Graco 3400 Users Manual 310813C GMAX Airless Sprayers Repair

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Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001

310813 Rev C

Repair

GMAX™ 3400

Airless Sprayers

Korean patent: 10-0647761

- For Portable Airless Spraying of Architectural Coatings and Paints -

3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure

Read all warnings and instructions

248663 ✓

248664 ✓✓

248665 ✓

248666 ✓✓

310802 309639

309250 309640

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Manual Conventions

2310813 Rev C

Contents

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Drive Housing and Connecting Rod . . . . . . . . . . . 8

Pinion Assembly/Clutch Armature/Clamp . . . . . . . 9

Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

GMAX 3400 Hi-Boy Sprayers . . . . . . . . . . . . . . . . 16

Pinion Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

GMAX 3400 Lo-Boy Sprayers . . . . . . . . . . . . . . . . 20

Pressure Control/Filter Assembly . . . . . . . . . . . . . 22

Pressure Control Wiring Diagram . . . . . . . . . . . . . 23

Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . 24

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

Manual Conventions

Note

WARNING

WARNING: a potentially hazardous situation which, if

not avoided, could result in death or serious injury.

Warnings in the instructions usually include a symbol

indicating the hazard. Read the general Warnings

section for additional safety information.

Hazard Symbol

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or

destruction of equipment.

Additional helpful information.

Warning

310813 Rev C 3

Warning

The following warnings include general safety information for this equipment. Further product specific warnings may

be included in the text where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent

fire and explosion:

• Use equipment only in well ventilated area.Do not fill fuel tank while engine is running or hot; shut off

engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable

and can ignite or explode if spilled on hot surface.

• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m)

away from explosive vapors.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just

a cut, but it is a serious injury that can result in amputation. Get immediate medical attention.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and

cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

Warning

4310813 Rev C

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids

containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical

reaction and equipment rupture, and result in death, serious injury, and property damage.

SUCTION HAZARD

Never place hands near the pump fluid inlet when pump is operating or pressurized. Powerful suction

could cause serious injury.

CARBON MONOXIDE HAZARD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon mon-

oxide can cause death. Do not operate in an enclosed area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe

burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating

area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic

fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

RECOIL HAZARD

Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.

WARNING

Maintenance

310813 Rev C 5

Maintenance

Pressure Relief Procedure

1. Lock gun trigger safety.

2. Turn engine ON/OFF switch to OFF.

3. Move pump 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.

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 operation.

DAILY: Check and fill the gas tank.

DAILY: Check level of TSL in displacement pump pack-

ing nut. Fill nut, if necessary. Keep TSL in nut to help

prevent fluid buildup on piston rod and premature wear

of packings and pump corrosion.

AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference

Honda Engines Owner's Manual for correct oil viscosity.

WEEKLY: Remove engine air filter cover and clean ele-

ment. 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.

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.

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

CAUTION

For detailed engine maintenance and specifications,

refer to separate Honda Engines Owner's Manual,

supplied.

Troubleshooting

6310813 Rev C

Troubleshooting

Problem Cause Solution

Engine will not start Engine switch is OFF Turn engine switch ON

Engine is out of gasoline 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 is disconnected of dam-

aged

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

Engine operates, but displacement

pump does not operate

Pump switch is OFF Turn pump switch ON

Pressure setting too low Turn pressure adjusting knob clock-

wise to increase pressure.

Fluid filter (29) is dirty Clean filter. Page 22.

Tip or tip filter is clogged

Clean tip or tip filter. Manual 309639.

Displacement pump piston rod is

stuck due to dried paint

Repair pump. Manual 309250.

Connecting rod is worn or damaged

Replace connecting rod. Page 8.

Drive housing is worn or damaged Replace drive housing. Page 8.

Electrical power is not energizing

clutch field

Check wiring connections. Page 11.

Reference pressure control repair. Page 13.

Reference wiring diagram. Page 23.

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 clutch wires from control

board and measure resistance across

clutch coil. At 70° F, the resistance

must be between 1.2 +0.2Ω; if not,

replace pinion housing.

