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INSTRUCTIONS-REPAIR 308870
Rev. B
KEEP FOR REFERENCE.
Read this and all related manuals for
First choice when
important warnings and instructions.
quality counts.
INSTRUCTIONS
GMax 7900
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa ) Maximum Working Pressure
GMax 7900
Model Series Description
232630 A Hi-Boy
232631 A Hi-Boy with RAC IV tip, gun and hose
232632 A Lo-Boy
232633 A Lo-Boy with RAC IV tip, gun and hose
All models are not available in all countries
PATENTS PENDING
Related Manual
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Warnings and Cautions Warning Symbol Caution Symbol 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. 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
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Component Identification and Function V D C 202 Main hose 203 Whip end hose 204 Contractor gun with RAC IV DripLess tip guard and 517 size SwitchT ip J H E G R K F P S A B U W Model 232631 T 202 M L 204 X 203 9034A N Fig. 1 A Pressure Control Switch ON/OFF, enables/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 E Muffler* Reduces noise of inter
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Maintenance CAUTION WARNING For detailed engine maintenance and specifications, INJECTION HAZARD refer to separate Honda Engines Owner’s Manual, The system pressure must be manually supplied. relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the DAILY: Check engine oil level and fill as necessary. skin and cause serious injury. To reduce the risk of DAILY: Check hose for wear and damage. an injury from injection, splashing fl
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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 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 Manu- al. Engine oil level is low Try to start engine. Replenish oil,
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PROBLEM CAUSE SOLUTION Pump output is low Strainer (31) is clogged Clean strainer 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. Engine speed is too low Increase throttle setting. Manual 308867. Clutch is worn or damaged Replace clutch. Page 9. Pres
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Rollers Removal 20 1. Relieve pressure; page 4. 98 97 9 2. Fig. 2. Remove six cap screws (10) lock washers 10 (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 9 1. Install rollers (98) and dowel pins (97) 99 24 2. Install cover assembly (24) with six lock washers 9033A Fig. 2 (9) and cap screws (10). Drive Housing Removal Installation 1. Liberally apply bearing grease (supplied with 1. replacement
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Cam Follower Bearings Removal Installation 1. Install two cam follower bearings (20c). 1. Relieve pressure; page 4. 2. Fig. 16. Cycle pump piston rod (222) to lowest 2. Install cam follower plate (20b). position. Turn engine off. 3. Fig. 4. Remove six cap screws (10), lock washers (9) and cover assembly (24). 3. Install two retainer rings (20d). Note: A screw driver may be needed to pry off cover assembly. 4. Remove four dowel pins (97) and rollers (98). 4. Drive in pump pin (101) until it enga
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Pinion Assembly/Rotor/Field/Shaft/Clutch Removal If pinion assembly (19) is not removed from clutch 6. Fig. 8. Remove retaining ring (19e). housing (5), do 1. through 4. Otherwise, start at 5. 7. Tap pinion shaft (19d) out with plastic mallet. 1. 19e Relieve pressure; page 4. 2. Disconnect field cable (X) from pressure control 19d and engine lead. X Fig. 8 8. Fig.9. Use an impact wrench or wedge something between armature (4a) and clutch housing to hold engine shaft during removal. Bottom
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Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 10. Lay two stacks of two dimes on smooth 6. Fig. 8. Tap pinion shaft (19d) in with plastic mallet. bench surface. 7. Install retaining ring (19e) with beveled side facing 2. Lay armature (4a) on two stacks of dimes. field (Y). 3. Press center of clutch down on bench surface. 8. Fig. 7. Place pinion assembly on bench with rotor side up. 4a 0.12 ±.01 in. (3.0 ±.25 mm) 9. Apply locktite to screws. Install four screws (16) and lockwasher
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Clutch Housing Removal 1. Fig. 12. Remove four capscrews (75) and lock- washers (77) which hold clutch housing (5) to engine. 5 7 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull off clutch housing (5). Installation 77 1. Fig. 12. Push on clutch housing (5). 75 2. Install four capscrews (75) and lockwashers (77) and secure clutch housing (5) to engine. Torque to D 200 in-lb (22.6 N m). 15 3. Install capscrew (15) from beneath mounting Fig. 12 plate (D)
