Repair GMAX™ II 3900/5900/7900 TexSpray™ 5900HD/7900HD Airless Sprayers Korean patent: 10-0647761 3A0243A ENG - 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.
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 PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. • Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents. • Many other fluids may contain chemicals that can react with aluminum.
Maintenance Maintenance Pressure Relief Procedure AFTER THE FIRST 20 HOURS OF OPERATION: Drain engine oil and refill with clean oil. Reference Honda Engines Owner's Manual for correct oil viscosity. 1. Lock gun trigger safety. 2. Turn engine ON/OFF switch to OFF. 3. Move pump 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.
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. Engine oil level is low. Determine fault correction from table, page 14. Turn engine switch ON. Refill gas tank. Honda Engine Manual. Try to start engine. Replenish oil, if necessary. Honda Engine Manual.
Troubleshooting Problem Pump output is low Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime Cause Strainer is clogged. Piston ball is not seating. Piston packings are worn or damaged. O-ring in pump is worn or damaged. Intake valve ball is not seating properly. Intake valve ball is packed with material. Engine speed is too low. Pump packings are worn. Paint is too thick. Engine speed is too high.
Troubleshooting Fluid Pump Runs Constantly 1. Perform Pressure Relief Procedure (page 4), turn prime valve forward to SPRAY position, and turn power switch OFF. 2. Remove control box cover. Troubleshooting Procedure: With a pressure gauge plumbed into the paint hose, start the engine. Turn pump switch ON. Does sprayer exceed maximum pressure? NO Pump problem. See the proper fluid pump manual for the sprayer for further troubleshooting procedures.
Troubleshooting Control Board Malfunction Troubleshooting Procedure (see following page for actual steps): Remove control box cover. Turn sprayer ON. Observe control board Green and Red LED lights. Go to step 1.
Troubleshooting Control Board Malfunction (Steps) STEP 1. Turn engine OFF and set meter to continuity. BEEP STEP 2. Turn engine ON. Set meter to AC volts and connect wires to control board. 12 -20 AC V - ti14939a ti14938a + - Control Board J2 ti14940a + - V + + Pump On/Off Switch STEP 3. Leave engine running and turn switch ON. Turn potentiometer to high and set meter to DC volts.
Troubleshooting Convertible Electric Motor Will Not Run Troubleshooting Procedure (see following page for actual steps): See Step 1. Is there over 100 AC volts? NO See step 2. Is there over 100 AC volts? NO Repair or replace the power cord. YES Replace the power switch. YES See Step 3. Is there over 100 DC volts? YES See engine test section. 10 NO See Step 4. Is there continuity through the thermal sensor? NO If engine is hot, let cool and retest.
Troubleshooting Convertible Electric Motor Will Not Run (Steps) STEP 2. Plug in cord and turn switch ON. Connect wires to control board and turn meter to AC volts. STEP 1. Plug in cord and turn switch ON. Connect wires to control board and turn meter to AC volts.
Troubleshooting Convertible Electric Motor Runs No AC Output to Sprayer Control Board Troubleshooting Procedure (see following page for actual steps): See step 1. Is there over 10-20 AC volts? NO See step 2. Is there continuity? YES YES See the sprayer control board troubleshooting in this manual. See step 3. Is there continuity? NO Repair or replace the power cord. NO Repair or replace the power cord. YES See step 4.
Troubleshooting Convertible Electric Motor Runs - No AC Output to Sprayer Control Board (Steps) 10-20 AC V - STEP 1. Plug in cord and turn switch ON. Connect wires to transformer and power cord. Turn meter to AC volts. STEP 2. Check AC power cord for an open wire. Turn meter to continuity test. Meter should read continuity.
Digital Display Messages Digital Display Messages DISPLAY* No Display SPRAYER OPERATION • 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 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. Sprayer may be pressurized. Pressure less than 200 psi (14 bar, 1.4 MPa).
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 NOTICE 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 1. Relieve pressure; page 4. 2. Remove bearing housing. Refer to Bearing Housing and Connecting Rod, Removal, page 15. NOTICE Premium models: Gallon counter sensor is connected to control board in pressure control. Pulling on the sensor wires could cause damage. 7. Install bearing housing. Refer to Bearing Housing and Connecting Rod, Installation, page 15. NOTICE DO NOT use drive housing screws (38) to align or seat drive housing with pinion housing.
Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature Removal 6. Remove retaining ring (29b). Pinion Assembly If pinion assembly (29) is not removed from clutch housing (19), do 1. through 3. Otherwise, start at 4. 7. Turn pinion assembly over and tap pinion shaft (29a) out with plastic mallet. 27 29b 29a 1. Remove drive housing; page 16. 2. Disconnect clutch cable connectors from inside of pressure control. 29d a.
Pinion Assembly/Clutch Armature/Clamp Installation Clutch Armature Pinion Assembly 1. Lay two stacks of two dimes on smooth bench surface. 1. Check o-ring (29d) and replace if missing or damaged. 2. Lay armature (25) on two stacks of dimes. 2. Tap pinion shaft (29a) in with plastic mallet. 3. Press center of hub (26) down to bench surface. 3. Install retaining ring (29b) with beveled side facing up. 25 26 0.12+01 in (3.0+.25 mm) 4. Place pinion assembly on bench with rotor side up. 5.
Clutch Housing Clutch Housing Removal 1. Remove four screws (20) and lock washers (21) which hold clutch housing (19) to engine. 2. Remove screw (35) from under mounting plate (D). 3. Pull off clutch housing (19). Installation 1. Push on clutch housing (19). 2. Install four capscrews (20) and lock washers (21) and secure clutch housing (19) to engine. Torque to 200 in-lb (22.6 N·m). 3. Install screw (35) from beneath mounting plate (D). Torque to 26 ft-lb (35.2 N·m).
