INSTRUCTIONS-PARTS LIST
308864G
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
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INSTRUCTIONS
5.5 HORSEPOWER, GASOLINE POWERED
GMAX 5900 Convertible
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model Series
Description
Sprayer, gas powered
232624
232625
A
A
Sprayer, gas powered, with RACt 5 tip,
gun and hose
232626
232629
232680
232681
232682
240774
240775
A
A
A
A
A
A
A
Sprayer, gas powered, with electric mo-
tor kit
Same as 232626 except with ETL ap-
proval to CSA and UL standards
8737A
Sprayer, gas powered, with Lo-Boy
suction set kit
Model 232624
Sprayer, gas powered, with RAC 5 tip,
gun and hose and Lo-Boy suction set kit
Related Manuals
Sprayer, gas powered, with Lo-Boy suc-
tion set kit and electric motor kit
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . 308863
Displacement Pump . . . . . . . . . . . . . . . . . 308798
Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . 309091
Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 309055
PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . 308919
Electric Motor Kit . . . . . . . . . . . . . . . . . . . . 308920
Drain Valve Kit . . . . . . . . . . . . . . . . . . . . . . 308961
Electric motor kit converts sprayer to
electric powered sprayer.
Same as 240774 except with ETL ap-
proval to CSA and UL standards
Table of Contents
Component Identification and Function . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Repair
Parts
Basic Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Complete Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lo-Boy Suction Set Kit . . . . . . . . . . . . . . . . . . . . . . . 22
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bearing Housing and Connecting Rod . . . . . . . . . . . 7
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley . . 9
ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . 12
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . 14
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441
ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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Component Identification and Function
202 Main hose
203 Whip end hose
204 Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip
C
V
R
H
S
J
D
E
G
F
K
A
P
X
T
U
B
203
Y
M
202
L
204
N
Model 232624
W
8738A
Fig. 1
A
B
C
D
E
F
Pressure Control Switch
Pressure Adjusting Knob
Air Cleaner*
ON/OFF, enables/disables clutch function
Controls fluid outlet pressure
Filters air entering carburetor
Fuel Tank*
Holds 0.95 gallons (3.6 liter) of 86 octane gasoline
Reduces noise of internal combustion
Muffler*
Spark Plug Cable*
Fuel Shutoff Lever*
Choke*
Routes electrical current to spark plug
G
H
J
On/off lever to regulate fuel flow from gasoline tank to carburetor
Enriches air/gasoline mixture for cold starting
Adjusts engine speed for large or small orifice spray tips
Enables/disables engine operation
Throttle Lever*
Engine Switch*
Secondary Fluid Outlet
Pressure Control
Primary Fluid Outlet
Engine*
K
L
Second hose and spray gun is connected here
Controls clutch cycling to maintain fluid pressure
Hose and spray gun is connected here
M
N
P
R
S
T
5.5 HP gasoline engine
Clutch Housing
Drive Housing
Transfers power from engine to drive assembly
Transfers power from clutch to displacement pump
Provides fluid to be sprayed through spray gun
Filters fluid between source and spray gun
Grounds sprayer system
Displacement Pump
Fluid Filter
U
V
W
X
Y
Grounding Clamp and Wire
Pressure Drain Valve
Cord
Relieves fluid pressure when open
Provides electric power from engine alienator to control and clutch
Locks down engine/motor and provides belt tension
Clamp
*
For more detailed explanations of these controls, refer to Honda engine manual; supplied
308864
3
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Maintenance
CAUTION
For detailed engine maintenance and specifications,
refer to separate engine manual, supplied.
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
DAILY: Check engine oil level and fill as necessary.
Manual 308863.
DAILY: Check that V-belt (60) is centered on pulleys
and is not inverted. Replace if worn or damaged.
D are instructed to relieve pressure,
D stop spraying,
DAILY: Check and fill gas tank.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
D check or service any system equipment,
D or install or clean spray tip.
DAILY: Check pressure drain valve for proper opera-
tion.
Pressure Relief Procedure
AFTER THE FIRST 20 HOURS OF OPERATION
AND EACH 100 HOURS THEREAFTER: Change
engine oil.
1. Lock gun safety latch.
2. Turn engine or electric motor ON/OFF switch to
OFF.
DAILY: Keep TSL in packing nut to help lubricate
pump packings. One full squirt of TSL is usually
enough.
3. Unplug power supply cord (electric motor).
4. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
WEEKLY: Remove cover of air filter (C) and clean
element. Replace element, if necessary. If operating in
an unusually dusty environment, check filter daily and
replace it, if necessary.
