Graco 309412F Gmax 7900 Users Manual Repair Instructions; English

309412F 309412EN-F

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Repair Instructions

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441

Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001

GMaxR7900

Airless Paint Sprayer

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

See page 2 for models numbers.

Related Manuals

Operation 309408...............................

Displacement Pump 309277......................

Spray Gun 309639..............................

Spray Tip 309640................................

PC Board 309459...............................

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

Clutch Replacement Kit 309890...................

309412F

ti1833a

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

3094122

Models

Model Series Description

233718 ALo--Boy

233719 AHi--Boy

233720 ALo--Boy with RACRX tip, gun and hose

233721 AHi--Boy with RAC X tip, gun and hose

Table of Contents

Warnings and Cautions 3.........................

Maintenance 4...................................

Troubleshooting 5................................

Repair

Rollers 8......................................

Drive Housing 9................................

Cam Follower Bearings 10......................

Engine 11.....................................

Pressure Control 13............................

Displacement Pump 15.........................

Parts

Pinion Assembly 17............................

Sprayers 18...................................

Pressure Control 21............................

Tip, Gun, Hose 22..............................

Dimensions 23...................................

Technical Data 23................................

Graco Warranty 24...............................

Graco Phone Number 24..........................

309412 3

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.

Fluid injection and high pressure hazard: High pressure spray or

leaks can inject fluid into the body.

To help prevent injection, always:

DEngage trigger safety latch when not spraying.

DKeep clear of nozzle and leaks.

DNever spray without a tip guard.

DDo PRESSURE RELIEF if you stop spraying or begin servicing

sprayer.

DDo not use components rated less than sprayer Maximum

Working Pressure.

DNever allow children to use this unit.

If high pressure fluid pierces your skin, the injury might look like

“just a cut”, but it is a serious wound! Get immediate medical atten-

tion.

Fire and explosion: Solvent and paint fumes can ignite or

explode.

To help prevent a fire and explosion:

DUse only in an extremely well ventilated area.

DEliminate all ignition sources; such as pilot lights, cigarettes and

plastic drop cloths (static arc hazard). Do not plug or unplug

power cords or turn lights on or off in spray area.

DGround Sprayer, object being sprayed, paint and solvent pails.

DHold gun firmly to side of grounded pail when triggering into pail.

DUse only conductive airless paint hose.

DDo 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.

DDo not fill fuel tank while engine is running or hot.

DDo not flush with gasoline.

WARNING

3094124

Maintenance

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:

Dareinstructedtorelievethepressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor 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.

C

A

UTION

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: Check pressure drain valve for proper opera-

tion.

DAILY: Check and fill the gas tank.

AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference

Honda Engines Owner’s Manual for correct oil viscos-

ity.

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.

309412 5

Troubleshooting

Relieve pressure;page 4.

PROBLEM CAUSE SOLUTION

E=XX is displayed Fault condition exists Determine fault correction from table, page 14.

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 3 to 4 times.

Clean or replace spark plug. Start engine.

Keep sprayer upright to avoid oil seepage.

False tripping of Watch-

Dog system. EMPTY is

displayed. Pump does

not run.

Operating conditions out of WatchDog parameters Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.

Operate without WatchDog active; Manual

309408.

Low pump output. See Troubleshooting Table, Pump Outlet Low,

page 6.

Engine operates, but

displacement pump

does not operate

Error code displayed? Determine fault correction from table, page 14.

Pump switch is OFF TurnpumpswitchON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

increase pressure.

Fluid filter (318) is dirty Clean filter. Page 20.

Tip or tip filter is clogged Clean tip or tip filter. Manual 309091.

Displacement pump piston rod is stuck due to dried

paint

Repair pump. Manual 309277.

Connecting rod is worn or damaged Replace connecting rod. Page 15.

Drive housing is worn or damaged Replace drive housing. Page 9.

Electrical power is not energizing clutch field Check wiring connections. Page 11.

Reference pressure control repair. Page 13.

Reference wiring diagram. Page 21.

With pump switch ON and pressure turned to

MAXIMUM, use a test light to check for power

between clutch test points on control board.

