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Repair
™
GMAX 3400
Airless Sprayers
310813D
Korean patent: 10-0647761
- For Portable Airless Spraying of Architectural Coatings and Paints -
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
Read all warnings and instructions
ti5447a
ti5944a
ti5523a
248664✓✓
248666 ✓✓
310802 311861
309250 309640
ti5944a
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
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Manual Conventions Contents WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GMAX 3400 Hi-Boy Sprayers . . . . . . . . . . . . . . . . 16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pinion Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 GMAX 3400 Lo-Boy Sprayers . . . . . . . . . . . . . . . . 20 Drive Housing and Connecting Rod . . . . . . .
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Warning Warning The following warnings include general safety information for this equipment. Further product specific warnings may be included in the text where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area.Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or
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Warning WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. � Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. � Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. � Check equipment daily. Repair or replace worn or damaged parts immediately. � Do not alter or m
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Maintenance Maintenance DAILY: Check gun safety for proper operation. Pressure Relief Procedure DAILY: Check pressure drain valve for proper operation. WARNING DAILY: Check and fill the gas tank. DAILY: Check level of TSL in displacement pump pack- Read Injection Hazard, page 3; Burn Hazard, page 4 ing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion. 1. Lock gun trigger safety. 2. Turn engine ON/OFF swit
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Troubleshooting Troubleshooting Problem Cause Solution Engine will not start Engine switch is OFF Turn engine switch ON Engine is out of gasoline 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 is disconnected of dam- Connect spark plug cable or replace aged spark plug Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion Remove
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Troubleshooting Problem Cause Solution Pump output is low Strainer (16) is clogged Clean strainer. Piston ball (206) is not seating Service piston ball. Manual 309250. Piston packings are worn or damaged Replace packings. Manual 309250. O-ring (227) in pump is worn or damaged Replace o-ring. Manual 309250. Intake valve ball is not seating properly Clean intake valve. Manual 309250. Intake valve ball is packed with material Clean intake valve. Manual 309250. Engine speed is too low Increase thro
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Drive Housing and Connecting Rod Drive Housing and Connecting Rod NOTE: The item numbers referenced are for the Hi-Boy models. The Lo-Boy models may have different item CAUTION numbers. Use the Hi-Boy item number and part to find DO NOT use drive housing screws (18) to align or seat the corresponding Lo-Boy part and item number. bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear. Removal 7. Install screws (18) in drive housing. Torque
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Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature Removal Pinion Assembly 41 If pinion assembly (50) is not removed from clutch housing 34 (51), do 1. through 3. Otherwise, start at 4. E E WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 ti5481b ti5987b 1. Relieve pressure, page 5. FIG. 4 2. Remove drive housing; page 8. 3. FIG. 14. Disconnect clutch (A) and clutch (B) connectors 7. FIG. 5. Remove retaining ring (50d). from co
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Pinion Assembly/Clutch Armature/Clamp Installation 4. Install armature (38) on engine drive shaft. Clutch Armature 1. FIG. 7. Lay two stacks of two dimes on smooth bench 5. Install four screws (35) and lock washers (34) with torque of 125 in-lb. surface. Pinion Assembly 2. Lay armature (38) on two stacks of dimes. 3. Press center of hub down to bench surface. 6. Install o-ring (50e). 7. FIG. 5. Tap pinion shaft (50c) in with plastic mallet. 8. Install retaining ring (50d) with beveled side fac