5. Rotate RAC 5 tip, if used, to reverse position.
6. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
7. Lock gun safety latch.
Repack connecting rod (22) top needle bearing after
every pump change.
8. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
Replacement elements can be purchased from your
local HONDA dealer.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
SPARK PLUG: Use only an BPR6ES (NGK) or
W20EPR--U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing plug.
4
308864
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Troubleshooting
WARNING
INJECTION HAZARD
To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from
moving parts, always follow Pressure Relief Procedure Warning, page 4, before checking, adjust-
ing, cleaning or shutting down sprayer.
Check everything in chart before disassembling sprayer.
PROBLEM
CAUSE
SOLUTION
Engine won’t start
Engine switch is OFF
Engine is out of gas
Engine oil level low
Turn engine switch on.
Refill gas tank. Honda Engines Owner’s Manual.
Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable disconnected or
spark plug damaged
Connect spark plug cable or replace spark plug.
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or 4 times.
Clean or replace spark plug. Try to start engine.
Keep sprayer upright to avoid oil seepage.
Pressure control switch turned OFF
Pressure setting too low
Turn on.
Engine operates, but
displacement pump
doesn’t
Increase pressure.
Clean filter.
Displacement pump outlet filter dirty
Tip or tip filter clogged
Clean tip or tip filter.
Replace belt.
Broken drive belt
Displacement pump rod seized by
dry paint
Service pump. See page 14.
Connecting rod worn or damaged
Drive housing worn or damaged
Replace. See page 7.
Replace. See page 8.
Electrical power not energizing clutch field
Check wiring connections. See page 20.
Reference control board diagnostics. See page 13.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check for
power between clutch terminals on control board.
Remove black clutch wires from control board and
measure resistance across wires. At 70_ F, the
resistance must be between 1.7 ±0.2Ω; if not, re-
place pinion housing.
Have pressure control checked by authorized Gra-
co dealer.
Clutch worn or damaged
Service. See page 9.
Service. See page 9.
Pinion assembly worn or damaged
308864
5
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PROBLEM
CAUSE
SOLUTION
Strainer (31) clogged
Piston ball (25) not seating
Piston packings worn or damaged
Clean.
Pump output low
Service piston ball check. Manual 308798.
Replace packings. Manual 308798.
Replace o-ring. Manual 308798.
O-ring (227) in displacement pump is worn or
damaged
Intake valve ball not seating properly
Engine speed is too low
V--belt slipping
Clean and service. Manual 308798.
Increase throttle setting. See Manual 308863.
Tighten V--belt with clamp (101). Adjust clamp
until it takes 15 lb of force to lock clamp down.
Clutch worn or damaged
Pressure setting is too low
Replace. See page 9.
Increase pressure. Manual 308863.
Clean filter. Manual 308863 or 309091.
Fluid filter (318), tip filter or tip is clogged or
dirty
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 is loose
throat packing nut
Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings worn or damaged
Displacement rod worn or damaged
Replace packings. Manual 308798.
Replace rod. Manual 308798.
Spitting from gun
Air in fluid pump or hose
Check for loose connections at pump intake
and tighten. Then prime pump. See Startup,
Manual 308863.
Tip partially clogged
Clear.
Fluid supply is low or empty
Refill and prime pump. See Startup, Manual
308863. Check fluid supply often to prevent
running pump dry.
Pump is difficult to prime
Air leak
Check all hose connections and tighten as
needed.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking
Shut off pump and relieve pressure. Disas-
semble and clean intake valve. Be sure ball
seat is not nicked or worn and that ball seats
well. Reassemble.
Worn packings
Fluid is too thick
Repack pump. Manual 308798.
Thin fluid according to supplier’s recommenda-
tions.
Engine speed is too high
Misadjusted throttle setting.
Worn engine governor
Decrease throttle setting before priming pump.
Manual 308863.
High engine speed at no
load
Reset engine throttle to 3600 -- 3800 rpm at no
load
Replace or service engine governor
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other.
when new and may cause noise Noise will dissipate after a day of run time
6
308864
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Bearing Housing and Connecting Rod
Removal
3. Clean mating surfaces of bearing and drive hous-
ings (17, 12).
1.
Relieve pressure; page 4.
4. Align connecting rod (14) with crank (E) and drive
housing locating pins (12b) with bearing housing
(17) holes. Push bearing housing onto drive hous-
ing or tap into place with plastic mallet.