Clutch Housing Engine Removal NOTE: All service to the engine must be performed by an authorized Honda dealer. 16 1. Remove Pinion Assembly/Clutch Armature/Clamp and Clutch Housing, as instructed on pages 17, and 18. 2. Disconnect all necessary wiring. ti5487a 3. Remove two locknuts (17) and screws (16) from base of engine. 4. Lift engine carefully and place on work bench. 1 To the field 2 3 To gallon counter 4 To ground Installation 1. Lift engine carefully and place on cart.
Pressure Control Pressure Control Pump ON/OFF Switch Removal 3. Press in on two retaining tabs on each side of pump ON/OFF switch (130f) and remove switch from cover. Installation 1. Remove two screws (71) and swing down cover (130a). 1. Install new pump ON/OFF switch (130f) so tabs of switch snap into place on inside of cover. 2. Disconnect pump ON/OFF switch (130f) connector from control board. 2. Connect pump ON/OFF switch connector to control board. 3.
Pressure Control Control Board Removal Installation 1. 2. 3. 1. 2. 3. 4. Remove two screws (71) and swing down cover (130a). Remove strain relief bushings (130r and 123). Disconnect at control board (130b): • Lead from potentiometer (130d) • Lead from transducer (66) • Lead from WatchDog switch (130g) • Lead from pump ON/OFF switch (130f) • Lead from gallon counter sensor (39) • Display connector (130m) • Engine, ground and clutch wires Remove four screws (130c) and control board (130b). 4. 5.
Displacement Pump Displacement Pump Removal 6. Raise latch lock. Push latch open. ti6369a 1. Flush pump. 2. Stop pump with piston rod in its lowest position. ti11422a 3. Do Pressure Relief, page 4. ti6370a 4. Separate drain hose from sprayer. 7. Ratchet open pump door. a. Ratchet pump door forward. ti6373a ti14904a 5. Disconnect material hose from pump. b. Twist latch u-bolt out of pump door recess. c. Place u-bolt on pump door outer edge. ti6300a d. If pump door is stuck, do steps e., f.
Displacement Pump f. Installation Place u-bolt on pump door protrusion 1. Adjust piston rod with pin holder to pull out piston rod. Tap piston rod on hard surface to push in piston rod. 2. Push pump collar flush with bearing housing ledge to be able to close pump door. ti6375a ti6325a 8. Ratchet pump door forward. ti5492a 3. Slide pump into connecting rod. Push pump pin until it is fully retained. NOTE: Pin will snap into position. 9. Open pump door. ti6378a ti14907a 4.
Displacement Pump 5. Rotate pump to align with material hose. Connect material hose and hand tighten to 70 in-lb. 7. Attach drain hose to sprayer. ti6299a ti14909a 6. Tighten latch and rotate latch lock into locked position. ti6204a 8. Fill pump with Graco TSL until fluid flows onto top of seal.
Hose Reel Hose Reel Removal 4. Remove swivel cap. Be sure to keep your head clear of hose reel while winding up hose. 1. Remove hose fitting from swivel cap and completely remove hose. ti13543a 5. Remove snap ring. ti15023a ti13542a 2. Remove cap from swivel. 6. Remove hose reel. ti13675a 3. Remove E-clip from swivel shaft.
Hose Reel Installation 5. Install E-clip. 1. Grease shaft. ti13537a 2. Make sure two washers and wave spring are on hub before hose reel is installed. ti13538a 6. Install hose to hose cap. Make sure to route hose through side arm of hose reel. ti13545a ti15023a 3. Install hose reel onto frame. Place C-clamp on reel and frame to allow snap ring to fit into place. Install snap ring. 7. Wrap up hose. Make sure hose is routed through hose guide. ti13536a 4. Install swivel cap.
Pivot Replacement Pivot Replacement Removal Installation 1. Install pivot (D). 2. Install pivot plate (A) on pivot and tighten two screws on pivot plate. 1. Remove Hose Reel, page 26. B 2. Remove rigid fluid tube from swivel shaft. D A ti15022a C 3. Install o-ring and replace swivel shaft (B) if it was removed. ti15025a 3. Remove two screws on pivot plate (A), swivel shaft (B) if necessary, and remove coupling (C) from swivel shaft. B ti13544a D A ti15022a B 4. Replace coupling (C). 5.
Technical Data Technical Data Honda GX120 Engine ANSI Power Rating @ 3600 rpm 4.0 Horsepower (3.0 kW) Honda GX160 Engine ANSI Power Rating @ 3600 rpm 5.5 Horsepower (4.1 kW) Honda GX 200 Engine ANSI Power Rating @ 3600 rpm Maximum working pressure 6.5 Horsepower (4.8 kW) 3300 psi (228 bar, 22.8 MPa) Noise Level Sound power 105 dBa per ISO 3744 Sound pressure 96 dBa measured at 3.1 feet (1 m) Maximum delivery rating 3900 1.25 gpm (4.73 liter/min) 5900/5900HD 1.60 gpm (6.06 liter/min) 7900 2.
Technical Data Dimensions 30 Sprayer (no hose and gun) Weight lb (kg) Height in. (cm) Width in. (cm) Length in. (cm) 3900 109 (50) 31.5 (80.0) 22.25 (56.5) 32.0 (81.3) 5900 139 (64) 32.25 (81.9) 24.5 (62.2) 32.25 (81.9) 7900 146 (67) 32.25 (81.9) 24.5 (62.2) 33.0 (83.8) TexSpray 7900HD 157 (71) 32.25 (81.9) 24.5 (62.2) 33.0 (83.
Notes Notes 3A0243A 31
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.