Remove 7--pin connector from control board

and measure resistance across clutch coil. At

70_F, the resistance must be between 1.7

±0.2Ω; if not, replace pinion housing.

Have pressure control checked by authorized

Graco dealer.

3094126

Troubleshooting

PROBLEM CAUSE SOLUTION

Clutch is worn, damaged, or incorrectly positioned Replace clutch. Manual 309890.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Manual

309890.

Pump output is low. Strainer (89) is clogged Clean strainer. Sprayer 233716 strainer is for

use in paint only.

Piston ball (206) is not seating Service piston ball. Manual 309277.

Piston packings are worn or damaged Replace packings. Manual 309277.

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

aged

Replace o-ring. Manual 309277.

Intake valve ball is not seating properly Clean intake valve. Manual 309277.

Intake valve ball is packed with material Clean intake valve. Manual 309277. Do not

leave 233716 sprayer under pressure for more

than 5 minutes when spraying texture and not

actively spraying.

Engine speed is too low Increase throttle setting. Manual 309408.

Clutch is worn or damaged Replace clutch. Manual 309890.

Pressure setting is too low Increase pressure. Manual 309408.

Fluid filter (318), tip filter or tip is clogged or dirty Clean filter. Manual 309408 or 309091.

Large pressure drop in hose with heavy

materials

Use larger diameter hose and/or reduce overall

length of hose. Use of more than 100 ft of 1/4

in. hose significantly reduces performance of

sprayer. Use 3/8 in. hose for optimum perfor-

mance (50 ft minimum).

Excessive paint leakage into

throat packing nut

Throat packing nut is loose Remove throat packing nut spacer. Tighten

throat packing nut just enough to stop leakage.

Throat packings are worn or damaged Replace packings. Manual 309277.

Displacement rod is worn or damaged Replace rod. Manual 309277.

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

prime pump. Manual 309408.

Tip is partially clogged Clear tip. Manual 309091.

Fluid supply is low or empty Refill fluid supply. Prime pump. Manual

309408. Check fluid supply often to prevent

running pump dry.

Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections.

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. Reas-

semble valve.

Pump packings are worn Replace pump packings. Manual 309277.

Paint is too thick Thin the paint according to the supplier’s

recommendations

309412 7

Troubleshooting

PROBLEM CAUSE SOLUTION

Engine speed is too high Decrease throttle setting before priming pump.

Manual 309408.

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.

High engine speed at no

l

o

a

d

Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load

l

oa

d

Worn engine governor Replace or service engine governor

Gallon counter not working Bad sensor, broken or disconnected wire Check connections. Replace sensor or wire.

No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.

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 DIncrease throttle setting

DAdjust 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

3094128

Rollers

Removal

1. Relieve pressure;page 4.

2. Fig. 1. Remove six cap screws (56) lock washers

(87), clip (35), and cover assembly (13).

Fig. 1

ti1860a

56

87

108

109

71

77 59

13

87

35

Note: A screw driver may be needed to pry off cover

assembly.

3. Remove dowel pins (108) and rollers (109)

Installation

1. Install rollers (109) and dowel pins (108)

2. Install cover assembly (13) with six lock washers

(87), clip (35), and cap screws (56).

309412 9

Drive Housing

Removal

1. Relieve pressure;page 4.

2. Fig. 2. Disconnect gallon counting sensor.

Fig. 2

ti1835a

3. Fig. 1. Remove six cap screws (56) lock washers

(87) and cover assembly (13).

4. Fig. 3. Remove two screws (59) and washers (87).

5. Remove four cap screws (56) lock washers (87)

from drive housing (71).

6. Lightly tap around drive housing (71) to loosen

drive housing. Pull drive housing straight off pinion

housing. Be prepared to support gear cluster

(102), which may also come out.

9046C

71

87 59

87

56

71h

71g

102 104 105

B

1

1Apply remaining grease to these areas

Fig. 3

21

71b

71c

71d

101

71a

8d

8e

Installation

1. Liberally apply bearing grease (supplied with

replacement gear cluster) to gear cluster (102),

washers (104) and (105) 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 (105) and silver

colored washer (104) onto drive housing (71).

