Repair GMAX™ II 3900/5900/5900HD/7900 TexSpray™ 7900HD Airless Sprayers 310893L Korean patent: 10-0647761 - For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Manual Conventions Contents WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bearing Housing & Connecting Rod . . . . . . . . . . . 8 Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pinion Assembly/Clutch Armature/Clamp . . .
Warning Warning The following are general warnings related to the setup, use, maintenance and repair of this equipment. Additional, more specific, warnings may be found throughout the text of this manual, 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.
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.
Maintenance Maintenance Pressure Relief Procedure WARNING Read Injection Hazard, page 3; Burn Hazard, page 4. 1. 2. 3. 4. 5. 6. Lock gun trigger safety. Turn engine ON/OFF switch to OFF. Move pump switch to OFF and turn pressure control knob fully counterclockwise. Unlock trigger safety. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure. Lock gun trigger safety. Open pressure drain valve. Leave valve open until ready to spray again.
Troubleshooting Troubleshooting Problem E=XX is displayed Engine will not start False tripping of WatchDog system. EMPTY is displayed. Pump does not run. Engine operates, but displacement pump does not operate Cause Solution Fault condition exists Engine switch is OFF Engine is out of gasoline Determine fault correction from table, page 15 Turn engine switch ON Refill gas tank. Honda Engines Owner's Manual. Engine oil level is low Try to start engine. Replenish oil, if necessary.
Troubleshooting Problem Pump output is low Cause Solution Strainer (82) is clogged Clean strainer. Piston ball is not seating Service piston ball. Manual 310894. Piston packings are worn or damaged Replace packings. Manual 310894. O-ring in pump is worn or damaged Replace o-ring. Manual 310894. Intake valve ball is not seating properly Clean intake valve. Manual 310894. Intake valve ball is packed with material Clean intake valve. Manual 310894.
Bearing Housing and Connecting Rod Bearing Housing and Connecting Rod NOTE: The item numbers referenced are for the 5900 Hi-Boy models. The 3900, 7900 and all Lo-Boy models may have different item numbers. Use the 5900 Hi-Boy item number and part to find the corresponding alternate part and item number. Removal WARNING CAUTION DO NOT use bearing housing screws (41) to align or seat bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear. 5.
Drive Housing Drive Housing Removal CAUTION DO NOT use drive housing screws (38) to align or seat drive housing with pinion housing. Align these parts with locating pins, to avoid premature bearing wear. WARNING 8. Install screws (38) in drive housing. Torque evenly to note 3 value in FIG. 2. 9. Install pump. Refer to Displacement Pump, Installation, page14. Read Injection Hazard, page 3; Burn Hazard, page 4 1. Relieve pressure; page 5. 2. Remove bearing housing.
Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature Removal Pinion Assembly 28 24 If pinion assembly (29) is not removed from clutch housing (19), do 1. through 3. Otherwise, start at 4. 29 E E WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 ti5481a ti5987b 1. Remove drive housing; page 9. FIG. 5 2. FIG. 4. Disconnect clutch cable connectors from inside of pressure control. a. FIG. 14.
Pinion Assembly/Clutch Armature/Clamp Installation Clutch Armature 1. 2. 3. FIG. 8. Lay two stacks of two dimes on smooth bench surface. Lay armature (25) on two stacks of dimes. Press center of hub (26) down to bench surface. 25 26 0.12+01 in (3.0+.25 mm) ti6321a dimes FIG. 8 4. Install armature (25) on engine drive shaft. 5. Install four screws (23) and lock washers (24) with torque of 125 in-lb. Pinion Assembly 6. FIG. 6. Check o-ring (29d) and replace if missing or damaged. 7.
Clutch Housing Clutch Housing Removal 1. 2. 3. 19 18 FIG. 11. Remove four screws (20) and lock washers (21) which hold clutch housing (19) to engine. Remove screw (35) from under mounting plate (D). Pull off clutch housing (19). Installation 1. 2. 3. 21 20 FIG. 11. Push on clutch housing (19). Install four capscrews (20) and lock washers (21) and secure clutch housing (19) to engine. Torque to 200 in-lb (22.6 N·m). Install screw (35) from beneath mounting plate (D). Torque to 26 ft-lb (35.2 N·m).
Pressure Control Pressure Control Pump ON/OFF Switch Removal Installation WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 1. FIG. 14. Remove two screws (71) and swing down cover (130a). 2. Disconnect pump ON/OFF switch (130f) connector from control board. 3. Press in on two retaining tabs on each side of pump ON/OFF switch (130f) and remove switch from cover. 1. Install new pump ON/OFF switch (130f) so tabs of switch snap into place on inside of cover. 2.