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On/Off Switch Removal Installation 1. Install new ON/OFF switch (309) so tabs of switch 1. snap into place on inside of pressure control Relieve pressure; page 4. housing. 2. Fig. 15. Remove five screws (307) and 2. Connect two wires (A) to ON/OFF switch. cover (322). 3. Install pressure control cover (322) with five 3. Disconnect two wires (A) from ON/OFF screws (307). switch (309). 4. Press in on two retaining tabs on each side of ON/OFF switch (309) and remove switch. 313 310 309 A 315 31
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Pressure Control Control Board Removal Installation When installing replacement control board, follow 1. instructions with control board to set model type. Relieve pressure; page 4. 2. Fig. 15. Remove five screws (307) and 1. Fig. 15. Install green ground wire and control cover (322). board (302) with five screws (303). 3. Fig. 22. Disconnect at control board (302): 2. Fig. 22. Connect to control board (302): Four clutch leads: two violet and two black. Lead (D) from potentiometer. Two re
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Pressure Control Control Board Diagnostics 1. Fig. 15. Remove five screws (307) and 3. Turn ON/OFF switch ON. cover (322). 4. Observe LED operation and reference following 2. Start sprayer. table: LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times Sprayer shuts down and LED contin- Run away pressure. 1. Check pressure transducer con- repeatedly Pressure greater than ues to blink two times repeatedly nection at control board 4500 psi (310 bar, 31 2. Replace pressure transducer MPa). 3. R
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Displacement Pump Removal 1. Flush pump. 5. Fig. 17. Use screwdriver to push out pump pin (101). 2. Fig. 16. Cycle pump with piston rod (222) in lowest position. 230 3. Relieve pressure; page 4. 101 4. Fig. 16. Remove suction tube (30) and hose (33). 9019A Fig. 17 6. Fig. 18. Loosen locknut by hitting firmly with a 222 20 oz (maximum) hammer. Unscrew pump. 33 30 9024A Fig. 16 9022A Fig. 18 Repair See manual 308798 for pump repair instructions. 2. Fig. 17. Push pin (101) into hole until retain
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Displacement Pump Pump Pin Clip Removal Installation 1. Fig. 17. Install clip (230). 1. Remove pump (28). 2. Install shield (95), pail hook (94) and pump bracket 2. Remove two bolts (86), washers (25), pump brack- (85) with two washers (25) and bolts (86). Torque et (85), pail hook (94) and shield (95). bolts to 40 ft-lb (54 N m). 3. Fig. 17. Remove clip (230). 3. Install pump (28).
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Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241116 Ref No. 20: Drive Housing Assembly 241537 Ref Ref No. Part No. Description Qty No. Part No. Description Qty 19a 241121 PINION HOUSING, COIL 1 20 DRIVE HOUSING 1 19b 105489 PIN 2 20a 194060 RETAINING CLIP, pump pin 1 19d 241114 PINION SHAFT 20b 193656 CAM FOLLOWER PLATE 1 19e 112770 RETAINING RING, large 20c 114691 CAM FOLLOWER BEARING 2 20d 114828 RETAINER CLIP 2 20g 114697 WASHER 1 20h 114698 WA
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Parts Drawing – Hi-Boy Sprayers Model 232630 93 78 DETAIL A Label Ref 11 87 See page 17 for the parts. 29 40 See manual 308798 for the parts. See page 22 for the parts. 45 See page 22 for the parts. 37 8699A 38 10 39 9027A Bottom View 52 961 19 Ref 35 20h 20 20g 72 98 17 97 83 24 4b 3 2 9 10 18 9 82 56 99 1 11 103 95 26 94 17 85 5 7 33 8 101 DETAIL A 86 17 49 25 16 47 4a 34 70 62 61 77 73 28 80 71 17 22 21 16 66 15 23 105 64 35 30 65 52 31 41 44 71 33(Ref) 42 12 43 62 9018A
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Parts List – Hi-Boy Sprayers Models 232630 Ref Ref No. Part No. Description Qty No. Part No. Description Qty 1 114530 ENGINE 1 41 179811 WHEEL, semi–pneumatic 2 2 113084 RIVET, blind 2 42 101242 RING, retaining 2 3 192014 PLATE, indicator 1 43 104811 HUBCAP 2 4 241113 CLUTCH ASSEMBLY,1 44 154636 WASHER 2 includes 4a, 4b, 16, 17, 72, 80 45 112827 BUTTON, snap 2 4a .ARMATURE, clutch, 5 in. 1 47 237686 GROUNDING CLAMP & WIRE 1 4b .ROTOR, 5 in. 1 49 112798 SCREW, hex washer hd, No. 8 x 3/8 in 1 5
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Parts Drawing – Lo-Boy Sprayers Model 232632 78 93 87 5 DETAIL A Label Ref 11 See page 17 for the parts. 29 See manual 308798 40 for the parts. See page 22 for the parts. 45 37 39 10 9027A 72 9 Bottom View 51 61 17 19 20h Ref 35 20g 30ae 30b 20 83 30ad 98 4b 97 9 30a 10 30aea 101 30aec 18 1 56 30e 11 82 30c 103 26 95 17 94 70 5 30aeb 85 99 30f 9 7 24 25 8 DETAIL A 17 86 49 16 34 4a 35 33 28 62 47 73 77 80 17 71 21 16 22 30ac 23 15 66 30ab 71 52 30aa 41 12 33 (Ref) 44 3 62 42