Install gear cluster (102) through washers (105)

and (104).

3. Place bronze colored washer (71g) and silver

colored washer (71h) on shaft protruding from

large shaft of drive housing (71). Align gears and

push new drive housing straight onto pinion hous-

ing and locating pins (B).

4. Install two washers (87) and screws (59).

5. Install four lock washers (87) and cap screws (56)

into drive housing (71).

6. Install cover assembly (13) with six lock washers

(87) and cap screws (56).

7. Fig. 4. Reconnect gallon counting sensor.

Fig. 4 ti1835a

30941210

Cam Follower Bearings

Removal

1. Relieve pressure;page 4.

2. Fig. 9. Cycle pump piston rod (222) to lowest

position. Turn engine off.

3. Fig. 5. Remove six cap screws (56), lock washers

(87) and cover assembly (13).

Note: A screw driver may be needed to pry off

cover assembly.

4. Remove four dowel pins (108) and rollers (109).

5. From front, drive out pump pin (77) with a screw

driver.

6. Remove two retainer rings (71d).

7. Remove cam follower plate (71b).

Note: Two 1/2 in. x 13 bolts may be

needed to remove cam follower plates.

8. Remove two cam follower bearings (71c).

Installation

1. Install two cam follower bearings (71c).

2. Install cam follower plate (71b).

3. Install two retainer rings (71d).

4. Drive in pump pin (77) until it engages with pump

pin retaining clip (71a).

5. Install four rollers (109) and dowel

pins (108).

6. Install cover assembly (13) with six lock washers

(87) and cap screws (56).

Fig. 5

77

13

87

109

71c

71

71b

71d

108

56

9046c

309412 11

Engine

Removal

1. Remove Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing,asin-

structed in manual 309890.

2. Fig. 6. Disconnect all necessary wiring.

3. Fig. 7. Remove two locknuts (7) and screws (6)

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.

Fig. 6

Green

1

2

To the field

To the engine

7

97

2

1

ti1835

Fig. 7

7

6

8710B

Installation

1. Lift engine carefully and place on cart.

2. Fig. 7. Install two screws (6) in base of engine and

secure with locknuts (7). Torque to 200 in-lb (22.6

NSm).

3. Fig. 6. Connect all necessary wiring.

4. Install Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing,as

instructed in manual 309890.

30941212

On/Off Switch

Removal

1. Relieve pressure;page 4.

2. Fig. 8. Remove four screws (54) and

display/cover (52).

3. Pull display connector wings (A) open on PC board

and pull display connector out.

4. Disconnect ON/OFF switch connector (B) from PC

board.

5. Press in on two retaining tabs on each side of

ON/OFF switch (51) and remove switch.

Installation

1. Install new ON/OFF switch (51) so tabs of switch

snap into place on inside of pressure control

housing.

2. Connect ON/OFF switch connector (B) to PC

board.

3. Push display connector into PC board close dis-

play connector wings (A) on PC board.

4. Install display/cover (52) with four screws (54).

Fig. 8

52

54

ti1841a

A

51

302

122

ED

61a

61s

Z

Y

B

141

147

55

50

145

29

61p

61q

74 310

310

139

122

51

309412 13

Pressure Control

Control Board

Removal

1. Relieve pressure;page 4.

2. Fig.8. Remove four screws (54) and

display/cover (52). Pull display connector wings

(A) open on PC board and pull display connector

out.

3. Remove 2 screws (139).

4. Fig. 15. Disconnect at control board (302):

DLead (D) from potentiometer.

DLead (E) from transducer.

DLead (B) from On/Off Switch connector.

5. Fig. 8. Remove five screws (122) from control

board and ground wire screw (122).

6. Remove connector (Y) at backside of pressure

control. Remove jam nut (Z) and control board

(302).

Installation

When installing replacement control board, follow

instructions with control board to set model type.

1. Fig, 8. Install control board (302) and jam nut (Z).

Install connector (Y) at backside of pressure

control.

2. Install ground wire and control board (302) with

six screws (122).

3. Fig. 15. Connect to control board (302):

DConnect ON/OFF switch connector (B).

DLead (E) to transducer.

