Graco GMax 308870 Instruction & Repair Manual
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Graco GMax 308870 Instruction & Repair Manual

Graco GMax 308870 Instruction & Repair Manual

Airless paint sprayer
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INSTRUCTIONS-REPAIR
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
GMax 7900
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa ) Maximum Working Pressure
GMax 7900
Model
Series
232630
A
232631
A
Hi-Boy with RAC IV tip, gun and hose
232632
A
232633
A
Lo-Boy with RAC IV tip, gun and hose
All models are not available in all countries
PATENTS PENDING
Related Manuals
Operation
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Displacement Pump
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Spray Gun
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Spray Tip
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PC Board
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Drain Valve Kit
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Repair
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Description
Hi-Boy
Lo-Boy
308867
308798
307614
308644
308919
308961

Table of Contents

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10
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
First choice when
quality counts.
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Hi-Boy Sprayers
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MINNEAPOLIS, MN 55440-1441
308870
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Rev. B
9035A
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Summary of Contents for Graco GMax 308870

  • Page 1: Table Of Contents

    INSTRUCTIONS-REPAIR KEEP FOR REFERENCE. Read this and all related manuals for important warnings and instructions. INSTRUCTIONS GMax 7900 Airless Paint Sprayer 3300 psi (227 bar, 22.7 MPa ) Maximum Working Pressure GMax 7900 Model Series Description 232630 232631 Hi-Boy with RAC IV tip, gun and hose...

  • 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: Component Identification And Function

    Component Identification and Function 202 Main hose 203 Whip end hose 204 Contractor gun with RAC IV DripLess tip guard and 517 size SwitchT ip 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 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: 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. PROBLEM CAUSE Engine won’t start...
  • 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 Engine speed is too low Clutch is worn or damaged Pressure setting is too low Fluid filter (318), tip filter or tip is clogged or...

  • Page 7: Rollers

    Removal Relieve pressure; page 4. 2. Fig. 2. Remove six cap screws (10) lock washers (9) and cover assembly (24). Note: A screw driver may be needed to pry off cover assembly. 3. Remove dowel pins (97) and rollers (98) Installation 1.

  • Page 8: Cam Follower Bearings

    Cam Follower Bearings Removal Relieve pressure; page 4. 2. Fig. 16. Cycle pump piston rod (222) to lowest position. Turn engine off. 3. Fig. 4. Remove six cap screws (10), lock washers (9) and cover assembly (24). Note: A screw driver may be needed to pry off cover assembly.

  • 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 and engine lead. Bottom View Fig. 5 3.

  • 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: On/Off Switch

    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.

  • 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): Four clutch leads: two violet and two black. Lead (D) from potentiometer. Lead (E) from transducer. Two red leads (A) to ON/OFF switch (309). 4.

  • Page 14: Control Board Diagnostics

    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...

  • Page 15: Displacement Pump

    Displacement Pump Removal 1. Flush pump. 2. Fig. 16. Cycle pump with piston rod (222) in lowest position. Relieve pressure; page 4. 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: Pump Pin Clip

    Displacement Pump Pump Pin Clip Removal 1. Remove pump (28). 2. Remove two bolts (86), washers (25), pump brack- et (85), pail hook (94) and shield (95). 3. Fig. 17. Remove clip (230). Installation 1. Fig. 17. Install clip (230). 2.

  • Page 17: Parts

    Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241116 Part No. Description 241121 PINION HOUSING, COIL 105489 241114 PINION SHAFT 112770 RETAINING RING, large 10 (Ref) 9 (Ref) 18 (Ref) Pinion housing/coil assembly (19a) includes clutch field and all bearings, pins and o-rings Ref No.
  • Page 18 Parts Drawing – Hi-Boy Sprayers Model 232630 DETAIL A Ref 11 Ref 35 DETAIL A Label See page 17 for the parts. See manual 308798 for the parts. See page 22 for the parts. See page 22 for the parts. 8699A Bottom View 33(Ref)

  • Page 19: Pinion Assembly

    Parts List – Hi-Boy Sprayers Models 232630 Part No. Description 114530 ENGINE 113084 RIVET, blind 192014 PLATE, indicator 241113 CLUTCH ASSEMBLY, includes 4a, 4b, 16, 17, 72, 80 .ARMATURE, clutch, 5 in. .ROTOR, 5 in. 193531 CLUTCH HOUSING 183401 KEY, parallel 193680 CLAMP 104008...

  • Page 20: Lo-Boy Sprayers

    Parts Drawing – Lo-Boy Sprayers Model 232632 DETAIL A Ref 11 Ref 35 30ae 30ad 30aea 30aec DETAIL A Label See page 17 for the parts. See manual 308798 for the parts. See page 22 for the parts. 30aeb 30ac 30b (Ref) Bottom View 30ab...
  • Page 21 Parts List – Lo-Boy Sprayers Model 232632 Part No. Description ENGINE 114530 113084 RIVET, blind 192014 PLATE, indicator 241113 CLUTCH ASSEMBLY, includes 4a, 4b, 16, 17, 72, 80 .ARMATURE, clutch, 5 in. .ROTOR, 5 in. 193531 CLUTCH HOUSING 183401 KEY, parallel 193680 CLAMP 104008...

  • Page 22: Parts Drawing - Sprayer

    Parts Drawing – Sprayer Models 232630 through 232633 318b 318z 318aa 318m 318n 318l 318j 318k 318f 318e 318d 318c 318a 318g 318h 8716A...

  • Page 23: Pressure Control

    Parts List – Sprayer Models 232630 through 232633 NO. PART NO. DESCRIPTION 193653 PLA TE, 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 24: Parts List & Drawing - Complete Sprayers

    Parts List & Drawing – Complete Sprayers Models 232631, 232633 Includes items 201 to 204 Part No. Description 232631 Hi-Boy Sprayer See parts list on page 18 232633 Lo-Boy Sprayer See parts list on page 21 240797 HOSE, grounded, nylon; 3/8 in. ID; cpld 3/8 npsm(fbe);...

  • Page 25: Dimensions

    Honda GX160 Engine Power Rating @ 3700 rpm ANSI ..... . . DIN 6270B/DIN 6271 ..... . .

  • Page 26: Graco Inc. P.o. Box

    Graco warrants all equipment manufactured by Graco and bearing its name date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the determined by Graco to be defective.

This manual is also suitable for:

232630232631232632232633Gmax 7900

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