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Graco Inc. 308868 manual

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Table of contents for the manual

  • Page 1

    308868 Rev . L First choice when quality counts. t Model 232621 Related Manuals Operation 308867 . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement Pump 308798 . . . . . . . . . . . . . . . . . Spray Gun 309091 . . . . . . . . . . . . . . . . . . . . . . . . . T exture Spray Gun 308491 . . . . . . . . . . . . . . . . . . Spray T ip 30[...]

  • Page 2

    308868 2 T able of Contents W arnings and Cautions 2 . . . . . . . . . . . . . . . . . . . . . . . . . Component Identification and Function 3 . . . . . . . . . . . . Maintenance 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T roubleshooting 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Bearing H[...]

  • Page 3

    308868 3 Component Identification and Function 8696B Fig. 1 S U W T X V P A B C E F G H J K 202 Main hose 203 Whip end hose 204 Contractor gun with RAC 5 DripLess tip guard and 517 size SwitchTip 203 204 202 M N L Model 23261 1 R D A Pressure Control Switch ON/OFF , enables/disables clutch function and pressure control B Pressure Adjusting Knob Con[...]

  • Page 4

    308868 4 Maintenance W ARNING 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 . T o reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relie[...]

  • Page 5

    308868 5 T roubleshooting W ARNING INJECTION HAZARD T o 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 W arning , page 4, before checking, adjust- ing, cleaning or shutting down sprayer . Check everything in chart before disassembling sp[...]

  • Page 6

    308868 6 PROBLEM CAUSE SOLUTION Pump output is low Strainer (31) is clogged Clean strainer . Sprayer 232627 strainer is for use in paint only . 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. [...]

  • Page 7

    308868 7 Bearing Housing and Connecting Rod NOTE: The item numbers referenced are for the Hi-Boy models. The Lo-Boy models may have different item numbers. Use the Hi-Boy item number and part to find the corresponding Lo-Boy part and item number . Removal 1. Relieve pressure ; page 4. 2. Fig. 3. Remove screws (14) and front cover (23). 3. For Hi-Bo[...]

  • Page 8

    308868 8 Drive Housing Removal 1. Relieve pressure ; page 4. 2. Fig. 4. Remove bearing housing. Do 1. through 8. of Bearing Housing and Connecting Rod proce- dure on page 7. 3. Remove two screws (81) and lockwashers (17). 4. Remove four screws (10) and lockwashers (17) from pinion housing (19). 5. Lightly tap around drive housing (20) to loosen dri[...]

  • Page 9

    308868 9 Pinion Assembly/Rotor/Field/Shaft/Clutch Removal If pinion assembly (19) is not removed from clutch housing (5), do 1. through 4. Otherwise, start at 5. 1. Relieve pressure ; page 4. 2. Disconnect field cable (X) from pressure control. 8699A Fig. 5 X Bottom View 3. Fig. 6. Remove five screws (10) and lockwashers (17) and pinion assembly (1[...]

  • Page 10

    308868 10 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. Fig. 10 4a 8705A 0.12 ± .01 in. (3.0 ± .25 mm) 4. Install armature (4a) on engine drive shaft. 5. Install four screws (16) an[...]

  • Page 11

    308868 11 Clutch Housing Removal 1. Fig. 12. Remove four capscrews (75) and lock- washers (77) which hold clutch housing (5) to engine. 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull of f clutch housing (5). Installation 1. Fig. 12. Push on clutch housing (5). 2. Install four capscrews (75) and lockwashers (77[...]

  • Page 12

    308868 12 On/Off Switch Removal 1. 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. Installation 1. Install new ON/OFF switch (309) so tabs of switch snap into place on inside[...]

  • Page 13

    308868 13 Pressure Control Control Board Removal 1. Relieve pressure ; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Fig. 22. Disconnect at control board (302): D Four clutch leads: two violet and two black. D Lead (D) from potentiometer . D Lead (E) from transducer . D T wo red leads (A) to ON/OFF switch (309). 4. Fig. 15. Re mo[...]

  • Page 14

    308868 14 Pressure Control Control Board Diagnostics 1. Fig. 15. Remove five screws (307) and cover (322). 2. Start sprayer . 3. T urn ON/OFF switch ON. 4. Observe LED operation and reference following table: LED BLINKS SPRA YER OPERA TION INDICA TES WHA T TO DO T wo times repeatedly Sprayer shuts down and LED contin- ues to blink two times repeate[...]

  • Page 15

    308868 15 Displacement Pump Removal 1. Flush pump. 2. Relieve pressure ; page 4. 3. Fig. 16. Cycle pump with piston rod (222) in its lowest position. 4. Fig. 16. Remove suction tube (30) and hose (33). Fig. 16 7672B 222 33 30 5. Fig. 17. Use screwdriver: push retaining spring up and push out pin (29). Fig. 17 7675B 29 6. Fig. 18. Loosen locknut by [...]