Have pressure control checked by authorized

Graco dealer

Clutch is worn, damaged, or incor-

rectly positioned

Adjust or replace clutch. Page 9.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 9.

Troubleshooting

310813 Rev C 7

Problem Cause Solution

Pump output is low Strainer (16) is clogged Clean strainer.

Piston ball (206) is not seating Service piston ball. Manual 309250.

Piston packings are worn or damaged

Replace packings. Manual 309250.

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

Replace o-ring. Manual 309250.

Intake valve ball is not seating properly

Clean intake valve. Manual 309250.

Intake valve ball is packed with material

Clean intake valve. Manual 309250.

Engine speed is too low

Increase throttle setting. Manual 310802.

Clutch is worn or damaged Adjust or replace clutch. Page 9.

Pressure setting is too low Increase pressure. Manual 310802.

Fluid filter (29), tip filter or tip is

clogged or dirty

Clean filter. Manual 310802 or 309639.

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 signifi-

cantly 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 309250.

Displacement rod is worn or damaged

Replace rod. Manual 309250.

Fluid is spitting from gun Air in pump or hose

Check and tighten all fluid connections.

Prime pump. Manual 310802.

Tip is partially clogged Clear tip. Manual 309639.

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

310802. 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. Reassemble valve.

Pump packings are worn

Replace pump packings. Manual 309250.

Paint is too thick Thin the paint according to the sup-

plier's recommendations

Engine speed is too high Decrease throttle setting before prim-

ing pump. Manual 310802.

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 load Misadjusted throttle setting Reset throttle to 3300 engine rpm at no

load

Worn engine governor Replace or service engine governor

Drive Housing and Connecting Rod

8310813 Rev C

Drive 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 5.

2. FIG. 1. Remove screws (10) and front cover (62).

3. Remove pump. Refer to Displacement Pump, Removal,

page 14.

4. Remove four screws (18) from drive housing (49).

5. Pull connecting rod (6) and lightly tap lower rear of drive

housing (49) with plastic mallet to loosen from pinion

housing (50). Pull drive housing and connecting rod

assembly off pinion housing.

6. Inspect crank (B) and connecting rod (6) for excessive

wear and replace parts as needed.

Installation

1. Evenly lubricate inside of bronze bearing (C) in drive

housing (49) with high-quality motor oil. Liberally pack top

roller bearing (E), lower bearing (D) inside connecting rod

(6) with bearing grease.

2. Assemble connecting rod (6) to drive housing (49). Rotate

connecting rod to lowest position.

3. Apply grease to washers 52, 57 and 56. Install in order

shown in FIG. 2.

4. Lubricate gears with 0.26 pint of 110293 grease (supplied

with drive housing). Pack grease evenly around gears.

5. Clean mating surfaces of pinion and drive housings.

6. Align connecting rod with crank (B) and carefully align

locating pins in drive housing (49) with holes in pinion

housing (50). Push drive housing onto pinion housing or

tap into place with plastic mallet.

7. Install screws (18) in drive housing. Torque evenly to note

3 value in Fig. 1.

8. Install pump. Refer to Displacement Pump, Installation,

page 14.

FIG. 2

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

CAUTION

Thrust washers may stick to grease inside of drive

housing. Do not lose or misplace.

CAUTION

DO NOT use drive housing screws (18) to align or seat

bearing housing with drive housing. Align these parts

with locating pins, to avoid premature bearing wear.

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Copper

Pinion Assembly/Clutch Armature/Clamp

310813 Rev C 9

Pinion Assembly/Clutch Armature/Clamp

Pinion Assembly/Clutch Armature Removal

Pinion Assembly

If pinion assembly (50) is not removed from clutch housing

(51), do 1. through 3. Otherwise, start at 4.

1. Relieve pressure, page 5.

2. Remove drive housing; page 8.

3. FIG. 14. Disconnect clutch (A) and clutch (B) connectors

from control board.

a. Remove two screws (91) and swing down cover (77).

b. Remove strain relief 24b.

4.

FIG. 3

. Remove four screws (18) and pinion assembly (50).