2. Stop sprayer at bottom of stroke to get crank (E) in
lowest position.To lower crank manually, remove
spark plug and carefully rotate crank by pulling
starter rope.
CAUTION
Do not use bearing housing screws (44) to align or
seat bearing housing; this may cause bearing and
drive housing misalignment and result in premature
bearing wear.
3. Fig. 3. Remove front cover (13). Unclip drain hose
(108) from pump. Unscrew pump suction tube
(107) from pump. Disconnect pump hose (47).
4. Push up retaining spring (18). Push pin (19) out
rear.
5. Install screws and lockwashers (44, 45). Tighten
screws evenly to 25 ft-lb (34 N¡m).
19
6. Install pump; page 14.
7. Fig. 3. Install remaining parts.
2
C
1
B
2
D
14
18
7675B
3
Fig. 2
45, 44
5. Loosen locknut (20). Unscrew displacement
pump (21).
13
E
6. Remove four screws and lockwashers (44, 45).
12
7. Tap lower rear of bearing housing (17) with a
plastic mallet to loosen from drive housing (12).
Pull bearing housing and connecting rod assembly
(14) straight off drive housing.
12b
57
17
18
19
8. Remove pail hanger (59) and install it on new
bearing housing.
47
20
9. Inspect crank (E) for excessive wear and replace
parts as needed.
59
21
Installation
1. Evenly lubricate inside of bronze bearing (B) in
bearing housing (17) with high-quality motor oil.
Liberally pack top roller bearing (C), lower bearing
(D) inside connecting rod assembly (14) with
bearing grease 114819.
106
107
108
1
2
Oil
Pack with bearing grease 114819
3
Torque to 25 ft-lb (34 N¡m)
2. Assemble connecting rod (14) and bearing
housing (17).
8697A
Fig. 3
308864
7
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Drive Housing
2. Place bronze colored washer (12g) on shaft pro-
1.
truding from large shaft of drive housing (12).
Note: If replacing a washer with pin holes with a
washer without pin holes, remove guide pins from
housing. Place silver colored washer (12h) on pin-
ion housing. Assemble washers (15) and (16) onto
gear (7). Align gears and push new drive housing
straight onto pinion housing and locating pins (A).
Relieve pressure; page 4.
Removal
2. Fig. 4. Remove bearing housing. Do Removal of
Bearing Housing and Connecting Rod proce-
dure on page 7.
3. Install four screws (9) and lockwashers (10) to
pinion housing (8) and drive housing (12).
4. Install two screws (41) and lockwashers (10) to
drive housing (12).
3. Remove two screws (41) and lockwashers (10).
5. Fig. 4. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod proce-
dure on page 7.
4. Remove four screws (9) and lockwashers (10)
from pinion housing (8).
1
5. Lightly tap around drive housing (12) to loosen
drive housing. Pull drive housing straight off pinion
housing (8). Be prepared to support gear cluster
(7) which may also come out.
9
10
A
8
2
12h
12g
12
10
CAUTION
Do not drop gear cluster (7) when removing drive
housing (12). Gear cluster is easily damaged. Gear
may stay engaged in drive housing or pinion housing.
A
1
41
15
7
16
15
Installation
1. Liberally apply bearing grease (supplied with re-
placement gear cluster) to gear cluster (18) and to
areas called out by note 2. Use full 0.68 pint (0.32
liter) of grease.
1
Torque to 200 in-lb
TI0178B
2
Apply remaining grease to these areas
Fig. 4
8
308864
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Removal
39
6
If pinion assembly (8) is not removed from clutch
housing (3), do 1. through 4. Otherwise, do 1 and then
start at 5.
E
1.
Relieve pressure; page 4.
2. Disconnect field cable (X) from pressure control.
X
8701A
Fig. 7
6. Fig. 8. Remove retaining ring (Z).
7. Tap pinion shaft (A) out with plastic mallet.
Z
A
8739A
Bottom View
Fig. 5
3. Fig. 6. Remove five screws (5) and lockwashers
(6) and pinion assembly (8).
8703A
Fig. 8
5
6
8. Fig. 10. Remove drive belt shield (74) and
belt (68).
8
9. Hold pulley (2) and remove four screws (3a) and
washers (3h) from hub (3d). Remove armature
(3g) and spacer (3f).
10. Remove set screw (112a) from bushing (112).
Remove three bolts (112b) and three washers
(112c). Use bolts to remove pulley from bushing.
Remove pulley and key (1).
5
6
8740A
Fig. 6
11. Remove three screws (27) from beneath mounting
plate (D).
