Generac 005818-0 Welding System User Manual
Contents
1. TEMP Je VIOLET jg Violet 310 Ref a Ref H 3 Potentiometer E Va r Pressure transducer 318z 318aa 5 Ref Ref 302 Ref 8716A 308868 23 Sa ees Ce Cree Crees Ce Cree Ce ek ata oa g S Parts List amp Drawing Complete Sprayers Models 232611 232613 232621 232623 232628 GMax 3900 5900 5900HD Airless Paint Sprayers Includes items 201 to 204 Ref No PartNo Description Qty 201 232611 GM3900 Hi Boy Sprayer 1 See parts list on page 16 GM5900 Hi Boy Sprayer 1 See parts list on page 16 GMB5900HD Hi Boy Sprayer 1 See parts list on page 16 GM3900 Lo Boy Sprayer 1 See parts list on page 21 GM5900 Lo Boy Sprayer 1 See parts list on page 21 HOSE grounded nylon 1 4 in ID 1 cpld 1 4 npsm fbe 50 foot 15 m spring guards both ends 3300 psi 227 bar 27 7 MPa HOSE grounded nylon 3 8 in ID 1 cpld 1 4 npsm fbe 50 foot 15 m spring guards both ends 3300 psi 227 bar 27 7 MPa HOSE grounded nylon 3 16 in ID cpld 1 4 nosm m x 1 4 npsm f swivel 3 foot 0 9 m spring guards both ends 1 HOSE grounded nylon 1 4 in ID cpld 1 4 nosm m x 1 4 npsm f swivel 3 foot 0 9 m spring guards both ends 1 CONTRACTOR SPRAY GUN Includes RAC 5 517 size SwitchTip and HandTite Gua2. 241008 GMax 3900 1 77 WASHER lock spring 241012 GMax 5900 1 104008 GMax 3900 4 23 COVER HOUSING DRIVE 100214 GMax 5900 4 179899 GMax 3900 1 78 114687 CLIP retainer 1 241308 GMax 5900 1 80 HUB armature 1 26 SPRING retaining 81 SCREW 176817 GMax 3900 1 107218 GMax 3900 2 183169 GMax 5900 1 114686 GMax 5900 2 28 DISPLACEMENT PUMP Manual 308798 82 206994 THROAT SEAL LIQUID not shown 1 239923 GMax 3900 1 87 240997 CONDUCTOR ground 1 240291 GMax 5900 1 89 240131 PLUG packless 1 29 PIN straight 91 Washer 176818 GMax 3900 1 114672 GMax 3900 3 183210 GMax 5900 1 114672 GMax 5900 2 30 241287 ASSEMBLY tube suction 92 114699 WASHER 1 ma ERNA aides Sosa ious Gi i A Danger amp Warning labels tags and cards are free 30aa 240513 SWIVEL tube inlet 1 308868 21 Parts Drawing Sprayer GMax 3900 and 5900 Sprayers Models 232610 through 232613 Models 232620 through 232623 232627 and 232628 8716A 22 308868 REF NO PART NO 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 318a 193651 318b 104361 318c 186075 318d 167025 318e 171941 309 Ref Parts List Sprayer Models 232610 through 232613 232620 through 232623 232627 and 232628 DE
3. 302 with five screws 303 2 Fig 22 Connect to control board 302 Two red leads A to ON OFF switch 309 Lead E to transducer Lead D to potentiometer e Four clutch leads two violet and two black 3 Fig 15 Install cover 322 with five screws 307 Pressure Control Transducer 5 Remove pressure control transducer 318z and packing o ring 318aa from filter housing 318a Installation 1 Fig 15 Install packing o ring 818aa and pres sure control transducer 31 82 in filter housing 318a Torque to 30 35 ft lb 2 Carefully feed transducer connector through rubber grommet 315 Install fluid filter 818 on control plate 301 with three screws 319 Connect lead E to motor control board 302 4 Install cover 322 with five screws 307 Pressure Adjust Potentiometer 2 Fig 15 Remove five screws 307 and cover 322 3 Fig 22 Disconnect at control board 302 e Four clutch leads two violet and two black e Lead D from potentiometer e Lead E from transducer e Two red leads A to ON OFF switch 309 4 Fig 15 Remove five screws 303 green ground wire and control board 302 Removal 1 i In A w ai Relieve pressure page 4 2 Fig 15 Remove five screws 307 and cover 322 Disconnect lead E from control board 302 Remove three screws 319 and fluid filter 318 from control plate 301 Carefully pull transducer connector through rubber grommet
4. 315 Removal 1 k Ins k w AE Relieve pressure page 4 2 Fig 15 Remove five screws 307 and cover 322 3 Disconnect lead D from control board 302 4 Loosen set screws on potentiometer knob 313 and remove knob shaft nut lockwasher 310 and pressure adjust potentiometer 310 5 Remove seal 311 from potentiometer 310 Installation 1 Install seal 311 on potentiometer 310 2 Fig 15 Install pressure adjust potentiometer 310 shaft nut lockwasher 310 and potentiome ter knob 313 a Turn potentiometer shaft 810 clockwise to internal stop Assemble potentiometer knob 313 to strike pin on plate 312 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 302 Install cover 322 with five screws 307 gt A 308868 13 Pressure Control Control Board Diagnostics 3 Turn ON OFF switch ON 4 Observe LED operation and reference following 1 Fig 15 Remove five screws 307 and cover 322 2 Start sprayer table LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times repeatedly Three times re peatedly Four times repeatedly Five times repeatedly Six times repeatedly 14 308868 Sprayer shuts down and LED contin ues to blink two times repeatedly Run away pressure Pressure greater than 4500 psi 310 bar 31 MPa Pressure transducer is faulty o
