Graco 310893P Gmax Ii 3900 5900 7900 Texspray 5900Hd 7900Hd Users Manual 3900, 5900, 7900, 5900HD/7900HD Airless Sprayers, Repair (English)
GMax II 248683 310893EN-P
2015-04-02
: Graco Graco-310893P-Gmax-Ii-3900-5900-7900-Texspray-5900Hd-7900Hd-Users-Manual-686181 graco-310893p-gmax-ii-3900-5900-7900-texspray-5900hd-7900hd-users-manual-686181 graco pdf
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Repair GMAX™ II 3900/5900/7900 TexSpray™ 5900HD/7900HD Airless Sprayers 310893P ENG 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. ti5475a ti5447a ti5474a 248683 248684 248685 248686 249335 248687 248688 248689 248690 249336 248699 248700 248701 248702 248703 249337 255632 GMAX ll 3900 ✓ ✓ ✓ ✓ ✓ GMAX ll 5900 ✓ ✓ ✓ ✓ ✓ TexSpray 5900HD ✓ GMAX ll 7900 ✓ ✓ ✓ ✓ ✓ TexSpray 7900HD ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Related Manuals 310892 311861 308491 310894 309640 Manual Conventions Contents WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bearing Housing & Connecting Rod . . . . . . . . . . . 8 Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pinion Assembly/Clutch Armature/Clamp . . . . . . 10 Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pump ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . 13 Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 16 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 GMAX II 3900 Parts Drawing . . . . . . . . . . . . . . . . . 20 GMAX II 5900/5900HD Parts Drawing . . . . . . . . . . 22 GMAX II 7900/TexSpray 7900HD Parts Drawing . . 24 Parts Drawing and List - Pinion Housing . . . . . . . 26 Lo-Boy Suction Set . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pressure Control and Filter Parts Drawing. . . . . . 28 Parts - Sprayers, RAC X® Tip, Gun & Hose . . . . . . . . . . 30 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32 Manual Conventions WARNING Hazard Symbol WARNING: a potentially hazardous situation which, if not avoided, could result in death or serious injury. Warnings in the instructions usually include a symbol indicating the hazard. Read the general Warnings section for additional safety information. 2 CAUTION CAUTION: a potentially hazardous situation which, if not avoided, may result in property damage or destruction of equipment. Note Additional helpful information. 310893P 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. • 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 explode if spilled on hot surface. • When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. • Ground equipment and conductive objects in work area. See Grounding instructions. • Use only grounded hoses. • Hold gun firmly to side of grounded pail when triggering into pail. • If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the spray tip. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Do not spray without tip guard and trigger guard installed. • Engage trigger lock when not spraying. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. PRESSURIZED EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply. 310893P 3 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 modify equipment. • Do not install a shut-off device between filter outlet and gun. • Use equipment only for its intended purpose. Call your Graco distributor for information. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. • Do not use hoses to pull equipment. • Keep children and animals away from work area. • Comply with all applicable safety regulations. PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage. SUCTION HAZARD Never place hands near the pump fluid inlet when pump is operating or pressurized. Powerful suction could cause serious injury. CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. Do not operate in an enclosed area. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDS’s to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: • Protective eyewear • Clothing and respirator as recommended by the fluid and solvent manufacturer • Gloves • Hearing protection RECOIL HAZARD Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury. 4 310893P 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. If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose. 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. WEEKLY: Remove engine air filter cover and clean element. Replace element, if necessary. If operating in an unusually dusty environment: check filter daily and replace, if necessary. Replacement elements can be purchased from your local HONDA dealer. AFTER EACH 100 HOURS OF OPERATION: Change engine oil. Reference Honda Engines Owner's Manual for correct oil viscosity. SPARK PLUG: Use only BPR6ES (NGK) or W20EPR-U (NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug wrench when installing and removing plug. Premium Sprayers Engine Oil Funnel: Use the supplied engine oil funnel when draining oil. CAUTION For detailed engine maintenance and specifications, refer to separate Honda Engines Owner's Manual, supplied. DAILY: Check engine oil level and fill as necessary. DAILY: Check hose for wear and damage. DAILY: Check that all hose fittings are secure. ti6200a DAILY: Check gun safety for proper operation. DAILY: Check pressure drain valve for proper operation. DAILY: Check and fill the gas tank. DAILY: Check level of TSL in displacement pump packing 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. 