FIG. 3

5. FIG. 4. Place pinion assembly (50) on bench with rotor

side up.

6. Remove four screws (41) and lock washers (34). Install

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

tighten screws until rotor comes off.

FIG. 4

7. FIG. 5. Remove retaining ring (50d).

8. Turn pinion assembly over and tap pinion shaft (50c) out

with plastic mallet.

FIG. 5

Clutch Armature

9. FIG. 6. Use an impact wrench or wedge something

between clutch armature (38) and clutch housing to hold

engine shaft during removal.

10. Remove four screws (35) and lock washers (34).

11. Remove armature (38).

FIG. 6

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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Pinion Assembly/Clutch Armature/Clamp

10 310813 Rev C

Installation

Clutch Armature

1. FIG. 7. Lay two stacks of two dimes on smooth bench

surface.

2. Lay armature (38) on two stacks of dimes.

3. Press center of hub down to bench surface.

FIG. 7

4. Install armature (38) on engine drive shaft.

5. Install four screws (35) and lock washers (34) with torque

of 125 in-lb.

Pinion Assembly

6. Install o-ring (50e).

7. FIG. 5. Tap pinion shaft (50c) in with plastic mallet.

8. Install retaining ring (50d) with beveled side facing up.

9. FIG. 4. Place pinion assembly on bench with rotor side up.

10. Apply locktite to screws. Install four screws (41) and lock

washers (34). Alternately torque screws to 125 in-lb until

rotor is secure. Use threaded holes to hold rotor.

11. FIG. 3. Install pinion assembly (50) with four screws (18).

12. FIG. 4. Connect clutch (A) and clutch (B) connectors to

control board.

Clamp Removal

1. Do Engine Removal.

2. Drain gasoline from tank according to Honda manual.

3.

FIG. 8

. Tip engine on side so gas tank is down and air

cleaner is up.

4. FIG. 9. Loosen two screws (35) on clamp (37),

5. Push screwdriver into slot in clamp (37) and remove

clamp.

FIG. 8

Clamp Installation

1. FIG. 9 Install engine shaft key (36)

2. Tap clamp (37) onto engine shaft (A). Maintain dimension

shown note 2. Chamfer must face engine.

3. Check dimension: Place rigid, straight steel bar (B) across

face of clutch housing (51). Use accurate measuring

device to measure distance between bar and face of

clamp. Adjust clamp as necessary. Torque two screws

(35) to 125 ±10 in-lb (14 ±1.1 N·m)

Face of clutch housing

1.550 ±.010 in. (39.37±.25 mm)

Torque to 125 ±.10 in-lb (14 ±1.1 N·m)

Chamfer this side

FIG. 9

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WARNING

Gasoline can spill and cause a fire or explosion if

engine is tipped on side.

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Clutch Housing

310813 Rev C 11

Clutch Housing

Removal

1. Remove clamp. Do Clamp Removal, page 10.

2. FIG. 10. Remove four screws (60) and lock washers (59)

which hold clutch housing (51) to engine.

3. Remove screw (64) from under mounting plate (D).

4. Pull off clutch housing (51).

Installation

1. FIG. 10. Push on clutch housing (51).

2. Install four capscrews (60) and lock washers (59) and

secure clutch housing (51) to engine. Torque to 200 in-lb

(22.6 N·m).

3. Install screw (64) from beneath mounting plate (D).

Torque to 26 ft-lb (35.2 N·m).

FIG. 10

Engine

Removal

NOTE: All service to the engine must be performed by

an authorized HONDA dealer.

1. Remove Pinion Assembly/Clutch Armature/Clamp and

Clutch Housing, as instructed on pages 9, 10 and 11.

2. FIG. 11. Disconnect all necessary wiring.

3. FIG. 12. Remove two locknuts (3) and screws (2) from

base of engine.

4. Lift engine carefully and place on work bench.

FIG. 11

FIG. 12

Installation

1. Lift engine carefully and place on cart.

2. FIG. 12. Install two screws (2) in base of engine and

secure with locknuts (3). Torque to 20 ft-lb (27.12 N·m).

