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Graco Inc. GMax 7900 manual

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Table of contents for the manual

  • Page 1

    308870 Rev . F First choice when quality counts. t Related Manuals Operation 308867 . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement Pump 308798 . . . . . . . . . . . . . . . . . Spray Gun 309091 . . . . . . . . . . . . . . . . . . . . . . . . . Spray T ip 309055 . . . . . . . . . . . . . . . . . . . . . . . . . . . PC Board 308919 [...]

  • Page 2

    308870 2 W arnings and Cautions W arning Symbol W ARNING 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. Fluid injection is a serious injury! If [...]

  • Page 3

    308870 3 Component Identification and Function 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 232631 R D 9034B A Pressure Control Switch ON/OFF , enables/disables clutch function and pressure control B Pressure Adjusting Knob Cont[...]

  • Page 4

    308870 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

    308870 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 . PROBLEM CAUSE SOLUTION Engine won ’ t start Eng[...]

  • Page 6

    308870 6 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 prope[...]

  • Page 7

    308870 7 Rollers Removal 1. Relieve pressure ; page 4. 2. Fig. 2. Remove six cap screws (10) lock washers (9) and cover assembly (24). Note: A screw driver may be needed to pry off cover assembly . 3. Remove dowel pins (97) and rollers (98) Installation 1. Install rollers (98) and dowel pins (97) 2. Install cover assembly (24) with six lock washers[...]

  • Page 8

    308870 8 Cam Follower Bearings Removal 1. Relieve pressure ; page 4. 2. Fig. 16. Cycle pump piston rod (222) to lowest position. T urn 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 fr[...]

  • Page 9

    308870 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 and engine lead. 9027A Fig. 5 X Bottom View 3. Fig. 6. Remove five screws (26) and lockwashers (17) and pi[...]

  • Page 10

    308870 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

    308870 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

    308870 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

    308870 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

    308870 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

    308870 15 Displacement Pump Removal 1. Flush pump. 2. Fig. 16. Cycle pump with piston rod (222) in lowest position. 3. Relieve pressure ; page 4. 4. Fig. 16. Remove suction tube (30) and hose (33). 9024B Fig. 16 222 33 30 9024C 5. Fig. 17. Use screwdriver to push out pump pin (101). Fig. 17 101 20a Detail A 9019B 6. Fig. 18. Loosen locknut by hitti[...]

  • Page 16

    308870 16 Displacement Pump Pump Pin Clip Removal 1. Remove pump (28). 2. Remove two bolts (86), washers (25), pump brack- et (85), pail hook (94) and shield (95). 3. Fig. 17. Remove clip (230). Installation 1. Fig. 17. Install clip (230). 2. Install shield (95), pail hook (94) and pump bracket (85) with two washers (25) and bolts (86). T orque bol[...]

  • Page 17

    308870 17 Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241 1 16 Ref No. 20: Drive Housing Assembly 241537 Ref No. Part No. Description Qty Ref No. Part No. Description Qty 19a 241 121 PINION HOUSING, COIL 1 19b 105489 PIN 2 19d 241 1 14 PINION SHAFT 19e 1 12770 RET AINING RING, large 20 DRIVE HO[...]

  • Page 18

    308870 18 Parts Drawing – Hi-Boy Sprayers 9018D 9027A Ref 1 1 40 45 37 38 39 Ref 35 DET AIL A 52 Model 232630 See manual 308798 for the parts. 1 2 3 Label See page 17 for the parts. 1 5 18 19 10 98 24 97 9 20 2 2 4a 94 101 28 21 25 80 43 41 42 4 See page 22 for the parts. 52 12 11 86 DET AIL A 44 3 2 85 95 16 17 7 8 73 15 71 17 16 72 17 4b 70 64 [...]

  • Page 19

    308870 19 Parts List – Hi-Boy Sprayers Models 232630* Ref No. Part No. Description Qty Ref No. Part No. Description Qty 1 1 14530 ENGINE 1 2 1 13084 RIVET , blind 2 3 192014 PLA TE, indicator 1 4 241 1 13 CLUTCH ASSEMBL Y ,1 includes 4a, 4b, 16, 17, 72, 80 4a .ARMA TURE, clutch, 5 in. 1 4b .ROT OR, 5 in. 1 5 193531 CLUTCH HOUSING 1 7 183401 KEY ,[...]

  • Page 20

    308870 20 9027A 30f Ref 1 1 40 45 37 39 51 Ref 35 DET AIL A Model 232632 See manual 308798 for the parts. 1 2 3 Label See page 17 for the parts. 1 5 19 9 98 101 97 99 20 2 2 3 4a 94 25 28 24 80 9 10 43 41 42 33 4 See page 22 for the parts. 52 12 11 62 DET AIL A 44 3 2 85 16 17 17 26 7 8 73 77 15 71 17 16 4 72 17 4b 35 30e 62 102 30c 30b 30a 71 30d [...]

  • Page 21

    308870 21 Parts List – Lo-Boy Sprayers Model 232632 Ref No. Part No. Description Qty Ref No. Part No. Description Qty 1 1 14530 ENGINE 1 2 1 13084 RIVET , blind 2 3 192014 PLA TE, indicator 1 4 241 1 13 CLUTCH ASSEMBL Y ,1 includes 4a, 4b, 16, 17, 72, 80 4a .ARMA TURE, clutch, 5 in. 1 4b .ROT OR, 5 in. 1 5 193531 CLUTCH HOUSING 1 7 183401 KEY , p[...]

  • Page 22

    308870 22 Parts Drawing – Sprayer Models 232630 through 232633 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

    308870 23 Parts List – Sprayer Models 232630 through 232633 REF NO. P ART NO. DESCRIPTION QTY REF NO. P ART NO. DESCRIPTION QTY 30 1 193653 PLA 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 HOUSING, control box 1 307 1 14631 SCREW , [...]

  • Page 24

    308870 24 Parts List & Drawing – Complete Sprayers Models 232631, 232633 Includes items 201 to 204 Ref No. Part No. Description Qty 201 232631 Hi-Boy Sprayer 1 See parts list on page 18 232633 Lo-Boy Sprayer 1 See parts list on page 21 202 240797 HOSE, grounded, nylon; 3/8 in. ID; 1 cpld 3/8 npsm(fbe); 50 foot (15 m); spring guards both ends [...]

  • Page 25

    308870 25 T echnical 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 . . . . . . . . . . . . . . . (2[...]

  • Page 26

    308870 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[...]