Graco Inc. 3A0243A manual

3A0243A Repair GMAX ™ II 3900/5900/7900 T e xSpra y ™ 5900HD/7900HD Airless Spra y er s K orean patent: 10- 0647761 - For P ortable Airless Spraying of Ar chitectural Coatings and P aints - 3300 psi (22.8 MP a, 228 bar) Maximum W orking Pressure IMPORT ANT SAFETY INSTRUCTIONS Read all warnings and instr uctions in this manual. Sa v e these inst[...]

Warning 2 3A0243A Wa r n i n g The f ollowing are ge neral warnings related to the se tup , us e, maint enance and repair of this equipment. Additional, more specific , warnings may be f ound throug hout the te xt of this manual, where applicab le. WA R N I N G FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fum es, in wor k ar[...]

Warning 3A0243A 3 PRESSURIZED ALUMINUM P ARTS HAZARD Use of fluids that are incompat ible with alumin um in pressurized equipment ca n cause serious chemi- cal reaction and equipment r upture . F ailure to f ollow this w ar ning can result in death, serious injury , or property damage. • Do not use 1,1,1-trichloroeth ane, meth ylene chloride, o t[...]

Maintenance 4 3A0243A Maintenance Pressure Relief Pr ocedure 1. Lock gun trigger sa f ety . 2. T ur n engine ON/OFF switch to OFF . 3. Mov e pump switch to OFF and tur n pre ssure contro l knob fully counterclockwise. 4. Unlock trigger safety . Hold metal par t of gun firmly to side of groun ded metal pail, and trigger gun to relie ve pressure. 5. [...]

Troubleshooting 3A0243A 5 T r oubleshooting Problem Cause Solution E=XX is display ed F ault condition exists . Deter mi ne fault correction from table , page 14. Engine will not star t Engine switch is OFF . T ur n engine switch ON. Engine is out of gasoline. Refill gas tank. Honda Engine Manual. Engine oil lev el is low . T r y to star t engine. [...]

Troubleshooting 6 3A0243A Pump output is low Strainer is clogged. Clean strainer . Piston ball is no t seating. Ser vice piston ball (see pump manual). Piston packings are worn or damaged. Replace packings (see pump manual). O-ring in pump is wor n or damaged. Replace o-r ing (see pump manual). Intake v alve ball is not seating properl y . Clean in[...]

Troubleshooting 3A0243A 7 Fluid Pump Runs Constantly 1. P erform Pressure Relief Procedure (page 4), tur n prime valv e f orwar d to SPRA Y position, and turn pow er switch OFF . 2. Remo ve control bo x cov er . T roubleshooting Pr ocedure: With a pressure gaug e plumbed into the paint hose, start the engin e. Turn pump switch ON. Does sprayer exce[...]

Troubleshooting 8 3A0243A Contr ol Boar d Malfunction T roubleshooting Pr ocedure (see follo win g page for actual st eps): Go to step 5. Does the clutch engage? Go to step 2. Do y ou ha ve proper engine v oltage? Go to step 4. Is 1-3 Ohms reading pres- ent? Mechanical problem. Repair or replac e clutch/pinion assembly . Replace the potentiomet er [...]

Troubleshooting 3A0243A 9 Contr ol Boar d Malfunction (Steps) - BEEP + - J1 J2 12 -20 AC V - + - + 10-12 DC V - + + 3900 5900/7900 J10 J5 J9 J4 J3 J1 J2 LED D12 J5 - 1-3 ohms - + + - STEP 1. T ur n engine OFF and set meter to continuity . T o Ground STEP 3 . Leav e engine running and turn s witch ON. T urn potentiomete r to high and set meter to DC[...]

Troubleshooting 10 3A0243A Con ver tible Electric Motor Will Not Run T roubleshooting Pr ocedure (see follo win g page for actual st eps): See Step 1. Is there over 100 AC volts? See step 2. Is th ere over 100 AC volts? Replace the power swit ch. See Step 3. Is there over 100 D C volts? See engine test section. Replace engine control board. YES NO [...]