5. 5 CART HANDLE amp HOSE RACK 1 LOCKWASHER spring 3 8 in 4 CAPSCREW socket head GMax 3900 3 8 16 x 1 5 in 4 GMax 5900 5900HD 3 8 16 x 2 25 in 4 SCREW self tap fil hd 8 32 x 1 in 4 SCREW flange hex hd 3 8 16 x 5 8 in 1 CAPSCREW sch 1 4 2 x 1 in 6 LOCKWASHER spring 1 4 in GMax 3900 17 GMax 5900 5900HD 11 GEAR COMBINATION GMax 3900 1 GMax 5900 5900HD 1 PINION ASSEMBLY Parts page 18 GMax 3900 1 GMax 5900 5900HD 1 DRIVE HOUSING Parts page 18 GMax 3900 1 GMax 5900 5900HD 1 BEARING HOUSING includes 67 and 68 GMax 3900 1 GMax 5900 5900HD 1 CONNECTING ROD GMax 3900 1 GMax 5900 5900HD 1 COVER HOUSING DRIVE GMax 3900 1 GMax 5900 5900HD 1 SPRING retaining GMax 3900 1 GMax 5900 5900HD 1 DISPLACEMENT PUMP Manual 308798 GMax 3900 1 GMax 5900 1 GMax 5900HD 1 PIN straight GMax 3900 1 GMax 5900 5900HD 1 TUBE intake GMax 3900 1 GMax 5900 1 Ref No 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 49 50 77 78 80 81 Part No 181072 189920 194194 194525 240795 192723 193031 240696 240726 193698 193683 183350 110243 108795 192027 191084 106062 179811 101242 104811 154636 112827 237686 112798 193700 193682 114984 164672 194178 194125 194126 114678 183461 162485 192719 112746 110837 110838 101682 109031 108842 104008 100214 114687 107218 114686 206994 240997 110249 240131 241718 11
6. GMax 3900 only 38 39 Ref 35 30b Ref _ 20 308868 Parts List GMax 3900 and GMax 5900 Lo Boy Sprayers Models 232612 and 232622 Ref Ref No PartNo Description Qty No PartNo Description Qty 1 ENGINE 30ab 176450 GUARD hose 1 108879 GMax 3900 1 30ac 194306 HOSE fluid 1 114530 GMax 5900 1 30ad 101818 CLAMP hose 2 2 113084 RIVET blind 2 30ae 170957 TUBE suction 1 3 192014 PLATE indicator 1 30b 194180 HOSE drain 1 4 CLUTCH ASSEMBLY 30c 194194 CLIP spring 1 includes 4a 4b 16 17 80 30d 162453 NIPPLE 1 241109 GMax 3900 1 30e 241718 DEFLECTOR 1 241113 GMax 5900 1 30f 187147 STRAINER 1 4a ARMATURE clutch 4 in 1 30g 144958 STRAP tie 1 GMax 3900 33 240795 HOSE coupled 1 ARMATURE clutch 5 in 1 34 NUT retaining GMax 5900 192723 GMax 3900 1 4b ROTOR 193031 GMax 5900 1 4 in GMax 3900 1 35 CART FRAME 5 in GMax 5900 1 240728 GMax 3900 1 5 CLUTCH HOUSING 240727 GMax 5900 1 193540 GMax 3900 1 36 193698 LABEL identification GMax 3900 1 193531 GMax 5900 1 193683 LABEL identification GMax 5900 1 6 LOCKWASHER spring 1 4 in 37 183350 WASHER plain 2 105510 GMax 3900 1 38 110243 RING retaining 2 104008 GMax 5900 1 39 108795 SCREW mch pn hd 10 32 x 5 16 in 4 7 183401 KEY parallel 1 40 SLEEVE 8 193680 COLLAR shaft 1 192027 GMax 3900 2 9 CAPSCREW socket head 1 4 20 x 3 4 in 191084 GMax 5900 2 100644 GMax 3900 4 41 WHEEL semi pneumatic 101864 GMax 5900 4 106062
7. engine shaft A with plastic mallet 3 Press clamp 8 onto engine shaft A Maintain dimension shown note 2 in Fig 11 Chamfer must face engine Check dimension Place rigid straight steel bar B across face of clutch housing 5 Use accurate measuring device to measure distance between bar and face of clamp Adjust clamp as necessary Torque two screws 16 to 125 10 in Ib 14 1 1 N m 10 308868 A Face of clutch housing 1 550 010 in 39 37 25 mm GMax 3900 1 812 010 in 46 02 25 mm GMax 5900 A Torque to 125 10 in lb 14 1 1 N m Chamfer this side 164 03483 Fig 11 Clutch Housing Removal 1 Fig 12 Remove four capscrews 75 and lock washers 77 which hold clutch housing 5 to engine Fig 12 8708A Engine 2 Remove screw 15 from under mounting plate D 3 Remove engine key 7 4 Pull off clutch housing 5 Installation 1 Fig 12 Push on clutch housing 5 2 Install four capscrews 75 and lockwashers 77 and secure clutch housing 5 to engine Torque to 200 in lb 22 6 Nem 3 Install capscrew 15 from beneath mounting plate D Torque to 26 ft lb 35 2 Nem Removal 1 Remove Pinion Assembly Rotor Field Pinion Clutch Clamp and Clutch Housing as in structed on pages 9 10 and 11 2 Fig 13 Disconnect all necessary wiring 3 Fig 14 Remove two locknuts 71 and screws 70 from base o