310893P OIL FUNNEL 5 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. Honda Engines Owner's Manual. Spark plug is disconnected or damaged Connect spark plug cable or replace spark plug Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times. Clean or replace spark plug. Start engine. Keep sprayer upright to avoid oil seepage Operating conditions out of WatchDog Turn pressure down. Contact Graco Technical parameters Assistance to adjust WatchDog parameters. Pump output is low, page 7. Operate without WatchDog active; Manual 310892. Error code displayed Reference Pressure Control repair, page 15 Pump switch is OFF Turn pump switch ON Pressure setting too low Turn pressure adjusting knob clockwise to increase pressure. Fluid filter (56) is dirty Clean filter. Page 28. Clean tip or tip filter. Manual 309639. Tip or tip filter is clogged Displacement pump piston rod is stuck Repair pump. Manual 310894. due to dried paint Connecting rod is worn or damaged Replace connecting rod. Page 8. Drive housing is worn or damaged Replace drive housing. Page 9. Electrical power is not energizing clutch Check wiring connections. Page 12. field Reference Digital Display Messages. Page 15. Reference wiring diagram. Page 29. With pump switch ON and pressure turned to MAXIMUM, use a test light to check for power between clutch test points on control board. Remove clutch wires from control board and measure resistance across clutch coil. At 70° F, the resistance must be between 1.2 +0.2Ω; if not, replace pinion housing. Have pressure control checked by authorized Graco dealer Clutch is worn, damaged, or incorrectly Adjust or replace clutch. Page 10. positioned Pinion assembly is worn or damaged Repair or replace pinion assembly. Page10. 6 310893P 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. Engine speed is too low Increase throttle setting. Manual 310892. Clutch is worn or damaged Adjust or replace clutch. Page 10. Pressure setting is too low Increase pressure. Manual 310892. Fluid filter (56), tip filter or tip is clogged or Clean filter. Manual 310892 or 309639. dirty Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime Large pressure drop in hose with heavy materials Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft of 1/4 in. hose significantly reduces performance of sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum). Throat packing nut is loose Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage. Throat packings are worn or damaged Replace packings. Manual 310894. Displacement rod is worn or damaged Replace rod. Manual 310894. Air in pump or hose Check and tighten all fluid connections. Reprime pump. Manual 310892. Tip is partially clogged Clear tip. Manual 309639. Fluid supply is low or empty Refill fluid supply. Prime pump. Manual 310892. Check fluid supply often to prevent running pump dry. Air in pump or hose Check and tighten all fluid connections. Reduce engine speed and cycle pump as slowly as possible during priming. Intake valve is leaking Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve. Pump packings are worn Replace pump packings. Manual 310894. Paint is too thick Thin the paint according to the supplier's recommendations Engine speed is too high Decrease throttle setting before priming pump. Manual 310892. Clutch squeaks each time clutch engages Clutch surfaces are not matched to each other Clutch surfaces need to wear into each when new and may cause noise other. Noise will dissipate after a day of run time. High engine speed at no load Misadjusted throttle setting Reset throttle to 3300 engine rpm at no load. Worn engine governor Replace or service engine governor Gallon counter not working Bad sensor, broken or disconnected wire. Check connections. Replace sensor or Displaced or missing magnet. wire. Reposition or replace magnet. No display, sprayer operates Display damaged or has bad connection 310893P Check connections. Replace display. 7 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. Install screws (41) and washers (42) in bearing housing. Torque evenly to note 3 value in Fig. 1. 6. Install pump. Refer to Displacement Pump, Installation, page 14. " Read Injection Hazard, page 3; Burn Hazard, page 4 1. Relieve pressure; page 5. 2. FIG. 1. Remove four screws (45) and front cover (44) 3. Remove pump. Refer to Displacement Pump, Removal, page 16. 4. Remove four screws (41) and washers (42) from bearing housing (40). 5. Pull connecting rod (43) and lightly tap lower rear of bearing housing with plastic mallet to loosen from drive housing (33). Pull bearing housing and connecting rod assembly off drive housing. 6. & 2. Assemble connecting rod (43) to bearing housing (40). Rotate connecting rod to lowest position. 3. Clean mating surfaces of bearing and drive housings. 