311

310

306

318aa

302

303

315

318z

318b

318k

318j

318l

318n

318m

318h

318g

318d

318c

318a

8716A

308864

Parts List – Sprayer

Models 232624

REF

NO.

PART NO.

DESCRIPTION

301 193653 PLATE,

302 241093

303 111839

BOARD, PC

SCREW, mch pan, 6–32 x 1/2 in.

304 240776 HARNESS,

305 193497

306 193652

307 114631

308 193052

GASKET, control

HOUSING, control box

SCREW, mch, pan hd

PLATE, instruction

309 114277

310 241443

311 193657

312 193654

313 114273

SWITCH, rocker, (spst)

POTENTIOMETER, pressure control

GASKET, potentiometer

PLATE, instruction

KNOB, potentiometer

314 193072

315 114629

318

318a 193651

318b 104361

318c 186075

318d 167025

LABEL, control

GROMMET, transducer

FILTER, fluid

HOUSING, filter

O-RING

SUPPORT, filter

STRAINER, mesh, 60

QTY

10

1

2

1

5

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

REF

NO.

PART NO.

DESCRIPTION QTY

318f 192706 BOWL, filter

318j 194102* HANDLE,

318k 114688* NUT, cap, hex hd

318l 114708* SPRING,

318m 114797* GASKET

318n 240914* VALVE

318z 240314

318aa 111457

319 110997

TRANSDUCER, pressure control includes 318aa

O-RING

SCREW, flange, hex

320 114532

321 189246

322 241444

TIE, wire, twist

LABEL, warning

COVER, pressure control

* Drain valve replacement kit 241276 available; includes

318g through 318n

Replacement warning labels may be ordered free of charge

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

309

(Ref)

304

(Ref)

Fig. 18

Pressure Control Wiring Diagram

Green

Black

D

310

(Ref)

Red

Potentiometer

E

Red

A

318z

(Ref)

Pressure transducer

318aa

(Ref)

Violet 302

(Ref)

8714A

308864

Parts List & Drawing –Clutch Assembly

Ref No. 3

Clutch Housing Assembly 241306

Includes 3b, 3c, 3e, 3j and 3k

Ref

No.

Part No.

Description

3a*

3b

3c

3d*

3e

3f

108803

114962

241305

193510

193493

194059

SCREW, hex, sch

RING, retaining, internal

SHAFT, drive, input includes 3b,3j, and 3k

HUB, armature

HOUSING, clutch

STOP, armature

Qty

4

1

1

1

1

1

Ref

No.

Part No.

Description Qty

3g*

3h*

3j

3k

193681

105510

115078

115079

ARMATURE, clutch

WASHER, lock, spring

O-RING

O-RING

* Clutch replacement kit 241113 includes 3a, 3d, 3g, 3h, 4, 6,

39

1

1

1

8

3b

3c

3e

3j

3k

3f

3g*

3d*

39*(Ref)

6*(Ref)

4*(Ref)

3h* 3a*

8745A

Model 232625

Includes items 125 to 128

Parts – Complete Sprayer

126

Ref.

No.

125

126

127

128

Part No.

232624

240794

238358

220955

Description Qty.

CONVERTIBLE GMax 5900C Sprayer

See parts list on page 16

HOSE, grounded, nylon; 1/4” ID; and 517–size SwitchTip

See 307614 for parts

1 cpld 1/4 npsm(fbe); 50 ft (15 m);’ spring guards both ends

HOSE, grounded, nylon; 3/16” ID; cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;

1

3 ft (0.9 m); spring guards both ends 1

“CONTRACTOR” SPRAY GUN

Includes RAC IV DripLess Tip Guard

1

128

127

308864

0160

Parts – Lo-Boy Suction Set Kit

Model 241287

Includes items 401 to 407

Ref.

No.

401

Part No.

241124

401a 240513

401b 176450

401c 194306

401d 101818

401e 170957

402

403

194180

194194

404

405

406

162453

187147

241718

407 144958

Description

.TUBE, suction, 5 gallon (20 liter) includes 401a through 401e

..SWIVEL, tube, inlet

..GUARD, hose

..HOSE, fluid

..CLAMP, hose

..TUBE, suction

.HOSE, drain

.CLIP, spring

.NIPPLE

.STRAINER

.DEFLECTOR

.STRAP, tie

Qty.

1

1

1

1

1

1

2

1

1

1

1

1

404

402

401a

401

402(REF)

406

405

401e

403

407

401b

401d

401c

8744A

308864

Technical Data

Honda GX160 Engine

Power Rating @ 3700 rpm

ANSI . . . . . . . . . . . . . . . . . . . . . . .

DIN 6270B/DIN 6271

NA . . . . . . . . . . . . . . . . . . . . . .

NB . . . . . . . . . . . . . . . . . . . . . .

Maximum Working Pressure

5.5 Horsepower

2.9 Kw – 4.0 Ps

3.6 Kw – 4.9 Ps

. . . . . . . . . . . . . . 3300 psi

(227 bar, 22.7 MPa)

Cycles/Gallon (liter)

Maximum Delivery

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

93 (25)

1.25 gpm (4.7 liter/min)

Fuel Tank Capacity

Maximum Tip Size

. . . . . . . . . . . 0.95 gallons (3.6 liter)

. . . . . . . . . . . . . . 1 gun with 0.041 tip

Inlet Paint Strainer

2 guns with 0.028 tip

. . . . . . . . . . . 16 mesh (1190 micron)

Stainless steel screen, reusable

Outlet Paint Filter . . . . . . . . . . . . . 60 mesh (250 micron)

Pump inlet Size

Fluid Outlet Size

Stainless steel screen, reusable

. . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)

. . . . . . . . . . . 1/4 npsm from fluid filter

Wetted parts

PTFE

. . . . . . . . . . . . . . zinc-plated carbon steel,

, Nylon, polyurethane, UHMW polyethylene,

Viton , Delrin , leather, aluminum, tungsten carbide,nickle-plated carbon steel, stainless steel, chrome plating

NOTE: Delrin , PTFE

Company.

, Viton are trademarks of the

Dimensions

Model 232624

Weight (dry, without packaging)

Height

Length

. . . . . . . 170 lb (77 kg)

. . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)

. . . . . . . . . . . . . . . . . . . . . . . . . . . 39 in. (99.1 cm)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)

Graco Phone

Number

TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify distributor closest to you: 1–800–690–2894 Toll Free

DANGER LABELS

The 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 below shows the best placement of these labels for good visibility.

Order the labels directly from your Graco distributor.

French 194931

Spanish 194932

German 194933

Greek 194934

Korean 194935

English 194125

Apply other language here

! :

308864

Graco Warranty

Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on date of sale by an authorized Graco distributor to original purchaser for use. With exception of any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from date of sale, repair or replace any part of equipment determined by Graco to be defective. This warranty applies only when 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 incompatibility of

Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or improper design, manufacture, installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon prepaid return of equipment claimed to be defective to an authorized Graco distributor for verification of claimed defect. If claimed defect is verified, Graco will repair or replace free of charge any defective parts. equipment will be returned to original purchaser transportation prepaid. If inspection of equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include costs of parts, labor, and transportation.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of 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 manufactured by Graco (such as electric motors, gas engines, switches, hose, etc.), are subject to 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 equipment hereunder, or furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in “Graco Contractor Equipment Warranty

Program”.

All written and visual data contained in this document reflects latest product information available at time of publication. Graco reserves right to make changes at any time without notice.

Sales Offices: Minneapolis, Detroit

Foreign Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC.

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

http://www.graco.com

PRINTED IN USA 308864 February 1999, August 1999

308864