8. grease for GMax 5900 2 Place bronze colored washer 20g on shaft pro truding from large shaft of drive housing 20 Note If replacing a washer with pin holes with a washer without pin holes remove guide pins from housing Place silver colored washer 20h on pinion housing Align gears and push new drive housing straight onto pinion housing and locating pins B 3 Install four screws 10 and lockwashers 17 from pinion housing 19 4 Install two screws 81 and lockwashers 17 5 Fig 3 Install bearing housing Do 1 through 6 of Bearing Housing and Connecting Rod proce dure on page 7 20h 20g T10178A 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 Ne s in Relieve pressure page 4 2 Disconnect field cable X from pressure control aes Bottom View 8699A Fig 5 3 Fig 6 Remove five screws 10 and lockwashers 17 and pinion assembly 19 Fig 6 8700A 4 Fig 7 Place pinion assembly 19 on bench with rotor side up 5 Remove four screws 72 and lockwashers 17 Install two screws in threaded holes E in rotor Alternately tighten screws until rotor comes off Fig 7 a 8701A 6 Fig 8 Remove retaining ring 19e 7 Tap pinion shaft 19d out with
9. or tap into place with plastic mallet A CAUTION DO NOT use bearing housing screws 13 to align or seat bearing housing with drive housing Align these parts with locating pins F to avoid prema ture bearing wear 5 Install screws 13 and lockwashers 12 on bear ing housing Torque evenly to note 3 value in Fig 3 6 Refer to Displacement Pump Installation page 15 A Oil A Pack with bearing grease 114819 A GMax 3900 Torque to 200 in Ib 22 6 N m GMax 5900 Torque to 25 ft lb 34 N m Model 232610 shown 8697A Fig 3 308868 7 Drive Housing Removal l 1 KA M amp F 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 5 Lightly tap around drive housing 20 to loosen drive housing Pull drive housing straight off pinion housing Be prepared to support gear cluster 18 which may also come out A GMax 3900 only A Torque to 125 in lb GMax 3900 Torque to 200 in lb GMax 5900 Apply remaining grease to these areas Fig 4 8 308868 Installation 1 Liberally apply bearing grease supplied with replacement gear cluster to gear cluster 18 and to areas called out by note 3 Use full 0 62 pint 0 29 liter of grease for GMax 3900 and 0 68 pint 0 32 liter of
10. plastic mallet Fig 8 8703A 8 Fig 9 Use an impact wrench or wedge something between armature 4a and clutch housing to hold engine shaft during removal 9 Remove four screws 16 and lockwashers 17 10 Remove armature 4a Fi g E 9 8704A 308868 9 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 4a 0 12 01 in 3 0 25 mm 1 Wo Pet et Pee Fig 10 disa 4 Install armature 4a on engine drive shaft 5 Install four screws 16 and lockwashers 17 with torque of 125 in lb 10 11 Fig 8 Tap pinion shaft A in with plastic mallet Install retaining ring Z with beveled side facing field Y Fig 7 Place pinion assembly on bench with rotor side up Apply locktite to screws Install four screws 16 and lockwashers 17 Alternately torque screws to 125 in lb until rotor is secure Use threaded holes to hold rotor Fig 6 Install pinion assembly 19 with five screws 10 and lockwashers 17 Fig 5 Connect field cable X to pressure control Clamp Removal 1 Fig 11 Loosen two screws 16 on clamp 8 2 Push screwdriver into slot in clamp 8 and remove clamp Installation 1 Fig 11 Install engine shaft key 7 2 Tap clamp 8 on
11. 1 6 cm LENGUT sieran nE ate ate ate 37 in 94 cm Vid fs tices Biers Gant one Se 22 in 55 9 cm GMax 5900 5900HD Model 232620 232627 233006 and 233007 Hi Boy without hose or gun Weight dry without packaging 150 Ib 68 kg Height oreari a betes 41 in 104 1 cm LONGI e Age ikaw kal cae ee ae 39 in 99 1 cm WIG o opi acter e aa dads wien 22 in 55 9 cm Model 232622 Lo Boy without hose or gun Weight dry without packaging 150 Ib 68 kg Height cee eee eee 41 in 104 1 cm Length oenar eee EOE 39 in 99 1 cm Width ee deuce R LEERE 22 in 55 9 cm Graco Phone Number TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 690 2894 Toll Free 308868 25 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 This warranty applies only when the equipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear a
12. 4672 114699 162485 240987 Parts List GMax 3900 5900 5900HD Hi Boy Sprayers Description Qty STRAINER GMax 3900 1 GMax 5900 5900HD 1 CLIP spring GMax 3900 5900 1 GMax 5900HD 1 HOSE coupled 1 NUT retaining GMax 3900 1 GMax 5900 5900HD 1 CART FRAME GMax 3900 1 GMax 5900 5900HD 1 LABEL identification GMax 3900 1 LABEL identification GMax 5900 1 WASHER plain 2 RING retaining 2 SCREW mch pn hd 10 32 x 5 16 in 4 SLEEVE GMax 3900 GMax 5900 5900HD WHEEL semi pneumatic GMax 3900 GMax 5900 5900HD RING retaining HUBCAP WASHER GMax 5900 5900HD only BUTTON snap GROUNDING CLAMP amp WIRE SCREW hex washer hd No 8 x 3 8 in PLUG tubing GMax 3900 CAP end GMax 5900 5900HD SCREW mch pn hd GMax 3900 only ADAPTER HOSE drain LABEL danger LABEL warning BUSHING strain relief NIPPLE GMax 3900 NIPPLE GMax 5900 5900HD HANGER pail LOCKNUT 5 16 18 SCREW flng hex hd 5 16 18 x 1 1 2 in LOCKNUT heavy hex 5 16 18 SCREW cap sch SCREW cap sch GMax 3900 GMax 5900 5900HD WASHER lock spring GMax 3900 GMax 5900 5900HD CLIP retainer HUB armature SCREW GMax 3900 2 GMax 5900 2 THROAT SEAL LIQUID not shown 1 1 1 1 1 AA CONDUCTOR ground ADAPTER male elbow 90 PLUG packless DEFLECTOR WASHER GMax 3900 3 5900 5900HD 2 WASHER 1 ADAPTER 1 PLUG packless 3 8 in 1 A Danger amp Warning labels tags an