4. Fig. 7. Place pinion assembly (8) on bench with
rotor side up.
12. Lift off clutch housing (3).
5. Remove four screws (39) and lockwashers (6).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
13. Remove retaining ring (3b). Pull jack shaft assem-
bly (3c) out.
308864
9
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Installation
11. Install five screws (5) and lockwashers (6).
12. Fig. 8. Tap pinion shaft (A) in with plastic mallet.
13. Install retaining ring (Z).
1. Fig. 10. Install jack shaft assembly (3c). Install
retaining ring (3b).
2. Fig. 9. Lay two stacks of two dimes on smooth
bench surface.
3. Lay armature (4a) on two stacks of dimes.
4. Press center of clutch down on bench surface.
14. Fig. 7. Place pinion assembly on bench with rotor
side up.
15. Apply locktite to screws. Install four screws (39)
and lockwashers (6). Alternately torque screws to
125 in-lb until rotor is secure.
4a
0.12 ±.01 in. (3.0 ±.25 mm)
16. Install pinion assembly with five screws (5) and
lockwashers (6).
8705A
Fig. 9
5. Place spacer (3f) and armature (3d, 3g) on jack
shaft assembly.
17. Fig. 5. Connect field cable (X) to pressure control.
6. Install three screws (27) through mounting plate
(D) and into clutch housing (3).
1
3e
3b
3f
74
7. Insta toll key (1) in bushing (112). Apply LocktiteE
3c
71
3g
3d
to three bolts (112).
Install bushing in pulley (2)
112a
112b
with three bolts (112b). Install set screw (112a) in
bushing. End of jackshaft (3c) must be 0.090 in.
below flush with end of bushing.
8. Hold pulley (2) and install four screws (3a) and
washers (3h) in hub (3d). Torque to 125 in-lb
(14 N¡m).
3h
3a
D
9. Install drive belt shield (74).
10. Push drive housing (12) and pinion housing (8)
assembly onto clutch housing (3). Tap lightly on
front of bearing housing (17) with a plastic mallet
to push drive housing and pinion housing assem-
bly onto clutch housing.
2
112
68
Fig. 10
27
8741A
10
308864
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On/Off Switch
Removal
Installation
1.
Relieve pressure; page 4.
1. Install new ON/OFF switch (309) so tabs of switch
snap into place on inside of pressure control
housing.
2. Fig. 11. Remove five screws (307) and
cover (322).
2. Connect two wires (A) to ON/OFF switch.
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.
3. Install pressure control cover (322) with five
screws (307).
313
310
1
309
A
315
319
318a
301
302
303
307
D
E
318z
322
318aa
8711A
1
Locate switch terminals as shown
Fig. 11
308864
11
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Pressure Control
Control Board
Removal
D Two red leads (A) to ON/OFF switch (80).
4. Remove five screws (303), green ground wire and
circuit board (302).
1.
Relieve pressure; page 4.
Installation
1. Fig. 11. Install control board (302) and green
ground wire with five screws (303).
2. Fig. 11. Remove five screws (307) and
cover (322).
2. Connect to control board (302):
3. Fig. 18. Disconnect at control board (302):
D Two red leads (A) to ON/OFF switch (309).
D Lead (E) to transducer.
D Four clutch leads: two violet and two black.
D Lead (D) to potentiometer.
D Lead (D) from potentiometer.
D Lead (E) from transducer.
D Four clutch leads: two violet and two black.
3. Install cover (322) with five screws (307).
Pressure Control Transducer
Removal
Installation
1. Fig. 11. Install packing o-ring (318aa) and pressure
control transducer (318z) in filter housing (318a).
Torque to 30--35 ft-lb.
1.
Relieve pressure; page 4.
2. Carefully feed transducer connector through
rubber grommet (315). Install fluid filter (318) on
control plate (301) with three screws (319).
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (E) from control board (302).
4. Remove three screws (319) and fluid filter (318)
from control plate (301). Carefully pull transducer
connector through rubber grommet (315).
3. Connect lead (E) to control board (302).
4. Install cover (322) with five screws (307).
5. Remove pressure control transducer (318z) and
packing o-ring (318aa) from filter housing (318a).
Pressure Adjust Potentiometer
Removal
Installation
1. Install seal (311) on potentiometer (310).
1.
2. Fig. 11. Install pressure adjust potentiometer (310),
shaft nut, lockwasher (310) and potentiometer
knob (313).
Relieve pressure; page 4.
a. Turn potentiometer shaft (310) clockwise to
internal stop. Assemble potentiometer knob
(313) to strike pin on plate (312).