DLead (D) to potentiometer.

4. Fig. 8. Push display connector into PC board close

display connector wings (A) on PC board. Install

display/cover (52) with four screws (54).

Pressure Control Transducer

Removal

1. Relieve pressure;page 4.

2. Fig. 8. Remove four screws (54) and

cover (52).

3. Disconnect lead (E) from control board (302).

4. Remove two screws (141) and guard (147). Care-

fully pull transducer connector through rubber

grommet (145).

5. Remove pressure control transducer (61q) and

packing o-ring (61p) from filter housing (61e).

Installation

1. Fig. 8. Install packing o-ring (61p) and pressure

control transducer (61q) in filter

housing (61e). Torque to 30--35 ft-lb.

2. Carefully feed transducer connector through

rubber grommet (145). Install guard (147) with two

screws (141).

3. Connect lead (E) to motor control board (302).

4. Install cover (52) with four screws (54).

Pressure Adjust Potentiometer

Removal

1. Relieve pressure;page 4.

2. Fig. 8. Remove four screws (54) and

cover (52) and two screws (139).

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

4. Loosen set screws on potentiometer knob (50) and

remove knob, shaft nut, lockwasher (310) and

pressure adjust potentiometer (310).

5. Remove spacer (74) from potentiometer (310).

Installation

1. Install spacer (74) on potentiometer (310).

2. Fig. 8. Install pressure adjust potentiometer (310),

shaft nut, lockwasher (310) and potentiometer

knob (50).

a. Turn potentiometer shaft (310) clockwise to

internal stop. Assemble potentiometer knob

(50) to strike pin on plate (29).

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 plate (29) with two screws (139).

5. Install cover (52) with four screws (54).

psi

bar

MPa

30941214

Pressure Control Repair

Digital Display Messages

Relieve pressure before repair;page 4. No display does not mean that sprayer is not pressurized.

DISPLAY SPRAYER

OPERATION

INDICATION ACTION

No Display Sprayer may be pressurized. Loss of power or display

not connected

Check power source. Relieve

pressure before repair or dis-

assembly. Verify display is

connected.

Sprayer may be pressurized. Pressure less than

200 psi (14 bar, 1.4 MPa)

Increase pressure as needed

Sprayer is pressurized. Power is ap-

plied. (Pressure varies with tip size and

pressure control setting.)

Normal operation Spray

Sprayer stops. Engine is running. Exceeded pressure limit Remove any filter clogs or

flow obstructions. Make sure

gun trigger is locked open if

using AutoClean valve.

Sprayer stops. Engine is running. Pressure transducer faulty,

bad connection or broken

wire.

Check transducer connections

and wire. Replace transducer

or control board, if necessary.

Sprayer stops. Engine is running. High clutch current 1. Check clutch 7--pin bulk-

head connector. Clean

contacts.

2. 1.7 ±0.2Ωacross clutch

field at 70_F

3. Replace clutch field as-

sembly

Sprayer stops. Engine is running.

Display alternates E=06.

High clutch temperature 1. If clutch is new, let spray-

er cool down and then re-

start

2. Inspect clutch. Replace

clutch if there is excessive

wear.

3. Remove pump pin, sepa-

rate pinion housing from

clutch housing. Rotate

rotor clockwise to check

for excessive drag.

Sprayer stops. Engine is running. Pressure greater than

2000 psi (138 bar, 14 MPa)

while in Flush Timer Mode

Chase paint from lines before

running in flush timer mode.

Make sure spray gun is trig-

gered and prime valve is open

when using AutoClean

After a fault, follow these steps to restart sprayer:

1. Correct fault condition

2. Turn sprayer OFF

3. Turn sprayer ON

309412 15

Displacement Pump

Removal

See manual 309277 for pump repair instructions.

1. Flush pump.

2. Fig. 9. Cycle pump with piston rod (222) in lowest

position.

3. Relieve pressure;page 4.

4. Fig. 9. Remove suction tube (30) and hose (33).

9024B

Fig. 9

222

33

30 9024C

5. Fig. 10. Use screwdriver to push out pump

pin (101).