13. GMax 3900 2 10 100644 CAPSCREW socket head 1 4 20 x 3 4 in 5 179811 GMax 5900 2 11 239998 CART HANDLE amp HOSE RACK 1 42 101242 RING retaining 2 12 106115 LOCKWASHER spring 3 8 in 4 43 104811 HUBCAP 2 13 CAPSCREW socket head 44 154636 WASHER GMax 5900 only 2 107210 GMax 3900 3 8 16 x 1 5 in 4 45 112827 BUTTON snap 2 114666 GMax 5900 3 8 16 x 2 25 in 4 46 108068 PIN spring straight 3 16 x 1 1 4 in 2 14 114418 SCREW self tap fil hd 8 32 x 1 in 4 47 237686 GROUNDING CLAMP amp WIRE 1 15 113802 SCREW flange hex hd 3 8 16 x 5 8 in 1 49 112798 SCREW hex washer hd No 8 x 3 8 in 1 16 108803 CAPSCREW sch 1 4 2 x 1 in 6 50 193700 PLUG tubing GMax 3900 2 17 LOCKWASHER spring 1 4 in 193682 CAP end GMax 5900 2 105510 GMax 3900 17 51 114984 SCREW 2 105510 GMax 5900 11 52 100020 WASHER GMax 3900 only 4 18 GEAR COMBINATION 53 164672 ADAPTER 2 241439 GMax 3900 1 5A 194125 LABEL danger 1 241440 GMax 5900 1 56A 194126 LABEL warning 1 19 PINION ASSEMBLY Parts page 18 61 114678 BUSHING strain relief 1 241108 GMax 3900 1 62 NIPPLE 3 8 18 npsm m x 1 4 npt m 241112 GMax 5900 1 183461 GMax 3900 1 20 DRIVE HOUSING 162485 GMax 5900 1 241007 GMax 3900 1 70 110837 SCREW fing hex hd 5 16 18 x 1 1 2 in 2 241011 GMax 5900 1 71 110838 LOCKNUT heavy hex 5 16 18 6 21 BEARING HOUSING 72 101682 SCREW cap sch 4 240523 GMax 3900 1 73 SCREW cap sch 4 241015 GMax 5900 1 109031 GMax 3900 4 22 CONNECTING ROD 108842 GMax 5900 4
14. INSTRUCTIONS REPAIR 308868 Rev L KEEP FOR REFERENCE GRACO e Read this and all related manuals for Firet choice wh n quality counts important warnings and instructions INSTRUCTIONS GMax 3900 5900 5900HD Airless Paint Sprayers 3300 psi 227 bar 22 7 MPa Maximum Working Pressure GMax 3900 ma saree a CE Hi Boy with gauge kit GMax 5900 Description 232621 Hi Boy with RAC 5 tip gun and hose Model 233621 0a a 2 All models are not available in all countries 232623 Lo Boy with RAC 5 tip gun and hose PATENTS PENDING 233006 Hi Boy with gauge kit GMax 5900HD Modei Series __Besevion 7 Spray GUN eee eee eee 309091 232627 Texture Spray Gun sss sees 308491 232628 Hi Boy with RAC 5 tip gun and hose Spray Tip 2 cceecceeeeeee eases 309055 233007 Hi Boy with gauge kit PC Board cc cee eee iia 308919 Drain Valve Kit 0005 308961 Related Manuals Operation fisbees eee saad ca Sera dees 308867 Displacement Pump 308798 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1999 GRACO INC Graco Inc is registered to I S EN ISO 9001 Table of Contents Warnings and Cautions 00ee eee eee 2 Displacement Pump 2 e eee eee 15 Component Identification and Function 3 Parts Maintenance c cece eee eens 4 GMax 3900 amp GMax 5900 Hi Boy Spray
15. SCRIPTION PLATE control BOARD PC SCREW mch pan 6 32 x 1 2 in HARNESS wiring GASKET control HOUSING control box SCREW mch pan hd PLATE instruction SWITCH rocker spst POTENTIOMETER pressure control GASKET potentiometer PLATE instruction KNOB potentiometer LABEL control GROMMET transducer FILTER fluid HOUSING filter O RING SUPPORT filter STRAINER mesh 60 SPRING compression Fa a E Cas Cas CC E Cr CC CC US CT REF NO PART NO 318f 192706 318g 193710 318h 193709 318 194102 318k 114688 3181 114708 318m 114797 318n 245103 318z 240314 318aa 111457 319 110997 320 114532 321A 189246 322 241444 323 193684 DESCRIPTION QTY BOWL filter SEAL valve SEAT valve HANDLE valve NUT cap hex hd SPRING compression GASKET VALVE TRANSDUCER pressure control includes 318aa O RING SCREW flange hex TIE wire twist LABEL warning COVER pressure control LABEL identification Drain valve replacement kit 245103 includes 318g through 318n A Replacement warning labels may be ordered free of charge Green A Black Z T E Red O JG A 304 Ref Fig 22 J3 CLUTCH J4 IO Pressure Control Wiring Diagram