3. FIG. 11. Connect all necessary wiring.

4. Install Pinion Assembly/Clutch Armature/Clamp and

Clutch Housing, as instructed on pages 9 and 10 and 11.

5. Set engine to 3300 rpm.

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Pressure Control

12 310813 Rev C

Pressure Control

On/Off Switch

Removal

1. Relieve pressure, page 5.

2. FIG. 13. Remove two screws (91) and swing down

cover (77).

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

4. Press in on two retaining tabs on each side of ON/OFF

switch (71) and remove switch from cover.

Installation

1. Install new ON/OFF switch (71) so tabs of switch snap

into place on inside of cover.

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

3. Swing up cover (77) and secure with two screws (91).

FIG. 13

WARNING

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Pressure Control

310813 Rev C 13

Control Board

Removal

1. Relieve pressure, page 5.

2. FIG. 13. Remove two screws (91) and swing down

cover (77)

3. Remove strain relief bushing (24a).

4. Disconnect engine and ground wires.

5. Disconnect at control board (90):

• Lead (D) from potentiometer

• Lead (E) from transducer

• Lead (B) from ON/OFF switch

• Clutch wires

6. Remove four screws (89) and control board (90).

Installation

1. FIG. 13. Install control board (90) with four screws (89).

2. Connect at control board (90):

• Clutch wires

• Lead (B) from ON/OFF switch

• Lead (E) from transducer

• Lead (D) from potentiometer

3. Connect engine and ground wires.

4. Install strain relief bushing (24a).

5. Swing up cover (77) and secure with two screws (91).

Pressure Control Transducer

Removal

1. Relieve pressure, page 5.

2. FIG. 13. Remove two screws (91) and swing down

cover (77)

3. Disconnect lead (E) from control board (90).

4. Pull transducer connector through rubber grommet (78).

5. Remove pressure control transducer (20) and o-ring (63)

from filter housing (30).

Installation

1. FIG. 13. Install o-ring (63) and pressure control transducer

(20) in filter housing (30). Torque to 35 - 45 ft-lb.

2. Install transducer connector and rubber grommet in

control housing.

3. Connect lead (E) to control board (90).

4. Swing up cover (77) and secure with two screws (91).

Pressure Adjust Potentiometer

Removal

1. Relieve pressure, page 5.

2. Fig. 13.Remove two screws (91) and swing down

cover (77).

3. Disconnect lead (D) from control board (90).

4. Loosen set screws on potentiometer knob (68) and remove

knob, shaft nut, lock washer and potentiometer (70).

5. Remove seal (69) from potentiometer.

Installation

1. Install seal (69) on potentiometer (70).

2. FIG. 13. Install potentiometer, shaft nut, lock washer and

potentiometer knob (68).

a.Turn potentiometer shaft clockwise to internal stop.

Assemble potentiometer knob (68) to strike pin on

cover (77).

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 (90).

4. Swing up cover (77) and secure with two screws (91).

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

Displacement Pump

14 310813 Rev C

Displacement Pump

Removal

1. Flush pump.

2. Relieve pressure, page 5.

3. FIG. 15. Stop pump with piston rod (201) in its lowest

position.

4.

FIG. 14

. Loosen two screws (10) and remove pail hook (9).

FIG. 14

5. FIG. 15. Remove hose (93). Use screwdriver; push

retaining spring up; push out pin (8).

FIG. 15

6. FIG. 16. Loosen jam nut by hitting firmly with a 20 oz

hammer. Unscrew pump.

FIG. 16

Repair

See manual 309250 for pump repair instructions

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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Displacement Pump

310813 Rev C 15

Installation

1. Fig. FIG. 17. Pull piston rod out. Screw in pump until holes

in connecting rod and piston rod align.

FIG. 17

2. FIG. 11. Push pin (8) into hole. Push retaining ring spring

into groove all the way around connecting rod.

3.

FIG. 18

. Screw jam nut down onto pump until nut stops.

Screw pump up into drive housing until top threads of pump

are flush with drive housing face (

FIG. 19

). Back off pump

and jam nut to align pump outlet to side. 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). Connect

hose (93).