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (D) from control board (302).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
4. Loosen set screws on potentiometer knob (313)
and remove knob, shaft nut, lockwasher (310) and
pressure adjust potentiometer (310).
3. Connect lead (D) to control board (302).
4. Install cover (322) with five screws (307).
5. Remove seal (311) from potentiometer (310).
12
308864
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Pressure Control
Control Board Diagnostics
1. Fig. 11. Remove five screws (307) and
cover (322).
2. Start sprayer.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
LED
BLINKS
SPRAYER OPERATION
INDICATES
WHAT TO DO
Two times Sprayer shuts down and LED contin- Run away pressure.
1. Check pressure transducer con-
nection at control board
2. Replace pressure transducer
3. Replace control board
repeatedly
Pressure greater than
4500 psi (310 bar, 31
MPa).
ues to blink two times repeatedly
Three
times re-
peatedly
Sprayer shuts down and LED contin- Pressure transducer is 1. Check pressure transducer con-
faulty or missing
ues to blink three times repeatedly
nection at control board
2. Replace pressure transducer
3. Replace control board
Four times Sprayer shuts down and LED contin- Generator voltage is
repeatedly
1. Increase engine throttle
2. Check wiring connections
3. Service Honda engine alternator
low
ues to blink four times repeatedly
Five times Sprayer shuts down and LED contin- High clutch current
1. Check clutch 5-pin bulkhead con-
nector. Clean contacts.
repeatedly
ues to blink five times repeatedly
2. Measure 1.7 ±0.2Ω across clutch
field at 70_F
3. Replace clutch field assembly
Six times
repeatedly
Sprayer shuts down and LED contin- High clutch temperature 1. If clutch is new, let sprayer cool
ues to blink six times repeatedly
down and then restart
2. Inspect clutch. Replace clutch if
there is excessive wear.
3. Remove pump pin, separate pin-
ion housing from clutch housing.
Rotate rotor clockwise to check
for excessive drag.
308864
13
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Displacement Pump
Removal
19
1. Flush pump.
2.
Relieve pressure; page 4.
3. Fig. 12. Cycle pump with piston rod (222) in its
lowest position.
7675B
Fig. 13
4. Fig. 12. Remove suction tube (107) and hose (47).
6. Fig. 14. Loosen jam nut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
222
47
107
7672B
Fig. 12
5. Fig. 13. Use screwdriver: push retaining spring up
and push out pin (19).
Repair
7673B
Fig. 14
See manual 308798 for pump repair instructions.
Installation
2. Fig. 13. Push pin (19) into hole. And push retaining
spring into groove all the way around connecting
rod.
WARNING
3. Fig. 16. Screw jam nut down onto pump until
stops. Screw pump up into bearing housing until it
is stopped by jam nut. Back off pump and jam nut
to align pump outlet to back. Tighten jam nut by
hand, then tap 1/8 to 1/4 turn with a 20 oz (maxi-
mum) hammer to approximately 75 5 ft--lb (102
N¡m).
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 and retaining spring
are properly installed.
CAUTION
If the pump jam nut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure jamnut is properly tightened.
1. Fig. 15. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
7673B
Fig. 16
4. Fig. 17. Fill packing nut with Graco TSL, through
one of the slits, until fluid flows onto the top of
seal.
1.5 in.
7677B
7676B
Fig. 15
Fig. 17
14
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Notes
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Parts -- Basic Sprayer
Model 232624, Series A
1
2
See exploded view on page 18
See parts in manual 308798
DETAIL A
76 Ref
75
74
79 68 112b
71
3
4
5
6
See Engine Detail on page 17
See parts on page 19
112a
1
81
See parts on page 21
65
5
64
63
Label
6
3
5
72
9
62
10
1
8
83
12h
12g
2 112
79
7
16
131
10
90
41
3
132
39
6
14
4
45
44
76
13
17
11
12
15
6
1
57
18
40
19
43
27
55
47
61
20 59
117
56
21
2
108
105
62
52
106
107
49
50
51
104
101
103
122
102
48
8(Ref) 82
86
42
4
42(Ref)
46
47(Ref)
60
88
58
109
108(Ref)
26 25
8739A
Bottom View
87
8742B
16
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Parts -- Basic Sprayer
Ref.
No.
Ref.
Part No.
Description
Qty.
No.
Part No.
Description
Qty.