16. d cards are free Models 233005 through 233007 include Pressure Gauge Kit 241339 5900HD only 308868 17 Parts List amp Drawing Pinion Assembly Ref No 19 and 20 Ref No 19 Pinion Housing Assembly 241108 for Ref No 20 Drive Housing Assembly 241007 for GMax 3900 Pinion Housing Assembly 241112 for GMax 3900 Drive Housing Assembly 241011 for GMax 5900 GMax 5900 Ref Ref No PartNo Description Qty No PartNo Description Qty 19 PINION HOUSING 1 20 DRIVE HOUSING 1 19b 105489 PIN 2 20g WASHER 19d PINION SHAFT 107089 GMax 3900 1 241110 GMax 3900 1 194173 GMax 5900 5900HD 1 241114 GMax 5900 5900HD 1 20h WASHER 19e RETAINING RING large 113094 GMax 3900 A 194411 GMax 3900 1 112770 GMax 5900 5900HD 1 194172 GMax 5900 5900HD 1 Must be ordered separately Must be ordered separately 19e 19d 19b 10 Ref 7 J 17 Ref lt y A 91 Ref 18 Ref A Only used on GMax 3900 Models 232610 and 232612 Pinion housing assembly 19 includes clutch field and connector mee 18 308868 Notes 308868 19 Parts Drawing GMax 3900 and GMax 5900 Lo Boy Sprayers Models 232612 and 232622 Label See page 18 for the parts See manual 308798 for the parts See page 22 for the parts Used on GMax 5900 only PP gt b gt amp Used on
17. ers 16 Troubleshooting 00 0 6 c cece eee 5 Pinion Assembly 0 eee eee eee eee 18 Repair GMax 3900 amp GMax 5900 Lo Boy Sprayers 20 Bearing Housing amp Connecting Rod 7 Pressure Control sidi erus Daiei 22 Drive HOUSING eee eee 8 Complete Sprayers 00 eee ee eee ees 24 Pinion Assembly Rotor Field Shaft Clutch 9 DIMENSIONS e a e a AE a a aa 25 Clamp 2 Seer en nanye ian en Ped tere ed 10 Technical Data tenaa EAEN eee 25 Clutch Housing cc eee cece es 11 Graco Phone Number 0000eeee 25 ifs ll ee eee re wee try ae eee ae etre 11 Graco Warranty 00 ccc cece cece eens 26 Pressure Control 0 000 cece e eee eens 13 Warnings and Cautions Warning Symbol Caution Symbol A WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A WARNING 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 To help prevent a fire and explosion eUse outdoors or in an extremely well ventilated area eDo not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solve
18. et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program 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 Sales Offices Minneapolis Detroit International Offices Belgium Korea Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com PRINTED IN USA 308868 January 1999 Revised 4 2001 26 308868
19. f engine 4 Lift engine carefully and place on work bench NOTE All service to the engine must be performed by an authorized HONDA dealer Fig 13 8709A To the engine GMax 5900s only Fig 1 4 8710A Installation Lift engine carefully and place on cart 2 Fig 14 Install two screws 70 in base of engine and secure with locknuts 71 Torque to 200 in lb 22 6 Nem Fig 13 Connect all necessary wiring Install Pinion Assembly Rotor Field Pinion Clutch Clamp and Clutch Housing as instructed on pages 9 and 10 and 11 08868 11 On Off Switch Installation Removal ly 1 AN S fF 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 12 308868 1 Install new ON OFF switch 309 so tabs of switch snap into place on inside of pressure control housing Connect two wires A to ON OFF switch Install pressure control cover 322 with five screws 307 318a 8711A Pressure Control Control Board Removal 1 In we n Relieve pressure page 4 Installation When installing replacement control board follow instructions with control board to set model type 1 Fig 15 Install green ground wire and control board
20. g 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 seep age Engine operates but dis Pressure control switch is OFF Turn pressure control switch ON placement pump does not operate Pressure setting is too low Turn pressure adjusting knob clockwise to increase pressure Fluid filter 818 is dirty Clean filter Page 22 Tip or tip filter is clogged Clean tip or tip filter Manual 309091 Displacement pump piston rod is stuck due to Repair pump Manual 308798 dried paint Connecting rod is worn or damaged Replace connecting rod Page 7 Drive housing is worn or damaged Replace drive housing Page 8 Electrical power is not energizing clutch field Check wiring connections Page 11 Reference control board diagnostics Page 14 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 2 0 2Q GMax3900 1 7 0 2Q GMax 5900 if not replace pinion housing Have pressure control checked by authorized Graco dealer Clutch is worn damaged or incorrectly Replace clutch Page 9 positioned Pinion assembly is worn or damaged Repair or replace pinion assembly Page 9 308868 5 PROBLEM CAUSE SOLUTION P
