Table of Contents
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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
5.5 HORSEPOWER, GASOLINE POWERED
GMAX 5900 Convertible
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model
Series
232624
A
Sprayer, gas powered
232625
A
Sprayer, gas powered, with RACt 5 tip,
gun and hose
232626
A
Sprayer, gas powered, with electric mo-
tor kit
232629
A
Same as 232626 except with ETL ap-
proval to CSA and UL standards
232680
A
Sprayer, gas powered, with Lo-Boy
suction set kit
232681
A
Sprayer, gas powered, with RAC 5 tip,
gun and hose and Lo-Boy suction set kit
232682
A
Sprayer, gas powered, with Lo-Boy suc-
tion set kit and electric motor kit
240774
A
Electric motor kit converts sprayer to
electric powered sprayer.
240775
A
Same as 240774 except with ETL ap-
proval to CSA and UL standards
Component Identification and Function
Maintenance
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Troubleshooting
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Repair
Bearing Housing and Connecting Rod
Drive Housing
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Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley
ON/OFF Switch
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Pressure Control Repair
Displacement Pump Repair
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- -1441
Description
Table of Contents
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ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
First choice when
quality counts.t
Model 232624
Related Manuals
Operator
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Displacement Pump
Spray Gun
Spray Tip
. . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board
Electric Motor Kit
Drain Valve Kit
3
Parts
4
Basic Sprayer
5
Pinion Assembly
Pressure Control
7
Wiring Schematic
8
Clutch Assembly
9
Complete Sprayer
11
Lo-Boy Suction Set Kit
12
Technical Data
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14
Dimensions
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Graco Phone Number
Graco Warranty
308864G
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8737A
308863
308798
309091
309055
308919
308920
308961
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Table of Contents
Related Manuals for Graco GMax 232624
Summary of Contents for Graco GMax 232624
- Page 1 INSTRUCTIONS-PARTS LIST This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. INSTRUCTIONS 5.5 HORSEPOWER, GASOLINE POWERED GMAX 5900 Convertible Airless Paint Sprayer 3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure Model Series 232624 Sprayer, gas powered 232625...
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Page 2: Warning Symbol
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. Fire and explosion can occur when spraying or flushing flammable fluid in an area where air circulation is poor and flammable vapors can be ignited by an open flame or sparks. -
Page 3: Displacement Pump
Component Identification and Function 202 Main hose 203 Whip end hose 204 Contractor gun with RAC 5 DripLess tip guard and 517 size SwitchTip Fig. 1 Pressure Control Switch Pressure Adjusting Knob Air Cleaner* Fuel Tank* Muffler* Spark Plug Cable* Fuel Shutoff Lever* Choke* Throttle Lever*... -
Page 4: Pressure Relief Procedure
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: D are instructed to relieve pressure, D stop spraying,... -
Page 5: 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. - Page 6 PROBLEM CAUSE Strainer (31) clogged Pump output low Piston ball (25) not seating Piston packings worn or damaged O-ring (227) in displacement pump is worn or damaged Intake valve ball not seating properly Engine speed is too low V--belt slipping Clutch worn or damaged Pressure setting is too low Fluid filter (318), tip filter or tip is clogged or...
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Page 7: Bearing Housing And Connecting Rod
Bearing Housing and Connecting Rod Removal Relieve pressure; page 4. 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. 3. Fig. 3. Remove front cover (13). Unclip drain hose (108) from pump. -
Page 8: Drive Housing
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. Remove two screws (41) and lockwashers (10). 4. Remove four screws (9) and lockwashers (10) from pinion housing (8). - Page 9 Pinion Assembly/Rotor/Shaft/Clutch/Pulley Removal If pinion assembly (8) is not removed from clutch housing (3), do 1. through 4. Otherwise, do 1 and then start at 5. Relieve pressure; page 4. 2. Disconnect field cable (X) from pressure control. Bottom View Fig.
- Page 10 Pinion Assembly/Rotor/Shaft/Clutch/Pulley Installation 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. 0.12 ±.01 in.