1
2
3
4
5
6
7
8
9
183401
193548
241306
241113
100644
105510
241440
241112
101864
KEY, parallel
PULLEY
1
1
1
1
4
11
1
1
101
102
103
104
105
106
107
108
109
111
241935
110885
108947
187147
241718
194194
193097
194178
110249
206994
LATCH, adjustable
SCREW, mach, pnhd, thrd forming
NUT, square
STRAINER
.DEFLECTOR
CLIP, spring
TUBE, intake
HOSE, coupled
ADAPTER, male elbow, 90_
THROAT SEAL LIQUID,
8 oz (0.27 liter) (not shown)
STRAP, retaining
SCREW, tapping, pnhd, #10 x 1/2 in.
LABEL, caution
ENGINE ASSY See Engine Detail
KEY, parallel
PULLEY
1
2
2
1
1
1
1
1
1
1
CLUTCH HOUSING ASSY
ROTOR, clutch, 5 in.
CAPSCREW, sckt hd,, 1/4--20 x 3/4 in.
LOCKWASHER, spring, 1/4 in.
GEAR, combination
PINION ASSEMBLY; Parts, page 18
CAPSCREW, socket head,
1/4--20 x 3/4 in.
WASHER, lock, spring
LABEL, danger
DRIVE HOUSING
COVER, HOUSING, DRIVE
CONNECTING ROD KIT
WASHER, thrust
4
10
11Y
12
13
14
15
16
17
18
19
20
21
104008
194125
241011
241308
241012
114672
114673
241015
183169
183210
193031
240291
4
1
1
1
1
2
1
1
1
1
1
1
117
122
131
132
114271
114984
290228
1
2
1
1
1
1
8
4
2
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
2
2
A
183401
193548
110996
114653
112406
194198
194087
114530
B
C
D
E
F
WASHER
NUT, flng hd, hex
BEARING HOUSING
SPRING, retaining
PIN, straight, 3/8 x1/8 in.
NUT, retaining
PUMP, displacement;
Parts, Manual 308798
BUSHING, strain relief
CORD, power, convertible
SCREW, 3/8--16 x 3/4 in.
SCREW, cap, sch
GROUNDING CLAMP & WIRE
SCREW, cap, sch
PRESSURE CONTROL
Parts, page 19
SCREW, thread forming
CAPSCREW, socket head,
LOCKWASHER, spring, 3/8 in.
ELBOW, street
FLUID HOSE, 3/8 in. ID, 3/8 npt
couplings, 2.5 ft long, spring guards
CAP, end;
WASHER, 5/8 in.
RING, retaining
HUBCAP
WHEEL, semi--pneumatic
SCREW, self--tap
LOCKNUT, 5/16--18
PLUG, packless
HANGER, pail
ADAPTER
NIPPLE, 3/8--18 npsm(m) x 1/4 npt(m)
FRAME, cart
SCREW, cap, flng hd
CAPSCREW, hex hd
GUARD, lower engine
HANDLE, slide
ENGINE, 5.5 HP
LABEL, warning
JACK, 1/4, motor
BOX, junction, engine
NUT, hex
SCREW, mach, hex washer hd
BUSHING, snap
SCREW, cap, hex hd, flanged
PLATE, mount motor
BRACKET, clamp
BUSHING, 3/4 in. (3 bolts, 3 washers)
BRACKET, J-box
BRACKET, tension
PLATE, indicator
RIVET, blind (not shown)
SCREW, cap, flanged hd
G
H
JY 194126
K
L
25
26
27
39
40
41
42
114425
114794
112395
101682
237686
114686
1
1
3
4
1
2
1
114805
194181
114816
114813
109099
112586
241313
194130
114959
194414
194925
192014
113084
111800
M
N
P
R
S
T
U
V
W
X
Y
Z
43
44
45
46
47
112798
114666
106115
155699
222516
1
4
4
1
1
1
2
2
2
2
2
4
2
1
1
2
1
1
2
2
1
1
4
2
1
2
1
2
2
1
4
4
1
1
1
48
49
50
51
52
56
57
58
59
60
61
62
63
64
65
68
71
72
74
75
76
79
81
82
83
86
87
88
90
193682
154636
101242
104811
179811
114818
112746
240131
192719
164672
162485
240712
110243
183350
241003
193547
111801
114827
194099
191084
239998
114810
112827
114809
108795
110838
114391
114687
114806
Y
X
Engine Detail
K
L
V
J
H
P
E
A F
N
M
RING, retaining
WASHER
GUARD, back
BELT, 4V
SCREW, cap, flng hd
SPACER, hex
GUARD, belt front
SLEEVE, cart
CART HANDLE
U
D
G
R
W
EXTRUSION, trim
BUTTON, snap
B
S
BUSHING, strain relief
SCREW, cap, sch
LOCKNUT, w/nylon insert, 5/16--18
SCREW, grounding
CLIP, retainer
Z
C
T
C
8743A
Y Replacement Danger and Warning labels, tags and
EXTRUSION, gasket
cards are available at no cost.