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Clutch Housing Clutch Housing Removal 51 36 1. Remove clamp. Do Clamp Removal, page 10. 2. FIG. 10. Remove four screws (60) and lock washers (59) which hold clutch housing (51) to engine. 3. Remove screw (64) from under mounting plate (D). 4. Pull off clutch housing (51). Installation 1. FIG. 10. Push on clutch housing (51). ti5536a 59 2. Install four capscrews (60) and lock washers (59) and 60 secure clutch housing (51) to engine. Torque to 200 in-lb (22.6 N·m). D 3. Install screw (64) from
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Pressure Control Pressure Control On/Off Switch Removal Installation 1. Install new ON/OFF switch (71) so tabs of switch snap into place on inside of cover. WARNING 2. Connect ON/OFF switch connector (B) to PC board. 3. Swing up cover (77) and secure with two screws (91). Read Injection Hazard, page 3; Burn Hazard, page 4 1. Relieve pressure, page 5. 2. FIG. 13. Remove two screws (91) and swing down cover (77). 3. Disconnect ON/OFF switch connector (B) from PC board. 4. Press in on two retain
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Pressure Control Control Board � Lead (E) from transducer Removal � Lead (B) from ON/OFF switch � Clutch wires 6. Remove four screws (89) and control board (90). WARNING Installation 1. FIG. 13. Install control board (90) with four screws (89). Read Injection Hazard, page 3; Burn Hazard, page 4 2. Connect at control board (90): � Clutch wires 1. Relieve pressure, page 5. � Lead (B) from ON/OFF switch 2. FIG. 13. Remove two screws (91) and swing down � Lead (E) from transducer cover (77) � Lead
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Displacement Pump Displacement Pump 6. FIG. 16. Loosen jam nut by hitting firmly with a 20 oz Removal hammer. Unscrew pump. 1. Flush pump. WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 2. Relieve pressure, page 5. ti5545a 3. FIG. 15. Stop pump with piston rod (201) in its lowest position. 4. FIG. 14. Loosen two screws (10) and remove pail hook (9). 10 FIG. 16 Repair ti5526a 9 See manual 309250 for pump repair instructions FIG. 14 5. FIG. 15. Remove hose (93). Use screwdriver; pus
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Displacement Pump Installation WARNING If pin works loose, parts could break off and project through the air and result in serious injury or property damage. Make sure pin is properly installed. ti6111a CAUTION ti6110a � Replacement pump comes with an outlet fitting installed. Replace installed fitting with fitting marked “GMAX 3400”. � If the pump jam nut loosens during operation, the ti5544a threads of the bearing housing and drive train will be damaged. Tighten jam nut as specified. 1.
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Parts Parts Parts Drawing - GMAX 3400 Hi-Boy Sprayers DETAIL A Ref 46 42 43 45 44 48 Ref 19 46 1 Bottom View 18 51 36 60 37 35 2 38 39 35 73 40 1 50 DETAIL A 52 53 99 49 59 9 72 101 10 62 41 64 34 10 3 67 57 56 ti5524a 18 6 19 7 94 8 80 74 83 93 54 61 82 4 95 3 5 100 11 14 81 15 (Ref 93) 13 FOR PARTS SEE PAGE 22 12 17 55 16 54 1 See parts page 18 77 16 310813D
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Parts Parts List - GMAX 3400 Hi-Boy Sprayers Model 248664 Ref. No. Part No. Description Qty. Ref. 48 109032 SCREW, mach, pnh 4 No. Part No. Description Qty. 49 287483 HOUSING, drive, 3400 1 1 108879 ENGINE, gasoline, 4.0 HP 1 includes 9, 10, 18 & grease 110293 2 110837 SCREW, flange, hex 2 50 287376 HOUSING, pinion, 3400 1 3 110838 NUT, lock 2 51 15E535 HOUSING, clutch, mach, 3400 1 4 246428 PUMP, displacement, st 1 52 116074 WASHER, thrust 1 Manual 309250 53 287484 CRANK, GMAX 3400 1 5 119789
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Parts Parts Drawing and List - Pinion Housing Ref No. 50: Pinion Housing No. Part No. Description Qty 50 PINION HOUSING 1 50a 287482 KIT, repair, coil 1 50b 105489 PIN 2 50c* 287485 PINION SHAFT 1 50d* 113094 RETAINING RING, large 1 * Must be ordered separately 50b 50a 50d 50c ti5539a 50e 18 310813D
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Parts Notes 310813D 19
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Parts Parts Drawing - GMAX 3400 Lo-Boy Sprayers DETAIL A Ref 46 42 43 45 44 48 Ref 19 46 Bottom View 1 18 51 36 60 37 35 2 38 39 35 73 40 1 50 DETAIL A 52 53 99 59 49 72 101 9 10 62 41 64 34 3 10 67 57 56 ti5525a 18 6 19 7 6a 74 94 83 82 8 80 93 3 61 95 100 54 4 5 11 14 81 17 (Ref 93) 15 FOR PARTS SEE PAGE 22 55 16 54 1 See parts page 18 77 20 310813D