- Page 11 Removal Relieve pressure; page 4. 2. Fig. 11. Remove five screws (307) and cover (322). 3. Disconnect two wires (A) from ON/OFF switch (309). 4. Press in on two retaining tabs on each side of ON/OFF switch (309) and remove. Fig.
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Page 12: Pressure Control
Removal Relieve pressure; page 4. 2. Fig. 11. Remove five screws (307) and cover (322). 3. Fig. 18. Disconnect at control board (302): D Four clutch leads: two violet and two black. D Lead (D) from potentiometer. D Lead (E) from transducer. Removal Relieve pressure;... -
Page 13: Control Board Diagnostics
1. Fig. 11. Remove five screws (307) and cover (322). 2. Start sprayer. SPRAYER OPERATION BLINKS Two times Sprayer shuts down and LED contin- repeatedly ues to blink two times repeatedly Three Sprayer shuts down and LED contin- times re- ues to blink three times repeatedly peatedly Four times... -
Page 14: Displacement Pump
Displacement Pump Removal 1. Flush pump. Relieve pressure; page 4. 3. Fig. 12. Cycle pump with piston rod (222) in its lowest position. 4. Fig. 12. Remove suction tube (107) and hose (47). Fig. 12 5. Fig. 13. Use screwdriver: push retaining spring up and push out pin (19). - Page 15 Notes 308864...
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Page 16: Parts Basic Sprayer
Parts - - Basic Sprayer Model 232624, Series A 112b 112a 2 112 8(Ref) 42(Ref) Bottom View 308864 See exploded view on page 18 See parts in manual 308798 See Engine Detail on page 17 See parts on page 19 See parts on page 21 Label 8739A... - Page 17 Parts - - Basic Sprayer Ref. Part No. Description 183401 KEY, parallel 193548 PULLEY 241306 CLUTCH HOUSING ASSY 241113 ROTOR, clutch, 5 in. 100644 CAPSCREW, sckt hd,, 1/4--20 x 3/4 in. 105510 LOCKWASHER, spring, 1/4 in. 241440 GEAR, combination 241112 PINION ASSEMBLY;...
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Page 18: Pinion Assembly
Parts List & Drawing - - Pinion Assembly Ref No. 8 and 12 Ref No. 8: Pinion Housing Assembly 241112 Part No. Description PINION HOUSING 105489 193358 PINION SHAFT 112770 RETAINING RING, large *Must be ordered separately 308864 Ref No. 12: Drive Housing Assembly 241011 Part No. -
Page 19: Pressure Control
Parts Drawing - - Sprayer Ref No. 42 Pressure Control Assembly 318b 318z 318aa 318m 318n 318l 318j 318k 318f 318a 318d 318c 318a 318g 318h 8716A 308864... -
Page 20: Pressure Control Wiring Diagram
Parts List - - Sprayer Models 232624 NO. PART NO. DESCRIPTION 193653 PLATE, control 241093 BOARD, PC 111839 SCREW, mch pan, 6--32 x 1/2 in. 240776 HARNESS, wiring. 193497 GASKET, control 193652 HOUSING, control box 114631 SCREW, mch, pan hd 193052 PLATE, instruction 114277... -
Page 21: Clutch Assembly
Parts List & Drawing - -Clutch Assembly Ref No. 3 Clutch Housing Assembly 241306 Includes 3b, 3c, 3e, 3j and 3k Part No. Description 108803 SCREW, hex, sch 114962 RING, retaining, internal 241305 SHAFT, drive, input includes 3b,3j, and 3k 193510 HUB, armature 193493... -
Page 22: Lo-Boy Suction Set Kit
Parts - - Lo-Boy Suction Set Kit Model 241287 Includes items 401 to 407 Ref. Part No. Description 241124 .TUBE, suction, 5 gallon (20 liter) includes 401a through 401e 401a 240513 ..SWIVEL, tube, inlet 401b 176450 ..GUARD, hose 401c 194306 ..HOSE, fluid 401d 101818... -
Page 23: Technical Data
Technical Data Honda GX160 Engine Power Rating @ 3700 rpm ANSI ..... . . DIN 6270B/DIN 6271 ..... . . -
Page 24: 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.