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INSTRUCTIONS-REPAIR
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
GMaxr 3900, 5900, 5900HD
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 3900
Model
Series
232610
A
232611
A
Hi-Boy with RACt 5 tip, gun and hose
232612
A
232613
A
Lo-Boy with RAC 5 tip, gun and hose
233005
A
GMax 5900
Model
Series
232620
A
232621
A
Hi-Boy with RAC 5 tip, gun and hose
232622
A
232623
A
Lo-Boy with RAC 5 tip, gun and hose
233006
A
GMax 5900HD
Model
Series
232627
A
232628
A
Hi-Boy with RAC 5 tip, gun and hose
233007
A
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Description
Hi-Boy
Lo-Boy
Hi-Boy with gauge kit
Description
Hi-Boy
Lo-Boy
Hi-Boy with gauge kit
Description
Hi-Boy
Hi-Boy with gauge kit
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
First choice when
quality counts.t
Model 232621
All models are not available in all countries
PATENTS PENDING
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Spray Tip
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PC Board
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308868
Rev. L
308867
308798
309091
308491
309055
308919
308961
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Table of Contents
Related Manuals for Graco GMax 232611
Summary of Contents for Graco GMax 232611
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Page 1: Related Manuals
INSTRUCTIONS-REPAIR KEEP FOR REFERENCE. Read this and all related manuals for important warnings and instructions. INSTRUCTIONS GMaxr 3900, 5900, 5900HD Airless Paint Sprayers 3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure GMax 3900 Model Series Description 232610 232611 Hi-Boy with RACt 5 tip, gun and hose 232612 232613 Lo-Boy with RAC 5 tip, gun and hose... -
Page 2: Table Of Contents
Warnings and Cautions ......Component Identification and Function Maintenance ........Troubleshooting . -
Page 3: Component Identification And Function
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: 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: D are instructed to relieve the pressure,... -
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 Pump output is low Strainer (31) is clogged Piston ball (25) is not seating Piston packings are worn or damaged O-ring (227) in displacement pump is worn or damaged Intake valve ball is not seating properly Intake valve ball is packed with material Engine speed is too low Clutch is worn or damaged Pressure setting is too low...
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Page 7: Bearing Housing And Connecting Rod
Bearing 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 Relieve pressure;... -
Page 8: Drive Housing
Removal Relieve pressure; page 4. 2. Fig. 4. Remove bearing housing. Do 1. through 8. of Bearing Housing and Connecting Rod proce- dure on page 7. 3. Remove two screws (81) and lockwashers (17). 4. Remove four screws (10) and lockwashers (17) from pinion housing (19). -
Page 9: Pinion Assembly/Rotor/Field/Shaft/Clutch
Pinion Assembly/Rotor/Field/Shaft/Clutch Removal If pinion assembly (19) is not removed from clutch housing (5), do 1. through 4. Otherwise, start at 5. Relieve pressure; page 4. 2. Disconnect field cable (X) from pressure control. Bottom View Fig. 5 3. Fig. 6. Remove five screws (10) and lockwashers (17) and pinion assembly (19). -
Page 10: Clamp
Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 10. Lay two stacks of two dimes on smooth bench surface. 2. Lay armature (4a) on two stacks of dimes. 3. Press center of clutch down on bench surface. 0.12 ±.01 in. (3.0 ±.25 mm) Fig. -
Page 11: Clutch Housing
Removal 1. Fig. 12. Remove four capscrews (75) and lock- washers (77) which hold clutch housing (5) to engine. 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull off clutch housing (5). Installation 1. - Page 12 Removal Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Disconnect two wires (A) from ON/OFF switch (309). 4. Press in on two retaining tabs on each side of ON/OFF switch (309) and remove switch. Fig.
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Page 13: Pressure Control
Removal Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and cover (322). 3. Fig. 22. Disconnect at control board (302): D Four clutch leads: two violet and two black. D Lead (D) from potentiometer. D Lead (E) from transducer. D Two red leads (A) to ON/OFF switch (309). - Page 14 1. Fig. 15. 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...
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Page 15: Warning
Displacement Pump Removal 1. Flush pump. Relieve pressure; page 4. 3. Fig. 16. Cycle pump with piston rod (222) in its lowest position. 4. Fig. 16. Remove suction tube (30) and hose (33). Fig. 16 Repair See manual 308798 for pump repair instructions. Installation WARNING If pin works loose, parts could break off due to... - Page 16 Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 232610, 232620 and 232627 DETAIL A Ref 11 Ref 35 DETAIL A Label See page 18 for the parts. See manual 308798 for the parts. See page 22 for the parts. Used on GMax 5900, 5900HD Used on GMax 3900 93 and 94 used on GMax 5900HD...
- Page 17 Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 232610, 232620 and 232627* Part No. Description ENGINE 108879 GMax 3900 114530 GMax 5900, 5900HD 113084 RIVET, blind 192014 PLATE, indicator CLUTCH ASSEMBLY, includes 4a, 4b, 16, 17, 80 241109 GMax 3900 241113 GMax 5900, 5900HD...
- Page 18 Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241108 for GMax 3900; Pinion Housing Assembly 241112 for GMax 5900 Part No. Description PINION HOUSING 105489 19d* PINION SHAFT 241110 GMax 3900 241114 GMax 5900, 5900HD 19e*...
- Page 19 Notes...
- Page 20 Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayers Models 232612 and 232622 DETAIL A Ref 11 Ref 35 DETAIL A Label See page 18 for the parts. See manual 308798 for the parts. See page 22 for the parts. Used on GMax 5900, only Used on GMax 3900, only 30aa...
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Page 21: Pinion Assembly
Parts List – GMax 3900 and GMax 5900 Lo–Boy Sprayers Models 232612 and 232622 Part No. Description ENGINE 108879 GMax 3900 114530 GMax 5900 113084 RIVET, blind 192014 PLATE, indicator CLUTCH ASSEMBLY, includes 4a, 4b, 16, 17, 80 241109 GMax 3900 241113 GMax 5900 .ARMATURE, clutch, 4 in.,... - Page 22 Parts Drawing – Sprayer GMax 3900 and 5900 Sprayers Models 232610 through 232613 Models 232620 through 232623; 232627 and 232628 318b 318z 318aa 318m 318n 318l 318j 318k 318f 318e 318d 318c 318a 318g 318h 8716A...
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Page 23: Pressure Control
Parts List – Sprayer Models 232610 through 232613; 232620 through 232623; 232627 and 232628 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... -
Page 24: Complete Sprayers
Parts List & Drawing – Complete Sprayers Models 232611, 232613, 232621, 232623, 232628 GMax 3900, 5900, 5900HD Airless Paint Sprayers Includes items 201 to 204 Part No. Description 232611 GM3900 Hi-Boy Sprayer See parts list on page 16 232621 GM5900 Hi-Boy Sprayer See parts list on page 16 232628 GM5900HD Hi-Boy Sprayer... -
Page 25: Dimensions
Honda GX120 Engine Power Rating @ 3700 rpm ANSI ..... . . DIN 6270B/DIN 6271 ..... . . -
Page 26: Graco Warranty
Graco Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by 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.