Pressure Control Control Board Removal 4. WARNING Installation Read Injection Hazard, page 3; Burn Hazard, page 4 1. 2. 3. • Display connector (130m) • Engine, ground and clutch wires Remove four screws (130c) and control board (130b). FIG. 14. Remove two screws (71) and swing down cover (130a) Remove strain relief bushings (130r and 123).
Pressure Control Digital Display Messages WARNING • • Digital messages are not available on all sprayers Blinking LED total count equals digital error code i.e., two blinks is the same as E=02 Relieve pressure before repair, page 5. DISPLAY* No Display SPRAYER OPERATION INDICATION ACTION Sprayer may be pressurized Loss of power or display not connected Check power source. Relieve pressure before repair or disassembly. Verify display is connected.
Displacement Pump Displacement Pump Removal 1. 2. 6. Raise latch lock. Push latch open. Flush pump. Stop pump with piston rod in its lowest position. WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 3. 4. Do Pressure Relief, page 5. Separate drain hose from sprayer FIG. 17 7. FIG. 18. Ratchet open pump door. a. Ratchet pump door forward. FIG. 15 5. Disconnect material hose from pump. FIG. 18 b. c. d. Twist latch u-bolt out of pump door recess. Place u-bolt on pump door outer edge.
Displacement Pump e. f. Twist latch u-bolt back from pump door outer edge Place u-bolt on pump door protrusion 10. FIG. 23. Pull out pump pin and place in pin holder FIG. 20 FIG. 23 8. Installation Ratchet pump door forward. 1. 2. FIG. 24. Adjust piston rod with pin holder to pull out piston rod. Tap piston rod on hard surface to push in piston rod. Push pump collar flush with bearing housing ledge to be able to close pump door. ti6325a FIG. 21 9. Open pump door. FIG. 24 FIG. 22 3. FIG. 25.
Displacement Pump 4. FIG. 26. Close pump door and rotate latch into position. Do not tighten latch. 7. 5. FIG. 26. Rotate pump to align with material hose. Connect material hose and hand tighten to 70 in-lb FIG. 28 8. FIG. 28. Attach drain hose to sprayer. FIG. 29. Fill pump with Graco TSL until fluid flows onto top of seal. FIG. 26 6. FIG. 27. Tighten latch and rotate latch lock into locked position. FIG. 29 FIG.
Displacement Pump 310893L 19
Parts Parts GMAX ll 3900 Parts Drawing 2EF $%4!), ! ,ABEL 3EE PAGE FOR PARTS 3EE MANUAL FOR PARTS 3EE PAGE FOR PARTS 3EE PAGE FOR PARTS 5SED ON (IGH BOYS SEE PAGE FOR ,OW BOY USE ON ONLY A 2EF "OTTOM 6IEW A 2EF B 2EF $%4!), !
Parts GMAX ll 3900 Parts List Ref 1 2 3 4 5 6 7 8 8a 9 10 11 12 14 15 16 17 18 19 20 21 22 23† 24† 25† 26† 27† 28† 29 30 31 32 33 34* 35 36 39* 40 41 42 43 44 45 Part 287411 156306 119420 15E891 192027 183350 108068 109032 100020 112827 245245 237686 112798 15C871 108879 110837 110838 183401 15E535 108842 100214 193680 108803 105510 101682 287463 114672 114699 287653 287467 116618 112395 119426 119562 287932 113467 104008 287471 287521 118444 310893L Description Qty FRAME, cart (3900) 1 WASHER, flat 2
Parts GMAX ll 5900/5900HD Parts Drawing $%4!), ! 2EF ,ABEL 3EE PAGE FOR PARTS 3EE MANUAL FOR PARTS 3EE PAGE FOR PARTS 3EE PAGE FOR PARTS 5SED ON (IGH BOYS SEE PAGE FOR ,OW BOY .
Parts GMAX ll 5900/5900HD Parts List Ref 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23† 24† 25† 26† 27† 28† 29 30 31 32 33 34* 35 36 37 38 39* 40 41 42 43 44 45 Part 287370 156306 119509 15E891 187604 183350 108068 108795 112827 245245 237686 112798 276974 114530 110837 110838 183401 15E277 108842 100214 193680 108803 105510 101682 287465 114672 114699 287460 287469 116618 112395 102962 104008 15C753 119562 287933 114666 106115 287472 287511 118444 310893L Description Qty FRAME, cart (5900/7
Parts GMAX ll 7900/TexSpray 7900 HD Parts Drawing $%4!), ! 2EF 3EE PAGE FOR PARTS 3EE MANUAL FOR PARTS 3EE PAGE FOR PARTS 3EE PAGE FOR PARTS ,ABEL 5SED ON (IGH BOYS SEE PAGE FOR ,OW BOY 2EF "OTTOM 6IEW A 2EF B 2EF $%4!), !