4. Align connecting rod with crank (B) and carefully align locating pins (F) in drive housing (33) with holes in bearing housing (40). Push bearing housing onto drive housing or tap into place with plastic mallet. 8 # Inspect crank (B) and connecting rod (43) for excessive wear and replace parts as needed. Evenly lubricate inside of bronze bearing (C) in bearing housing (40) with high-quality motor oil. Liberally pack top roller bearing (E), lower bearing (D) inside connecting rod (43) with bearing grease. $ TIB ! Installation 1. % 1 2 3 Oil Pack with bearing grease 114819 GMAX II 3900: Torque to 200 in-lb (22.6 N.m) GMAX II 5900: Torque to 25 ft-lb (34 N.m) GMAX II 7900: Torque to 40 ft-lb (54 N.m) TexSpray 7900HD: Torque to 40 ft-lb (54 Nm FIG. 1 310893P 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. Refer to Bearing Housing and Connecting Rod, Removal, page 8. " CAUTION TIA A Premium models: Gallon counter sensor is connected to control board in pressure control. Pulling on the sensor wires could cause damage. B 3. Premium sprayers: Remove two screws (108) and gallon counter sensor (39). 1 " CAUTION Thrust washers may stick to grease inside of drive housing. Do not lose or misplace. 4. Remove six screws (38). 5. Lightly tap around drive housing (33) to loosen drive housing. Pull drive housing straight off pinion housing. Be prepared to support combination gear (32) which may also come out. FIG. 2. Apply all grease supplied with replacement gear cluster to gear teeth and to areas called out by note 3. 2. FIG. 3. Ensure thrust washers (30, 31; 5900/7900) (30, 31, 72; 3900) are on combination gear (32) and washers (Fig. 2; 33a, 33b) are on crankshaft of drive housing (33) as shown. 3. Clean mating surfaces of pinion and drive housings. 4. Align gears and push new drive housing straight onto pinion housing (29) and locating pins (B). 5. Install six screws (38). 6. Install gallon counter sensor (39) with two screws (108). GMAX II 3900: Torque to 140 ±10 in-lb (15.8 ±1.1N.m) GMAX II 5900: Torque to 200 ±10 in-lb (22.6 ±1.1 N.m) GMAX II 7900: Torque to 200 ±10 in-lb (22.6 ±1.1 N.m) Texspray 7900HD: Torque to 200 ±10 in-lb (22.6 ±1.1 N.m) 2 Gallon counter sensor 3 Pack with grease 114819 Installation 1. 1 FIG. 2 7. Install bearing housing. Refer to Bearing Housing and Connecting Rod, Installation, page 8. 310893P 1 Copper 2 Steel TIA FIG. 3 9 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. Remove two screws (71) and swing down cover (130a). b. Disconnect engine leads from board to engine. c. Remove strain reliefs 130r and 123. 6. FIG. 6. Remove retaining ring (29b). 7. Turn pinion assembly over and tap pinion shaft (29a) out with plastic mallet. 3. 27 FIG. 4. Remove four screws (36) and pinion assembly (29). 29b 36 37 29a 19 29 29d ti5482a FIG. 6 36 Clutch Armature 37 ti5480a 8. FIG. 7. Use an impact wrench or wedge something between clutch armature (25) and clutch housing to hold engine shaft during removal. 9. Remove four screws (23) and lock washers (24). FIG. 4 4. FIG. 5. Place pinion assembly (29) on bench with rotor side up. 5. Remove four screws (28) and lock washers (24). Install two screws in threaded holes (E) in rotor. Alternately tighten screws until rotor comes off. 10. Remove armature. TIA FIG. 7 10 310893P 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. Tap pinion shaft (29a) in with plastic mallet. 8. Install retaining ring (29b) with beveled side facing up. 9. FIG. 5. Place pinion assembly on bench with rotor side up. 10. Apply thread sealant to screws. Install four screws (28) and lock washers (24). Alternately torque screws to 125 in-lb until rotor is secure. Use threaded holes to hold rotor. 11. FIG. 4. Install pinion assembly (29) with four screws (36) and washers (37). 12. FIG. 14. Connect clutch cable connectors to inside of pressure control. Clamp Removal 1. Do Engine Removal. 1 Face of clutch housing WARNING 2 1.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3900 2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 & 7900 3 Torque to 125 ±.10 in-lb (14 ±1.1 N·m) Gasoline can spill and cause a fire or explosion if engine is tipped on side. 2. 3. 4. 5. 4 Chamfer this side Drain gasoline from tank according to Honda manual. FIG. 9. Tip engine on side so gas tank is down and air cleaner is up. FIG. 10. Loosen two screws (24) on clamp (22), Push screwdriver into slot in clamp (22) and remove clamp. 19 " ti6199a TIA ! FIG. 9 Clamp Installation 1. 2. 3. FIG. 10 FIG. 10. Install engine shaft key (18) Tap clamp (22) onto engine shaft (A). Maintain dimension shown note 2. Chamfer must face engine. Check dimension: Place rigid, straight steel bar (B) across face of clutch housing (19). Use accurate measuring device to measure distance between bar and face of clamp. Adjust clamp as necessary. Torque two screws (24) to 125 ±10 in-lb (14 ±1.1 N·m) 310893P 11 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). D ti5486a 35 FIG. 11 Engine Removal NOTE: All service to the engine must be performed by an authorized HONDA dealer. 1. 2. 3. 