308864
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Parts List & Drawing -- Pinion Assembly
Ref No. 8 and 12
Ref No. 8: Pinion Housing Assembly 241112
Ref No. 12: Drive Housing Assembly 241011
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
8
PINION HOUSING
PIN
PINION SHAFT
RETAINING RING, large
1
2
1
1
12
12g*
12h*
HOUSING, drive
WASHER
WASHER
1
1
1
8b
8d*
8e*
105489
193358
112770
194173
194172
*Must be ordered separately
*Must be ordered separately
8d
8b
8e
9 (Ref.)
10 (Ref.)
8
12h
12g
15 (Ref)
12
10 (Ref.)
9 (Ref.)
7(Ref.)
16 (Ref)
TI0177B
18
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Parts Drawing -- Sprayer
Ref No. 42
Pressure Control Assembly
307
301
318f
314
313
304
305
304
310
312
309
318a
319
308
302
318d
318c
303
315
318b
320
318z
306
311
310
318aa
323
318a
305
322
318g
307
318h
318m
318n
318l
318j
318k
8716A
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Parts List -- Sprayer
Models 232624
REF
REF
NO. PART NO.
DESCRIPTION
QTY
NO. PART NO.
DESCRIPTION
QTY
301 193653
302 241093
303 111839
304 240776
305 193497
306 193652
307 114631
308 193052
309 114277
310 241443
311 193657
312 193654
313 114273
314 193072
315 114629
318
PLATE, control
1
1
5
1
2
1
10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
318f 192706
318g 193710*
318h 193709*
318j 194102*
318k 114688*
318l 114708*
318m 114797*
318n 245103*
318z 240314
BOWL, filter
1
1
1
1
1
1
1
1
1
BOARD, PC
SEAL, valve
SCREW, mch pan, 6--32 x 1/2 in.
HARNESS, wiring.
GASKET, control
SEAT, valve
HANDLE, valve
NUT, cap, hex hd
SPRING, compression
GASKET
HOUSING, control box
SCREW, mch, pan hd
PLATE, instruction
SWITCH, rocker, (spst)
POTENTIOMETER, pressure control
GASKET, potentiometer
PLATE, instruction
KNOB, potentiometer
LABEL, control
VALVE
TRANSDUCER, pressure control
includes 318aa
O-RING
318aa 111457
319 110997
320 114532
321Y 189246
322 241444
323 193684
1
3
1
1
1
1
SCREW, flange, hex
TIE, wire, twist
LABEL, warning
COVER, pressure control
LABEL, identification
GROMMET, transducer
FILTER, fluid
318a 193651
318b 104361
318c 186075
318d 167025
318e 171941
HOUSING, filter
O-RING
* Drain valve replacement kit 245103 available; includes
318g through 318n
Y Replacement warning labels may be ordered free of charge
SUPPORT, filter
STRAINER, mesh, 60
SPRING, compression
Pressure Control Wiring Diagram
Green
310
(Ref)
Black
309
(Ref)
D
Red
Potentiometer
E
Pressure
transducer
Red
A
318z
(Ref)
318aa
(Ref)
Violet
304
302
(Ref)
(Ref)
8714A
Fig. 18
20
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Parts List & Drawing --Clutch Assembly
Ref No. 3
Clutch Housing Assembly 241306
Includes 3b, 3c, 3e, 3j and 3k
Ref
Ref
No.
Part No.
Description
Qty
No.
Part No.
Description
Qty
3a*
3b
3c
108803
114962
241305
SCREW, hex, sch
RING, retaining, internal
SHAFT, drive, input
includes 3b,3j, and 3k
HUB, armature
4
1
1
3g*
3h*
3j
193681
105510
115078
115079
ARMATURE, clutch
WASHER, lock, spring
O-RING
1
8
1
1
3k
O-RING
3d*
3e
3f
193510
193493
194059
1
1
1
HOUSING, clutch
STOP, armature
* Clutch replacement kit 241113 includes 3a, 3d, 3g, 3h, 4, 6,
39
3b
3c
3e
3j
3k
3f
3g*
3d*
39*(Ref)
6*(Ref)
4*(Ref)
3h* 3a*
8745A
Parts -- Complete Sprayer
Model 232625
Includes items 125 to 128
126
Ref.