Troubleshooting 3A0243A 11 Con ver tible Electric Motor Will Not Run (Steps) V - - L2 L1 + V - - L2 L1 + TS TS +M -M L2 L1 TS TS +M -M - BEEP - TS TS +M -M 100 + DC V - - + STEP 1. Plug in cord and turn s witch ON . Connect wires to control board and tur n me ter to AC vo l ts . STEP 2. Plug in cord and turn s witch ON. Connect wires to contro l bo[...]

Troubleshooting 12 3A0243A Con ver tible Electric Motor Runs - No A C Output to Spray er Control Boar d T roubleshooting Pr ocedure (see follo win g page for actual st eps): See step 1. Is there o ver 10- 20 AC vo l t s ? YES NO YES YES YES NO NO NO YES See step 2. Is there co ntinuity? Repair or replace the pow er cord. See the spra y er control b[...]

Troubleshooting 3A0243A 13 Con vertible Electric Motor Runs - No A C Output to Sprayer Contr ol Boar d (Steps) 10-20 AC V - - + - BEEP - TS TS +M -M L2 L1 Ground 10-20 AC V - - + L2 L1 V - - + - BEEP - STEP 1. Plug in cord and turn s witch ON . Connect wires to transformer and pow er cord. T ur n meter to AC volts . White to barrel Pow e r C o r d [...]

Digital Display Messages 14 3A0243A Digital Displa y Messages • Digital messages are not a v ailable on all spr ay ers • Blinking LED total count equals digital error code i.e., two b links is the same as E=02 * Error codes also appear on control board as a blinking red LED . LED is an alter nate to digita l messages. 1. Remov e two scre ws (71[...]

Bearing Housing and Connecting Rod 3A0243A 15 Bearing Housing and Connecting Rod NO TE: The item numbers ref erenced are fo r the 5900 Hi-Bo y models. Th e 3900, 7900 and all Lo-Bo y models ma y hav e diff erent item n umbers. Use the 5900 Hi-Bo y item numbe r and par t to find the correspo nding alter- nate par t and item n umber . Remo val 1. Rel[...]

Drive Housing 16 3A0243A Drive Housing Remo val 1. Relie v e pressure; page 4. 2. Remov e bear ing h ousing. Refer to Bearing Hous- ing and Connecting Rod, Remo val , page 15. 3. Premium spray ers: Remove two screws (108) and gallon counter sensor (39). 4. Remov e six screws (38). 5. Lightly tap around drive housing (33) to loosen driv e housing. P[...]

Pinion Assembly/Clutch Armature /Clamp 3A0243A 17 Pinion Assembl y/Clutc h Armature/Clamp Pinion Assembl y/Clutch Armature Remo val Pinion Assembl y If pinion assemb ly (29) is not remo ved f rom clutch hous- ing (19), do 1. t hrough 3. Otherwise , star t at 4. 1. Remo ve driv e housing; page 16. 2. Disconnect clutch cable conne ctors from inside o[...]

Pinion Assembly/Clutch Armature/Clamp 18 3A0243A Installation Clutch Armature 1. Lay two stacks of two dimes on smooth bench sur- f ace. 2. Lay armature (2 5) on two stacks of dimes. 3. Press center of hub (26) down to be nch surf ace. 4. Install armature (25) on engine dr iv e shaft. 5. Install f our scre ws (23) and loc k w ashers (24) with torqu[...]

Clutch Housing 3A0243A 19 Clutch Housing Remo val 1. Remo ve f our scr ews (20) and lo ck w ashers (21) which hold clutch housin g (19) to engine. 2. Remove scre w (35) from un der mounting plate (D). 3. Pull off clutch ho using (19). Installation 1. Push on clutch hou sing (19). 2. Install f our capscre ws (20) and loc k washers (21) and secure cl[...]

Clutch Housing 20 3A0243A Engine Remo val NO TE: All ser vice to the engine must be perfo r med by an authoriz ed Honda dealer . 1. Remov e Pinion Assembly/Clutc h Arma- ture/Clamp and Clutch Housing , as instructed on pages 17, a nd 18. 2. Disconnect all necessa r y wir ing. 3. Remove two locknuts (17) a nd screws (16) fro m base of engine . 4. Li[...]