Parts GMAX ll 7900/TexSpray 7900HD Parts List Ref 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23† 24† 25† 26† 27† 28† 29 30 31 32 33 34* 35 36 37 38 39* 40 41 42 43 44 45 47 Part 287370 156306 119509 15E891 191084 183350 108068 108795 112827 245245 237686 112798 276974 116080 110837 110838 183401 15E277 108842 100214 193680 108803 105510 101682 287466 114672 114699 287459 287470 116618 112395 102962 104008 15C753 119562 287934 112599 112600 287473 287520 118444 249122 289590 67 111457 310893
Parts Drawing and List - Pinion Housing, Drive Housing Parts Drawing and List - Pinion Housing, Drive Housing Ref 29: Pinion Housing Ref 33: Drive Housing GMAX ll 3900: 287463 GMAX ll 5900: 287465 GMAX ll 7900: 287466 TexSpray 7900HD: 287466 GMAX ll 3900: 287467 GMAX ll 5900: 287469 GMAX ll 7900: 287470 TexSpray 7900HD: 287470 Ref 29 Part 287474 287476 287477 29a 287525 241114 29b 29c 29d 113094 112770 105489 165295 114683 33a 116191 116192 Description KIT, repair, field 3900 5900 7900/TexSpray 79
LoBoy Suction Set Kits (Kits include suction set and drain hose) LoBoy Suction Set Kits (Kits include suction set and drain hose) GMAX ll 3900/5900/7900 5 Gallon Kit: 287631 GMAX ll 3900/5900/7900 55 Gallon Kit: 287541 Ref 82 90 109 110 111 112 114 115 153 154 155 156 157 158 159 160 161 Part Description Qty 189920 STRAINER, 1-11 1/2 npsm 1 O-RING 115099 3900/5900 1 119566 7900 1 HOSE, suction 288038 3900/5900, includes 82, 110, 111, 1 112, 114, 288039 7900 1 15C980 NUT, jam 1 15H854 O-RING 2 15C981 WASH
Pressure Control and Filter Parts Drawing Pressure Control and Filter Parts Drawing All Models A 0REMIUM 0ART .UMBER R B C C P M G N K F D E A J H D B A D C E 4EX3PRAY ($ G F 3TANDARD -ODELS 4EX3PRAY ($ A 0REMIUM -ODELS 0ART .UMBER 3TANDARD 0ART .
Pressure Control and Filter Parts List Pressure Control and Filter Parts List REF 53★† 54★† 55★† 56★† 57★ 58★ 59★ 60★‡ 61★‡ 62★‡ 65 ★ † 66★† 67★† 71 72*† 87 91* 91a* 92* 96★† 113 123 130 130a* 130a 130b 130c 130d 130e 130f 130g 130h 130j 130k 130m* 130n* 130p* 130r 150 PART 287510 287517 15C765 117285 15C766 244067 15C780 15C972 224807 235014 15E022 111699 164672 162485 243222 111457 116585 15E284 287419 289282 287293 115524 244346 104813 15E925 119545 249583 249584 287516 117317 241443 198650 116752 11
Parts - Sprayers, RAC™ X Tip, Gun & Hose Parts - Sprayers, RAC™ X Tip, Gun & Hose Ref 40: Bearing Housing Premium Models and TexSpray 7900HD include items 202 to 204 or 205. 141 Item 206 for TexSpray 7900HD only. 40 163 106 165 166 104 105 142 TI A Ref 202 Part 240794 289667 204 288420 241705 205 206 30 159841 241735 Description Qty HOSE, grounded, nylon; 1/4 in. ID; cpld 1 1/4 npsm(fbe); 50 ft (15 m); spring guards both ends; 3300 psi (228 bar, 22.
Technical Data Technical Data Honda GX120 Engine ANSI Power Rating @ 3600 rpm Honda GX160 Engine ANSI Power Rating @ 3600 rpm Honda GX 200 Engine ANSI Power Rating @ 3600 rpm 4.0 Horsepower (3.0 kW) 5.5 Horsepower (4.1 kW) 6.5 Horsepower (4.8 kW) Maximum working pressure 3300 psi (228 bar, 22.8 MPa) Noise Level Sound power 105 dBa per ISO 3744 96 dBa measured at 3.1 feet (1 m) Sound pressure Maximum delivery rating 3900 5900/5900HD 7900 Maximum tip size 3900 1.25 gpm (4.73 liter/min) 1.60 gpm (6.
Graco Standard Warranty Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale 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.