No.
Part No.
Description
Qty.
128
125
126
232624
240794
CONVERTIBLE GMax 5900C Sprayer
See parts list on page 16
1
1
1
127
HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(fbe); 50 ft (15 m);’
spring guards both ends
HOSE, grounded, nylon; 3/16” ID;
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;
3 ft (0.9 m); spring guards both ends
“CONTRACTOR” SPRAY GUN
Includes RAC 5t DripLesst Tip Guard
and 517--size SwitchTipt
127
128
238358
220955
0160
See 309091 for parts
1
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Parts -- Lo-Boy Suction Set Kit
Model 241287
Includes items 401 to 407
Ref.
No.
401
Part No.
Description
Qty.
401
241124
.TUBE, suction, 5 gallon (20 liter)
includes 401a through 401e
..SWIVEL, tube, inlet
..GUARD, hose
..HOSE, fluid
..CLAMP, hose
..TUBE, suction
.HOSE, drain
.CLIP, spring
.NIPPLE
.STRAINER
.DEFLECTOR
1
402(REF)
406
401a 240513
401b 176450
401c 194306
401d 101818
401e 170957
402
403
404
405
406
407
1
1
1
2
1
1
1
1
1
1
1
405
403
407
194180
194194
162453
187147
241718
144958
401a
404
402
401e
401c
.STRAP, tie
401b
8744A
401d
22
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Technical Data
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)
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . 93 (25)
Maximum Delivery . . . . . . . . . . 1.25 gpm (4.7 liter/min)
Fuel Tank Capacity . . . . . . . . . . . 0.95 gallons (3.6 liter)
Maximum Tip Size . . . . . . . . . . . . . . 1 gun with 0.041 tip
2 guns with 0.028 tip
Inlet Paint Strainer . . . . . . . . . . . 16 mesh (1190 micron)
Stainless steel screen, reusable
Graco Phone
Number
Honda GX160 Engine
TO PLACE AN ORDER, contact your Graco distribu-
tor, or call this number to identify distributor closest to
you: 1--800--690--2894 Toll Free
DANGER LABELS
The English language DANGER label is on your
sprayer. If you have painters who do not read En-
glish, order one of the following labels to apply to
your sprayer. The drawing below shows the best
placement of these labels for good visibility.
Order the labels directly from your Graco distributor.
Outlet Paint Filter . . . . . . . . . . . . . 60 mesh (250 micron)
Stainless steel screen, reusable
Pump inlet Size . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)
Fluid Outlet Size . . . . . . . . . . . 1/4 npsm from fluid filter
Apply other
language here
Wetted parts . . . . . . . . . . . . . . zinc-plated carbon steel,
Teflonr, Nylon, polyurethane, UHMW polyethylene,
Vitonr, Delrinr, leather, aluminum, tungsten car-
bide,nickle-plated carbon steel, stainless steel,
chrome plating
French
Spanish 194932
German 194933
Greek
Korean
194931
194934
194935
NOTE: Delrinr, Teflonr, Vitonr are trademarks of the DuPont
Company.
03497A
English 194125
Dimensions
Model 232624
Weight (dry, without packaging) . . . . . . . 170 lb (77 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 41 in. (104.1 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 in. (99.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in. (55.9 cm)
308864
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Graco Warranty
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on date of sale by an authorized Graco distributor to original purchaser for use. With exception of any
special extended or limited warranty published by Graco, Graco will, for a period of twelve months from date of sale, repair or replace
any part of equipment determined by Graco to be defective. This warranty applies only when equipment is installed, operated and
maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or improper design, manufacture,
installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon prepaid return of equipment claimed to be defective to an authorized Graco distributor for
verification of claimed defect. If claimed defect is verified, Graco will repair or replace free of charge any defective parts. equipmentwill
be returned to original purchaser transportation prepaid. If inspection of equipment does not disclose any defect in material or
workmanship, repairs will be made at a reasonable charge, which charges may include costs of parts, labor, and transportation.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warrantymust bebrought withintwo (2)years ofdate
of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches, hose, etc.), are subject to warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in
making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach
of warranty, negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in “Graco Contractor Equipment Warranty
Program”.
All written and visual data contained in this document reflects latest product information available at time of publication. Graco
reserves right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441
PRINTED IN USA 308864 February 1999, 08/2009
24
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