Fig. 10

101

71a

Detail A 9019B

6. Fig. 11. Loosen locknut by hitting firmly with a

20 oz (maximum) hammer. Unscrew pump.

9022A

Fig. 11

Repair

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 prop-

erty damage. Make sure pin (101) and retaining

clip (71a) are properly installed. See Detail A. Fig.

10.

C

A

UTION

If the pump locknut loosens during operation, the

threads of the bearing housing will be damaged.

Make sure locknut is properly tightened.

1. Fig. 12. Pull piston rod out 1.0 in. Screw in pump

until holes in housing plates and piston rod align.

Fig. 12

1.0 in.

9020A

2. Fig. 10. See Detail A. Push pin (101) into hole

until retaining clip (71a) snaps over pin.

Fig. 13. 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

±5ft--lb(102N¡m).

9021A

Fig. 13

Fig. 14. Fill packing nut with Graco TSL until fluid flows

onto the top of seal.

Fig. 14 9023A

30941216

Displacement Pump

Pump Pin Clip

Removal

1. Remove pump (85).

2. Remove two bolts (107), washers (79), pump

bracket (110), pail hook (90) and shield (113).

3. Fig. 10. Remove clip (71a).

Installation

1. Fig. 10. Install clip (71a).

2. Install shield (113), pail hook (90) and pump brack-

et (110) with two washers (79) and bolts (107).

Torque bolts to 40 ft-lb (54 NSm).

3. Install pump (85).

309412 17

Parts List & Drawing -- Pinion Assembly

Ref No. 8 and 71

Ref No. 8: Pinion Housing Assembly 245400 Ref No. 71: Drive Housing Assembly 245444

Ref

No. Part No. Description Qty

Ref

No. Part No. Description Qty

8a 245266 PINION HOUSING, COIL 1

8b 105489 PIN 2

8d 241114 PINION SHAFT

8e 112770 RETAINING RING, large

71 DRIVE HOUSING 1

71a 194060 RETAINING CLIP, pump pin 1

71b 193656 CAM FOLLOWER PLATE 1

71c 114691 CAM FOLLOWER BEARING 2

71d 114828 RETAINER CLIP 2

71g 114697 WASHER 1

71h 114698 WASHER 1

101 195523 PIN 1

56 (Ref)

87 (Ref)

71

71h71g

102 (Ref)

8a

104 (Ref)

87 (Ref)

59 (Ref)

1

1Pinion housing/coil assembly (8a) includes clutch field and all bearings, pins and o-rings

101

105 (Ref)

8d

8e

71a

71d

71c

71b

9046C

21 (Ref)

8b

30941218

34

45

97 7

DETAIL A

BOTTOM VIEW

ti1831a

119

140

104

102

21

84

Parts Drawing -- Sprayers

103

85

107

79

110

113

77

68

13

76 87 56

108

109

*71

65,

66

105

8

87

56

1b

42

88

98

REF 49

81

49

92

16

27

31

32

32

4

64

28

94

41

124 123

132

9

100

44

42

23

1a

3

36, 86

42

26

24

42

70

57

DETAIL A

Ref 28

7

6

60

35

59

87

38

39

92

43

10

5

128

Ref 119

96

27

37 139

139

44

95

34 69

See page 20 for parts

11

142

40

67

33

*See Pinion Assembly Parts

List for more information.

309412 19

Parts List

Models 233718, 233719

Ref.

No. Part No. Description Qty.

Ref.

No. Part No. Description Qty.