Pressure Control 3A0243A 21 Pressure Contr ol Pump ON/OFF Switch Re m ova l 1. Remov e two screws (71) and s wing down cov er (130a). 2. Disconnect pu mp ON/OFF swit ch (130f) connector from contr ol board. 3. Press in on tw o retaining tabs on each side of pump ON/OFF switch (130f) and r emov e switch from cov er . Installation 1. Install new pump[...]

Pressure Control 22 3A0243A Contr ol Board Re m ova l 1. Remov e two scre ws (71) and swing do wn cov er (130a). 2. Remov e strain relief bushings (130r and 123). 3. Disconnect at control board (130b): • Lead from potentiometer (130d) • Lead from transducer (66) • Lead from W atchDog switch (130g) • Lead from pump ON/OFF switch (130f) • L[...]

Displacement Pump 3A0243A 23 Displacement Pump Remo val 1. Flush pump . 2. Stop pump with piston rod in it s lowest positio n. 3. Do Pressure Relie f , page 4. 4. Separ ate drain hose f rom spra y er . 5. Disconnect ma terial hose from pump . 6. Raise latch loc k. Push latch open. 7. Ratchet ope n pump door . a. Ratchet pump door f orward. b . T wi[...]

Displacement Pump 24 3A0243A f . Place u-bolt on pum p door protr usion 8. Ratchet pump door f orward. 9. Open p ump door . 10. Pull out pump pin and place in pin holder Installation 1. Adjust piston r od with pin holder to pull out pi ston rod. T ap piston rod on hard surf ace to push in piston rod. 2. Push pump collar fl ush with bearing housing [...]

Displacement Pump 3A0243A 25 5. Rotate pump to align with mater ial hose. Connect mater ial hose a nd hand t ighten to 7 0 in-lb. 6. Tighten latch and rotate latch lock into locked posi- tion. 7. Attach drain hose to spray er . 8. Fill pump with Graco TSL until fluid flows onto top of seal. ti6299a ti6312a ti62 04a TI6312a ti6204a ti14909a ti5493a[...]

Hose Reel 26 3A0243A Hose Reel Remo val 1. Remov e hose fitting from s wivel cap and completely remov e hose. 2. Remov e cap f rom swiv el. 3. Remov e E-clip from s wivel shaft. 4. Remo ve s wiv el cap . 5. Remo ve sna p ring. 6. Remo ve h ose reel. Be sure to k eep your head clear of hose reel while winding up ho se. ti15023a ti13675a ti13538a ti1[...]

Hose Reel 3A0243A 27 Installation 1. Grease sha ft. 2. Make sure two washers and wav e spr ing are on hub bef ore hose reel is installed. 3. Install hose reel onto frame . Place C-clamp on re el and frame to allow snap r ing to fit into place. Install snap ring. 4. Install s wivel cap . 5. Install E-clip . 6. Install hose to ho se cap . Make sure t[...]

Pivot Replacement 28 3A0243A Piv ot Replacement Remo val 1. Remov e Hose Re el, page 26. 2. Remo ve rigid fluid t ube from s wivel shaft. 3. Remov e two sc rews on pivot plate (A), swiv el shaft (B) if necessary , and remo ve coupling (C) from s wivel sh aft. 4. Remov e pivot (D). Installation 1. Install piv ot (D). 2. Install pi vot pla te (A) on [...]

Technical Data 3A0243A 29 Te c h n i c a l D a t a Honda GX120 Engine ANSI P ow er Rating @ 3600 r pm 4.0 Horsepower (3.0 kW) Honda GX160 Engine ANSI P ow er Rating @ 3600 r pm 5.5 Horsepower (4.1 kW) Honda GX 200 Engine ANSI P ow er Rating @ 3600 r pm 6.5 Horsepower (4.8 kW) Maximum working pressure 3300 psi (228 bar , 22.8 MPa) Noise Lev el Sound[...]

Technica l Data 30 3A0243A Dimensions Spra yer (no hose and gun) W eight 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) T exSpra y 7900HD 157 (71) 32.2 5 (81.9) 24.5 (62.2) 33.0 (83.8)[...]

Notes 3A0243A 31 Notes[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 3A0243 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]