21. gun Air in pump or hose Check and tighten all fluid connections Reprime pump Manual 308867 Tip is partially clogged Clear tip Manual 309091 Fluid supply is low or empty Refill fluid supply Prime pump Manual 308867 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 Reas semble valve Pump packings are worn Replace pump packings Manual 308798 Paint is too thick Thin the paint according to the supplier s recommendations Engine speed is too high Decrease throttle setting before priming pump Manual 308867 Clutch squeaks each time Clutch surfaces are not matched to each other Clutch surfaces need to wear into each other clutch engages when new and may cause noise Noise will dissipate after a day of run time High engine speed at no Misadjusted throttle setting Reset throttle to 3600 3800 engine rpm at no load load Worn engine governor Replace or service engine governor 6 308868 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 2 Fig 3 Remove screw
22. imited 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 reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis
23. nd tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution 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 THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 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 l
24. nts in pressurized aluminum equipment Such use could result in a chemical reaction with the possibility of explosion eRemove extinguish or unplug all ignition sources tape wall switch Do not smoke in spray area eNever fill fuel tank while the engine is running or hot eGround Sprayer object being sprayed paint and solvent pails eHold gun firmly to side of a grounded pail when triggering into pail eUse only conductive airless paint hose eNever run engine in inclosed area Fluid injection is a serious injury If high pressure fluid pierces your skin the injury might look like just a cut But it is a serious wound Get immediate medical attention To help prevent injection always eEngage trigger safety latch when not spraying ePoint gun away from yourself or anyone else eRelieve pressure before checking or repairing any leak eRelieve pressure when you turn off the sprayer or stop spraying MPa bar PSI eDo not use components rated less than system Maximum Working Pressure Never allow children to use this unit If you are injured using this equipment get immediate medical treatment 2 308868 Component Identification and Function Minimum Operating Speed 202 Main hose V DC 203 Whip end hose 204 Contractor gun with RAC 5 DripLess tip guard and 517 size SwitchTip ER OT soe NNN 9 sos M Fig 1 L 8696B A Pressure Control Switch ON OFF enable
25. page 22 for the parts Used on GMax 5900 5900HD Used on GMax 3900 93 and 94 used on GMax 5900HD 8699A POPPE PPP Used on GMax 3900 5900 AN AD A A 3 GN Wi f 41 8713B 16 308868 Models 232610 232620 and 232627 Ref No 1 OP 4a 4b ooN 10 12 13 14 15 17 18 19 20 21 22 23 26 28 29 30 Part No 108879 114530 113084 192014 241109 241113 193540 193531 105510 104008 183401 193680 100644 101864 100644 239998 106115 107210 114666 114418 113802 108803 105510 105510 241439 241440 241108 241112 241007 241011 240523 241015 241008 241012 179899 241308 176817 183169 239923 240291 240800 176818 183210 192641 193097 Description Qty ENGINE GMax 3900 1 GMax 5900 5900HD 1 RIVET blind 2 PLATE indicator 1 CLUTCH ASSEMBLY includes 4a 4b 16 17 80 GMax 3900 1 GMax 5900 5900HD 1 ARMATURE clutch 4 in 1 GMax 3900 ARMATURE clutch 5 in 1 GMax 5900 5900HD ROTOR 4 in GMax 3900 1 5 in GMax 5900 5900HD 1 CLUTCH HOUSING GMax 3900 1 GMax 5900 5900HD LOCKWASHER spring 1 4 in GMax 3900 4 GMax 5900 5900HD 4 KEY parallel 1 CLAMP 1 CAPSCREW socket head 1 4 20 x 3 4 in GMax 3900 4 GMax 5900 5900HD 4 CAPSCREW socket head 1 4 20 x 3 4 in
26. pressure stop spraying check or service any of the system equipment or install or clean the spray tip Pressure Relief Procedure 1 Lock gun trigger safety 2 Turn engine ON OFF switch to OFF 3 Move pressure control 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 4 308868 For detailed engine maintenance and specifications refer to separate Honda Engines Owner s Manual supplied 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 opera tion DAILY Check and fill the gas tank AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscos ity WEEKLY Remove air filter cover and clean element Replace element if necessary If operating in an unusually dust