1 241113 CLUTCH, ASSEMBLY

includes 1a, 1b, 23, 42, 44, 88, 1

1a ARMATURE, clutch 1

1b ROTOR 1

3 193680 COLLAR, shaft 1

4 114530 ENGINE, gas, 5.5 HP, Honda 1

5 183350 WASHER 2

6 110837 SCREW, flange, hex 2

7 110838 NUT, lock 2

8 245400 PINION ASSEMBLY; Parts page 17 1

9 193682 PLUG, tube 2

10 191084 SLEEVE, cart 2

11 114271 STRAP, retaining 1

13 241536 COVER, assembly 1

16 241920 DEFLECTOR, threaded 1

21 116806 SWITCH, reed w/conn 1

24 193531 CLUTCH HOUSING 1

26 183401 KEY, parallel 1

27 246331 HOSE, drain, Lo--Boy 1

244240 HOSE, drain, Hi--Boy 1

28 245164 FRAME, cart GMAX 7900 1

31 113084 RIVET, blind 2

32 192014 PLATE, indicator 1

33 113802 SCREW 1

34 108851 WASHER 2

35 197124 CLIP 1

36 108842 SCREW 4

37 198904 SCREW, #8 2

38 114967 COUPLING, Hi--Boy only 1

39 198122 TUBE, Hi--Boy only 1

40 114678 GROMMET 1

41 104811 CAP, hub 2

42 105510 WASHER, lock, spring (hi-clr) 15

43 112827 BUTTON, snap 2

44 108803 SCREW, hex, socket head 6

45 114687 CLIP 1

49 245249 TUBE, suction, 30 gal (assembly) 1

56 101864 SCREW, cap sch 10

57 196670 LABEL, crtl box cover 1

59 114693 SCREW, cap, socket hd 2

60 290228 LABEL, caution 1

64Y194126 LABEL, warning 1

65Y194127 LABEL, warning 1

66Y194317 LABEL, danger, English 1

67Y195119 LABEL, warning tag 1

68Y195519 LABEL, caution 1

69Y192840 LABEL, warning 1

70 100644 SCREW, cap, sch 5

71 245444 DRIVE HOUSING; Parts page 17 1

76 198653 LABEL, identification 1

77 195523 PIN, PUMP 1

79 100018 WASHER, lock, spring 2

81 196723 CLIP, spring, Lo--Boy only 1

84 193394 NUT, retaining 1

85 246257 DISPLACEMENT PUMP;

Manual 309277 1

86 100214 WASHER, lock 4

87 104008 WASHER, lock, spring 12

88 101682 SCREW, cap, sch 4

92 189920 STRAINER 1

94 237686 CLAMP, grounding assy 1

95 112798 SCREW, thread form, hex hd 1

96 108795 SCREW, mach, pnh 4

97 240997 CONDUCTOR, ground 4

98 162485 FITTING, nipple, adapter 3

100 114984 SCREW, tapping, phil pan hd 2

102 241539 GEAR, combination 1

103 241540 REPAIR KIT, HOOK, PAIL

(includes item 113) 1

104 114699 WASHER, thrust 1

105 114672 WASHER, thrust 1

107 110343 SCREW, cap, sch. 2

108 114695 PIN, dowel 4

109 241322 ROLLER, assembly 4

110 194118 BRACKET, pump 1

113 195377 SHIELD, paint 1

119 245245 HANDLE, cart 1

123 198720 WHEEL, semi-pneumatic 12 in. 2

124 198723 AXLE, clip 2

128 108068 PIN, spring straight 2

132 116891 WASHER 2

139 112774 SCREW, machine 1

140 198847 HOSE, coupled 1

141 109575 SCREW, threadforming 2

YReplacement Danger and Warning labels, tags, and cards

are available at no cost.

30941220

Parts Drawing -- Sprayer

61n 61m 61k

310

74

55

147

141

122

302

51

29

310

50

51

302a

61d

61e

145

61c

61b

61a

Ref 70

150

54

61j

61p

61f

139

139

52

61h

61g

61s

61q

22

61r

143

151

ti1838a

152

309412 21

Parts List -- Sprayer

REF

NO. PART NO. DESCRIPTION QTY

REF

NO. PART NO. DESCRIPTION QTY

22 162485 ADAPTER 2

29 198553 PANEL, control 1

50 116167 KNOB, potentiometer 1

51 116752 SWITCH, rocker, (spst) 1

52 245393 DIGITAL DISPLAY 1

Includes 54, 57, 151, 152

53 198534 PLATE, control 1

54 116252 SCREW, #8 taptite, phil 4

55 198548 HOUSING, control 1

FILTER, fluid 1

61 245396 KIT, repair, filter 1

(includes 61a--61s)