FIG. 18

4. FIG. 19. Fill packing nut with Graco TSL until fluid flows

onto the top of seal. Install pail hook (9).

FIG. 19

WARNING

If pin works loose, parts could break off and project

through the air and result in serious injury or property

damage. Make sure pin is properly installed.

CAUTION

• Replacement pump comes with an outlet fitting

installed. Replace installed fitting with fitting marked

“GMAX 3400”.

• If the pump jam nut loosens during operation, the

threads of the bearing housing and drive train will

be damaged. Tighten jam nut as specified.

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Parts

16 310813 Rev C

Parts

Parts Drawing - GMAX 3400 Hi-Boy Sprayers

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Parts

310813 Rev C 17

Parts List - GMAX 3400 Hi-Boy Sprayers

Model 248663

▲Replacement Danger and Warning labels, tags, and

cards are available at no cost

* Included in Clutch Replacement Kit 241109

Ref.

No. Part No. Description Qty.

1 108879 ENGINE, gasoline, 4.0 HP 1

2 110837 SCREW, flange, hex 2

3 110838 NUT, lock 2

4 246428 PUMP, displacement, st 1

Manual 309250

5 119789 FITTING, elbow, street, 45°, 1/4 npt 2

6 287053 ROD, connecting 1

7 195150 NUT, jam, pump 1

8 196762 PIN, straight 1

9 15C146 HOOK, pail 1

10 117501 SCREW, mach, hex washer hd 4

11 115099 WASHER, garden hose 1

12 15E813 NUT, jam 1

13 15B652 WASHER, suction 1

14 103413 O-RING 2

15 15E805 TUBE, intake (3400) 1

16 246385 STRAINER, 7/8-14 unf 1

17 276888 CLIP, drain line 1

18 119426 SCREW, mach, hex washer hd 8

19 287411 FRAME, cart (GMAX 3400 hi) 1

34 105510* WASHER, lock, spring (hi-collar) 10

35 108803 SCREW, hex, socket head 6

36 183401 KEY, parallel 1

37 193680 COLLAR, shaft 1

38 * ARMATURE, clutch, 4 in. 1

39 * HUB, armature 1

40 * ROTOR, clutch, 4 in. 1

41 101682* SCREW, cap, sch 4

42 112827 BUTTON, snap 2

43 192027 SLEEVE, cart 2

44 108068 PIN, spring straight 2

45 183350 WASHER, 2

46 245245 HANDLE, cart 1

48 109032 SCREW, mach, pnh 4

49 287483 HOUSING, drive, 3400 1

includes 9, 10, 18 & grease 110293

50 287376 HOUSING, pinion, 3400 1

51 15E535 HOUSING, clutch, mach, 3400 1

52 116074 WASHER, thrust 1

53 287484 CRANK, GMAX 3400 1

includes 52, 56, 57

54 244240 HOSE, coupled, includes 55 1

55 241920 DEFLECTOR, threaded 1

56 180131 BEARING, thrust 1

57 107434 BEARING, thrust 1

59 100214 WASHER, lock 4

60 108842 SCREW, cap, hex hd 4

61 119420 WHEEL, pneumatic 2

62 287487 COVER, front, painted, includes 10 1

64 112395 SCREW, cap, flnghd 1

67 15C871 CAP, leg 2

72 237686 WIRE, ground assembly w/clamp 1

73 112798 SCREW, thread forming, hex hd 1

80 156306 WASHER, flat 2

82 119510 HOLDER, manual 1

83 15E736 BRACKET, holder, manual 1

93 241926 HOSE, coupled 1

94 15E850 LABEL, identification 1

95 15E891 CLIP, retaining 2

99▲15F638 LABEL, warning 1

100 114678 BUSHING, strain relief 1

101 119569 BUSHING, strain relief 1

Ref.

No. Part No. Description Qty.