27. r missing Sprayer shuts down and LED contin ues to blink three times repeatedly Sprayer shuts down and LED contin ues to blink four times repeatedly Generator voltage is low Sprayer shuts down and LED contin ues to blink five times repeatedly High clutch current Sprayer shuts down and LED contin ues to blink six times repeatedly High clutch temperature Check pressure transducer con nection at control board Replace pressure transducer Replace control board Check pressure transducer con nection at control board Replace pressure transducer Replace control board Increase engine throttle Check wiring connections Service Honda engine alternator Check clutch 5 pin bulkhead con nector Clean contacts Measure 1 2 0 2Q GMax 3900 1 7 0 2Q GMax 5900 across clutch field at 70 F Replace clutch field assembly If clutch is new let sprayer cool down and then restart Inspect clutch Replace clutch if there is excessive wear Remove pump pin separate pin ion housing from clutch housing Rotate rotor clockwise to check for excessive drag Displacement Pump Removal 1 Flush pump X Ne aN R amp T 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 gt 222 33 Fig 16 oid 76728 Repair See manual 308798 for pump repair instructions Installation A WARNING If pin works loose part
28. rd See 309091 for parts 1 TEXTURE SPRAY GUN Includes GHD527 Heavy Duty SwitchTip and Guard See 308491 for parts 1 232621 232628 232613 232623 202 240794 240797 203 238358 241735 204 220955 241705 Ref No Part No Description Qty 205 159841 BUSHING 3 8 X 14 IN 1 5900HD only Accessories DANGER LABELS An 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 shows the best place ment of these labels for good visibility Order the labels from your Graco distributor Apply other language here 194931 194932 194933 194934 Korean 194935 English 194125 24 308868 French Spanish German Greek 203 0160 Displacement Pump Repair Kits Packing repair kits GMax 3900 239928 GMax 5900 5900HD 240248 Technical Data Honda GX120 Engine Power Rating 3700 rpm ANSI ecetadwpeahd imate bhataad 4 0 Horsepower DIN 6270B DIN 6271 NAM asta pe eS 2 1 Kw 2 8 Ps IN e RE EEEE E Sessa aes 2 6 Kw 3 6 Ps Honda GX160 Engine Power Rating 3700 rpm ANSllsacicdic adit setae ae 5 5 Horsepower DIN 6270B DIN 6271 NA EAE E E T ae O 2 9 Kw 4 0 Ps NB P E E EE 3 6 Kw 4 9 Ps Maximum working pressure 3300 psi 227 bar 22 7 MPa Noise Level Sound power 00 cece eee eens 105 dBa per ISO 3744 Sound pressure 006s 96 dBa meas
29. s 14 and front cover 23 Relieve pressure page 4 3 For Hi Boy models remove spring clip 82 and drain hose 54 Unscrew suction tube 30 from pump hold wrench on pump intake valve A to keep pump from loosening For Lo Boy models unscrew swivel union 30aa from pump 4 Disconnect pump outlet hose 33 from displace ment pump outlet nipple 62 5 Fig 2 Use screwdriver to push up retaining spring 26 at top of pump Push out pin 29 26 Fig 2 7675B 6 Fig 3 Loosen retaining nut 34 Unscrew and remove displacement pump 28 7 Remove four screws 13 and lockwashers 12 from bearing housing 21 8 Pull connecting rod 22 and lightly tap lower rear of bearing housing 21 with plastic mallet to loosen from drive housing 20 Pull bearing hous ing and connecting rod assembly 22 off drive housing 9 Inspect crank B for excessive wear and replace parts as needed Installation 1 Evenly lubricate inside of bronze bearing C in bearing housing 21 with high quality motor oil Liberally pack top roller bearing E lower bearing D inside connecting rod assembly 22 with bearing grease 2 Assemble connecting rod 22 and bearing housing 21 3 Clean mating surfaces of bearing and drive hous ings 4 Align connecting rod with crank B and carefully align locating pins F in drive housing 20 with holes in bearing housing 21 Push bearing hous ing onto drive housing
30. s 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 A CAUTION If the pump locknut loosens during operation the threads of the bearing housing will be damaged Make sure locknut is properly tightened 1 Fig 19 Pull piston rod out 1 5 in Screw in pump until holes in bearing cross link and piston rod align 7676B Fig 19 5 Fig 17 Use screwdriver push retaining spring up and push out pin 29 29 o ws Nae 6 Fig 18 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump Fig 17 7673B Fig 18 2 Fig 17 Push pin 29 into hole And push retaining spring into groove all the way around connecting rod Fig 20 Screw jam nut down onto pump until nut 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 maximum ham mer to approximately 75 5 ft lb 102 N m 7673B Fig 20 Fig 21 Fill packing nut with Graco TSL until fluid flows onto the top of seal 7677B 308868 15 Fig 21 Parts Drawing GMax 3900 5900 5900HD Hi Boy Sprayers Models 232610 232620 and 232627 Label See page 18 for the parts See manual 308798 for the parts See