61a 196675 BOWL, filter 1

61b 104361 O-RING 1

61c 244067 STRAINER, mesh, 60 1

61d 196786 TUBE, diffuser 1

61e 245401 KIT, repair, filter base 1

61f 193710 SEAL, valve 1

61g 193709 SEAT, valve 1

61h 114797 GASKET 1

61j 245103* VALVE 1

61k 114708 SPRING, compression 1

61m 194102 HANDLE, valve 1

61n 114688 NUT, cap, hex hd 1

61p 111457 O-RING 1

61q 243222 TRANSDUCER, pressure control 1

includes 61p

61r 197055 GASKET, plug 1

61s 196781 PLUG, AutoClean 1

74 198650 SPACER, shaft 1

122 114331 SCREW, pnhd 6--32 6

133 109575 SCREW, threadformer 2

139 112774 SCREW, mach 4

143 245475 PLUG, packless 1

145 114296 BUSHING, step 1

147 198994 GUARD, transducer 1

150Y189246 LABEL, warning 1

151 198884 LABEL, instruction, GMax 1

152 198648 LABEL, GMax, LCD 1

302 245394 BOARD, PC 1

Includes 302a

302a NUT, nylon 1

310 241443 POTENTIOMETER, pressure control 1

* Drain valve replacement kit 245103 includes 61f, 61g, 61h,

61k, 61m, and 61n.

YReplacement Danger and Warning labels, tags, and cards

are available at no cost.

Fig. 15

Pressure Control Wiring Diagram

VIEW A VIEW A

ti1834a

71 8

52

51

61q

310

97

302

30941222

Parts List/Drawing -- Sprayers with RAC 5

Tip, Gun & Hose

Models 233720, 233721

Includes items 201 to 204

Ref

No. Part No. Description Qty

201 233719 Hi-Boy Sprayer 1

See parts list on page 19

233718 Lo-Boy Sprayer 1

See parts list on page 19

202 240797 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)

203 238358 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

204 246220 CONTRACTOR SPRAY GUN

Includes RAC X 517--size SwitchTipt

and HandTitetGuard

See 309639 for parts 1

205 159841 ADAPTER 1

204

203

202 0160

205

Accessories

French 194931

Spanish 194932

German 194933

Greek 194934

Korean 194935

English 194125

Apply other

language here

03497A

DANGER LABELS

An English language DANGER label is on your

sprayer. If you have painters who do not read En-

glish, order one of the following labels to apply to

your sprayer. The drawing shows the best place-

ment of these labels for good visibility.

Order the labels from your Graco distributor.

Displacement Pump Repair Kits

Packing repair kits.

GMax 7900 240916

309412 23

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 3/8 npsm from fluid filter............

Wetted parts zinc-plated carbon steel,..............

PTFE, Nylon, UHMW polyethylene,

Vitonr,Delrinr, leather, aluminum, tungsten carbide,

nickel and zinc-plated carbon steel, stainless steel,

chrome plating, PEEK

NOTE: Delrinr,PTFE,Vitonrare trademarks of the DuPont

Company.

Dimensions

Model 233718, 233720

Lo-Boy Cart without hose or gun

Weight (dry, without packaging) 180 lb (82.1 kg).....

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

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

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

Model 233719, 233721

Hi-Boy without hose or gun

Weight (dry, without packaging) 175 lb (79.4 kg).....

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

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

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

30941224

Graco Standard Warranty

Graco warrants all equipment manufactured by Graco and bearing its nameto be free from defects inmaterial andworkmanship onthe

date of sale by an 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 of the equipment

determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-

dance 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 sub-

stitution of non--Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility 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 distributor for

verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The

equipmentwill be returned to the original purchaser transportation prepaid. Ifinspection of the equipmentdoes notdisclose 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 WARRANTIES, 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 that no other

remedy (including, but not limited to, incidental or consequential damages forlost 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 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 manufactured

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 equipment

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 proceedings

entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-

sent 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 procedures concernées.

ADDITIONAL WARRANTY COVERAGE

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

Program”.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call 1--800--690--2894 to identify your closest distributor.

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.

MM 309412

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441

www.graco.com

PRINTED IN USA 309412E 1/2002 Rev. 08/2009