Parts

18 310813 Rev C

Parts Drawing and List - Pinion Housing

Ref No. 50: Pinion Housing

* Must be ordered separately

No. Part No. Description Qty

50 PINION HOUSING 1

50a 287482 KIT, repair, coil 1

50b 105489 PIN 2

50c* 287485 PINION SHAFT 1

50d* 113094 RETAINING RING, large 1

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Parts

310813 Rev C 19

Notes

Parts

20 310813 Rev C

Parts Drawing - GMAX 3400 Lo-Boy Sprayers

'(7$,/$

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Parts

310813 Rev C 21

Parts List - GMAX 3400 Lo-Boy Sprayers

Model 248665

▲Replacement Danger and Warning labels, tags, and

cards are available at no cost

* Included in Clutch Replacement Kit 241109

† Included in Suction Hose Kit 249356

Ref

No. Part No. Description Qty

1 108879 ENGINE, gasoline, 4.0 HP 1

2 110837 SCREW, flange, hex 2

3 110838 NUT, LOCK 2

4 246428 PUMP, displacement, st 1

Manual 309250

5 119789 FITTING, elbow, street, 45°, 1/4 npt 2

6 287053 ROD, connecting; includes 6a, 8 1

6a 196750 RING, retaining 1

7 195150 NUT, jam, pump 1

8 196762 PIN, straight 1

9 15C146 HOOK, pail 1

10 117501 SCREW, mach, hex washer hd 4

11† 115099 WASHER, garden hose 1

12 15E813 NUT, jam 1

14† 103413 PACKING, o-ring 2

15† 287416 HOSE, suction 1

16† 246385 STRAINER, 7/8-14 unf 1

17† 276888 CLIP, drain line 1

18 119426 SCREW, mach, hex washer hd 8

19 287411 FRAME, cart (GMAX 3400 Hi) 1

34 105510* WASHER, lock, spring (hi-collar) 10

35 108803 SCREW, hex, socket head 6

36 183401 KEY, parallel 1

37 193680 COLLAR, shaft 1

38 * ARMATURE, clutch, 4 in. 1

39 * HUB, armature 1

40 * ROTOR, clutch, 4 in. 1

41 101682* SCREW, cap, sch 4

42 112827 BUTTON, snap 2

43 192027 SLEEVE, cart 2

44 108068 PIN, spring straight 2

45 183350 WASHER 2

46 245245 HANDLE, cart 1

48 109032 SCREW, mach, pnh 4

49 287483 HOUSING, drive, 3400 1

includes 9, 10, 18 & grease 110293

50 287376 HOUSING, pinion, 3400 1

51 15E535 HOUSING, clutch, mach, 3400 1

52 116074 WASHER, thrust 1

53 287484 CRANK, GMAX 3400 1

includes 52, 56, 57

54† 244240 HOSE, coupled, includes 55 1

55† 241920 DEFLECTOR, threaded 1

56 180131 BEARING, thrust 1

57 107434 BEARING, thrust 1

59 100214 WASHER, lock 4

60 108842 SCREW, cap, hex hd 4

61 119420 WHEEL, pneumatic 2

62 287487 COVER, front, painted, includes 10 1

64 112395 SCREW, cap, flng hd 1

67 15C871 CAP, leg 2

72 237686 WIRE, gnd assy w/clamp 1

73 112798 SCREW, thread forming, hex hd 1

80 156306 WASHER, flat 2

82 119510 HOLDER, manual 1

83 15E736 BRACKET, holder, manual 1

93 241926 HOSE, coupled 1

94 15E850 LABEL, identification 1

95 15E891 CLIP, retaining 2

99▲15F638 LABEL, warning 1

100 114678 BUSHING, strain relief 1

101 119569 BUSHING, strain relief 1

Ref

No. Part No. Description Qty

Pressure Control/Filter Assembly

22 310813 Rev C

Pressure Control/Filter Assembly

GMAX 3400 Sprayers

Models 248663 through 248666

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Pressure Control/Filter Assembly

310813 Rev C 23

Pressure Control/Filter Assembly

GMAX 3400 Sprayers

Models 248663 through 248666

REF

NO.