31. s disables clutch function and pressure control B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner Filters air entering the carburetor D Fuel Tank Uses 86 octane unleaded gasoline Muffler Reduces noise of internal combustion Routes electrical current to spark plug Throttle Lever Adjusts engine speed for large or small orifice spray tips K Engine Switch Enables disables engine operation N Primary Fluid Outlet Hose and spray gun is connected here OR Clutch Housing Transfers power from engine to drive assembly S Drive Housing Transfers power from clutch to displacement pump T Displacement Pump Provides fluid to be sprayed through spray gun U Fluid Filter Filters fluid between source and spray gun Grounding Clamp and Wire Grounds sprayer system Pail Hanger Provides a hanger for paint pail X Pressure Drain Valve Relieves fluid pressure when open For more detailed explanations of these controls refer to the Honda Engines Owner s Manual supplied 308868 3 Maintenance A CAUTION A WARNING INJECTION HAZARD ba 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
32. ump output is low Strainer 31 is clogged Clean strainer Sprayer 232627 strainer is for use in paint only Piston ball 25 is not seating Service piston ball Manual 308798 Piston packings are worn or damaged Replace packings Manual 308798 O ring 227 in displacement pump is worn or Replace o ring Manual 308798 damaged Intake valve ball is not seating properly Clean intake valve Manual 308798 Intake valve ball is packed with material Clean intake valve Manual 308798 Do not leave 232627 sprayer under pressure for more than 5 minutes when spraying texture and not actively spraying Engine speed is too low Increase throttle setting Manual 308867 Clutch is worn or damaged Replace clutch Page 9 Pressure setting is too low Increase pressure Manual 308867 Fluid filter 318 tip filter or tip is clogged or Clean filter Manual 308867 or 309091 dirty Large pressure drop in hose with heavy Use larger diameter hose and or reduce overall materials length of hose Use of more than 100 ft of 1 4 in hose significantly reduces performance of sprayer Use 3 8 in ae for optimum perfor mance 50 ft minimum Excessive paint leakage into Throat packing nut is loose Remove throat packing nut spacer Tighten throat packing nut throat packing nut just enough to stop leakage Throat packings are worn or damaged Replace packings Manual 308798 Displacement rod is worn or damaged Replace rod Manual 308798 Fluid is spitting from
33. ured at 3 1 feet 1 m Cycles gallon liter Maximum delivery rating GMax3900 1 15 gpm 4 4 liter min GMax5900 5900HD 1 5 gpm 5 7 liter min Maximum tip size GMax3900 1 gun with 0 034 in tip 2 guns with 0 024 in tip 3 guns with 0 017 in tip GMax5900 5900HD 1 gun with 0 041 in tip 2 guns with 0 028 in tip 3 guns with 0 022 in tip 4 guns with 0 019 in tip Inlet paint strainer 16 mesh 1190 micron stainless steel screen reusable Outlet paint filter 60 mesh 250 micron stainless steel screen reusable Pump inlet SIZ eee eee 3 4 in npt m Fluid outlet size 1 4 npsm from fluid filter Wetted parts zinc plated carbon steel PTFE Nylon polyurethane UHMW polyethylene Viton Delrine leather aluminum tungsten car bide nickle plated carbon steel stainless steel chrome plating GMax3900 v5 0 aes oie hee a aes 182 48 NOTE Delrin and Viton are trademarks of the DuPont GMax5900 5900HD 0 93 25 Company GMax 3900 Model 232610 233005 Hi Boy without hose or gun Weight dry without packaging 110 Ib 49 9 kg Hegi 5453 E sod 40 in 101 6 cm CEng ei a erin ap E AT ence aces 37 in 94 cm Wa een deaa oe e ey 22 in 55 9 cm Model 232612 Lo Boy Cart without hose or gun Weight dry without packaging 110 Ib 49 9 kg Hegne as ea iad Seen Ean tees 40 in 10
34. y environment check filter daily and replace if necessary Repack connecting rod 22 top needle bearing after every pump change Replacement elements can be purchased from your local HONDA dealer WEEKLY Check level of TSL in displacement pump packing nut Fill nut if necessary Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings 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 Troubleshooting A WARNING INJECTION HAZARD i 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 Turn engine switch ON Engine is out of gas 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 cable is disconnected or damaged Connect spark plug cable or replace spark plug Fuel shutoff lever is OFF Move lever to ON position Oil is seepin
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