  • Page 16

    308868 16 Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayer s Ref 1 1 40 45 37 38 39 Ref 35 DET AIL A Models 232610, 232620 and 232627 See manual 308798 for the parts. 1 2 3 Label See page 18 for the parts. 1 5 18 19 23 22 13 12 21 20 2 2 3 4a 26 34 30 31 28 14 80 54 43 41 42 33 67 4 See page 22 for the parts. 51 50 11 62 DET AIL A 44 5 5 Us[...]

  • Page 17

    308868 17 Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 232610, 232620 and 232627* Ref No. Part No. Description Qty Ref No. Part No. Description Qty 1 ENGINE 108879 GMax 3900 1 1 14530 GMax 5900, 5900HD 1 2 1 13084 RIVET , blind 2 3 192014 PLA TE, indicator 1 4 CLUTCH ASSEMBL Y , includes 4a, 4b, 16, 17, 80 241 10 9 GMax 3900 1 241 [...]

  • Page 18

    308868 18 Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241 108 for GMax 3900; Pinion Housing Assembly 241 1 12 for GMax 5900 Ref No. 20: Drive Housing Assembly 241007 for GMax 3900; Drive Housing Assembly 24101 1 for GMax 5900 Ref No. Part No. Description Qty Ref No. Part No. Description Qty 19 [...]

  • Page 19

    308868 19 Notes[...]

  • Page 20

    308868 20 Parts Drawing – GM ax 3900 and GMax 5900 Lo-Boy Sprayer s 30f Ref 1 1 40 45 37 38 39 Ref 35 DET AIL A Models 232612 and 232622 See manual 308798 for the parts. 1 2 3 Label See page 18 for the parts. 1 5 19 23 22 13 12 21 20 2 2 3 4a 26 34 28 14 80 9 43 41 42 33 4 See page 22 for the parts. 51 50 11 62 DET AIL A 44 5 5 Used on GMax 5900,[...]

  • Page 21

    308868 21 Parts List – GMax 3900 and GMax 5900 Lo – Boy Sprayers Models 232612 and 232622 Ref No. Part No. Description Qty Ref No. Part No. Description Qty 1 ENGINE 108879 GMax 3900 1 1 14530 GMax 5900 1 2 1 13084 RIVET , blind 2 3 192014 PLA TE, indicator 1 4 CLUTCH ASSEMBL Y , includes 4a, 4b, 16, 17, 80 241 10 9 GMax 3900 1 241 1 13 GMax 590[...]

  • Page 22

    308868 22 Parts Drawing – Sprayer GMax 3900 and 5900 Sprayers Models 232610 through 232613 Models 232620 through 232623; 232627 and 232628 318k 318j 318l 307 322 305 310 31 1 306 315 318z 318aa 303 302 309 308 312 310 313 314 304 305 301 307 304 318c 318a 318b 318d 318e 318f 8716A 319 321 320 318n 318m 318h 318g 323[...]

  • Page 23

    308868 23 Parts List – Sprayer Models 232610 through 232613; 232620 through 232623; 232627 and 232628 REF NO. P ART NO. DESCRIPTION QTY REF NO. P ART NO. DESCRIPTION QTY 30 1 193653 P LA TE, control 1 302 241093 BOARD, PC 1 30 3 1 1 1839 SCREW , mch pan, 6 – 32 x 1/2 in. 5 304 240776 HARNESS, wiring. 1 30 5 193497 GASKET , control 2 306 193652 [...]

  • Page 24

    308868 24 Parts List & Drawing – Complete Sprayers Models 23261 1, 232613, 232621, 232623, 232628 GMax 3900, 5900, 5900HD Airless Paint Sprayers Includes items 201 to 204 Ref No. Part No. Description Qty Ref No. Part No. Description Qty 201 23261 1 GM3900 Hi-Boy Sprayer 1 See parts list on page 16 232621 GM5900 Hi-Boy Sprayer 1 See parts list[...]

  • Page 25

    308868 25 T echnical Data Honda GX120 Engine Power Rating @ 3700 rpm ANSI 4.0 Horsepower . . . . . . . . . . . . . . . . . . . . . . . DIN 6270B/DIN 6271 NA 2.1 Kw – 2.8 Ps . . . . . . . . . . . . . . . . . . . . . . NB 2.6 Kw – 3.6 Ps . . . . . . . . . . . . . . . . . . . . . . Honda GX160 Engine Power Rating @ 3700 rpm ANSI 5.5 Horsepower . .[...]

  • Page 26

    308868 26 Graco W arranty 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 by a n 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 perio[...]