PART

NO. DESCRIPTION

QT

Y

20 243222 TRANSDUCER, pressure contl

includes 63

1

21 224807 BASE, valve 1

22 235014 VALVE, drain; includes 22a, 22b 1

24 119545 BUSHING, strain, relief 2

25 15C780 HANDLE, 1

26 15C972 PIN, grooved 1

27 164672 NIPPLE, adapter 1

28 15C766 TUBE, diffusion 1

29 FILTER, fluid

244071 30 mesh 1

244067 60 mesh, original equipment 1

244068 100 mesh 1

244069 200 mesh 1

30 15E284 HOUSING, filter 1

31 287285 CAP, filter, includes 28, 58 1

58 117285 O-RING 1

63 111457 O-RING 1

65 248314 PLUG, auto clean, includes 66 1

66 15D541 SEAL, washer 1

68 116167 KNOB, potentiometer 1

69 198650 SPACER, shaft 1

70 241443

POTENTIOMETER; includes 70a, 70b

1

71 116752 SWITCH, rocker 1

77 249357

BOX, control

includes 68, 69, 70, 71, 79, 89, 90, 97

1

78 15E925 GASKET, transducer 1

79 119548 PLUG, cap 1

81 113161 SCREW, flange, hex hd 3

84 164672 ADAPTER 1

85 104813 PLUG, pipe 1

89 117317 SCREW, plastite, pan head 4

90 287486 CONTROL, board, 3400 1

91 116585 SCREW, mach, pan hd 6

97 15E856 LABEL, identification 1

REF

NO.

PART

NO. DESCRIPTION

QT

Y

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Complete Sprayers - with RAC X Tip, Gun & Hose

24 310813 Rev C

Complete Sprayers - with RAC X Tip, Gun & Hose

Models 248664, 248666

GMAX 3400 Airless Paint Sprayers

Includes items 201 to 204

Ref

No. Part No. Description Qty

201 248663 Hi-Boy Sprayer 1

See parts list on page 17

248665 Lo-Boy Sprayer 1

See parts list on page 21

202 240794 HOSE, grounded, nylon; 1/4 in. ID; 1

cpld 1/4 npsm(fbe); 50 ft (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 ft (0.9 m); spring guards both

ends

1

204 246220 CONTRACTOR II SPRAY GUN

Includes RAC X 517-size SwitchTip

and HandTite Guard

See 309639 for parts 1

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Technical Data

310813 Rev C 25

Technical Data

Dimensions

Honda GX120 Engine

ANSI Power Rating @ 3600 rpm 4.0 Horsepower

(2.9 kW)

Maximum working pressure 3300 psi

(227 bar, 22.7 MPa)

Noise Level

Sound power 100 dBa

per ISO 3744

Sound pressure 86 dBa

measured at 3.1 feet (1 m)

Maximum delivery rating 0.75 gpm (2.84 liter/min)

Maximum tip size 1 gun with 0. 027 in. tip

Inlet paint strainer 12 mesh (893 micron)

stainless steel screen, reusable

Outlet paint filter 60 mesh (250 micron)

stainless steel screen, reusable

Pump inlet size 1¼-12 unf-2b

Fluid outlet size ¼ npsm from fluid filter

Wetted parts zinc-plated carbon steel,

PTFE, Nylon, polyurethane, UHMW polyethylene, fluo-

roelastomer, acetal, leather, aluminum, tungsten carbide,

nickel- and zinc-plated carbon steel, stainless steel,

chrome plating

Sprayer

(without hose and gun)

Weight lb (kg) Height in. (cm) Width in. (cm) Length in. (cm)

248663 Hi-Boy 89 (40.4) 31.5 (80) 22.5 (58) 31 (79)

248665 Lo-Boy 89 (40.4) 31.5 (80) 22.5 (58) 31 (79)

Graco Standard Warranty

26 310813 Rev C

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in

material and workmanship on the date of sale 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 accordance with Graco’s written

recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty

installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of

non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the 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 equipment will be returned

to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will

be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

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 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 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 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 the Graco Contractor Equipment Warranty Program.

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

English GN 310813 MM 310813

Graco Headquarters: Minneapolis

International Offices: Belgium, Korea, China, Japan

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

http://www.graco.com

Written in U.S.A. 2/2005, Rev 11/2006