4. Remove Pinion Assembly/Clutch Armature/Clamp and Clutch Housing, as instructed on pages 9, 10 and 11. FIG. 12. Disconnect all necessary wiring. FIG. 13. Remove two locknuts (17) and screws (16) from base of engine. Lift engine carefully and place on work bench. 1 To the field 2 3 16 To the engine 3 To gallon counter 4 To ground ti5487a 17 1 FIG. 13 Bottom View 3900 Installation Green 1. 2. ti5485b 2 4 2 Bottom View 5900/7900 3. 4. Lift engine carefully and place on cart. FIG. 13. Install two screws (16) in base of engine and secure with locknuts (17). Torque to 26 ft-lb (22.6 N·m). FIG. 12. Connect all necessary wiring. Install Pinion Assembly/Clutch Armature/Clamp and Clutch Housing, as instructed on pages 9, 10 and 11. FIG. 12 12 310893P 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. Connect pump ON/OFF switch connector to control board. 3. Swing up cover (130a) and secure with two screws (71). '2/5.$ #,54#( 4/ %.').% A #,54#( R C F C B G M #,54#( G A E '!,,/. #/5.4%2 D F J D H TIA FIG. 14 310893P 13 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). 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) 1. 2. 3. 4. 5. FIG. 14. Install control board (130b) with four screws (130c). Connect engine wires to control board (130b). Connect at control board (130b): • Ground and clutch wires • Display connector (130m) • Lead from gallon counter sensor (39) • Lead from pump ON/OFF switch (130f) • Lead from WatchDog switch (130g) • Lead from transducer (66) • Lead from potentiometer (130d) Install new strain relief bushings (123 and 130r). Swing up cover (130a) and secure with two screws (71). Pressure Control Transducer Removal Installation 1. WARNING 2. Read Injection Hazard, page 3; Burn Hazard, page 4 1. 2. 3. 4. 3. 4. FIG. 14. Install o-ring (67) and pressure control transducer (66) in filter housing (72). Torque to 35 - 45 ft-lb. Install transducer connector and rubber grommet in control housing. Connect transducer (66) lead to control board (130b). Swing up cover (130a) and secure with two screws (71). FIG. 14. Remove two screws (71) and swing down cover (130a) Disconnect transducer (66) lead from control board (130b). Pull transducer connector through rubber grommet (113). Remove pressure control transducer (66) and o-ring (67) from filter housing (72). Pressure Adjust Potentiometer Removal WARNING Installation 1. 2. Read Injection Hazard, page 3; Burn Hazard, page 4 1. 2. 3. 4. 14 FIG. 14. Remove two screws (71) and swing down cover (130a) Disconnect potentiometer (130d) lead from control board (130b). Loosen set screws on potentiometer knob (130h) and remove knob, shaft nut, lock washer and potentiometer (130d). Remove shaft spacer (130e) from potentiometer. 3. 4. Install shaft spacer (130e) on potentiometer (130d). FIG. 14. Install potentiometer, shaft nut, lock washer and potentiometer knob (130h). a.Turn potentiometer shaft clockwise to internal stop. Assemble potentiometer knob (130h) to strike pin on cover (130a). b.After adjustment of step a., tighten both set screws in knob 1/4 to 3/8 turn after contact with shaft. Connect potentiometer lead to control board (130b). Swing up cover (130a) and secure with two screws (71). 310893P 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. Sprayer may be pressurized Pressure less than 200 psi (14 bar, 1.4 MPa) Increase pressure as needed Sprayer is pressurized. Power is applied. (Pressure varies with tip size and pressure control setting.) Normal operation Spray Sprayer stops. Engine is running. Exceeded pressure limit 1. ti6314a psi bar MPa ti6315a 2. ti6316a 3. 4. Sprayer stops. Engine is running. Pressure transducer faulty, bad connection or broken wire 1. 2. ti6317a 3. Sprayer stops. Engine is running. High clutch current 1. 2. ti6318a 3. Sprayer stops. Engine is running. Loss of paint to pump or severe pressure loss 1. 2. (with constant green LED) 3. Sprayer stops. Engine is running. Pressure greater than 2000 psi (138 bar, 14 MPa) while in Flush Timer Mode 1. 2. Check fluid path for clogs, such as clogged filter Open prime valve and gun if running AutoClean Use Graco paint hose, 1/4 in. x 50 ft minimum. Smaller hose or metal braid hose may result in pressure spikes. Replace transducer if fluid path is not clogged and proper hose is used. Check transducer connection Disconnect and reconnect transducer plug to ensure good connection with control board socket Open prime valve. Replace sprayer transducer with known good transducer and run sprayer. Replace transducer if sprayer runs or control board if sprayer does not run. Check wiring connections. Measure: 1.2 +0.2Ω (GMAX II 3900); 1.7 +0.2Ω (GMAX II 5900/ 7900 & TexSpray 7900HD) across clutch field at 70°F Replace clutch field assembly Check for empty paint condition, clogged inlet strainer, failed pump or severe leak Reduce pressure and turn pump switch OFF and ON to restart pump WatchDog function can be deactivated by turning WatchDog switch OFF Open prime valve and gun Verify no flow obstructions or clogged filter ti6320a * Error codes also appear on control board as a blinking red LED. LED is an alternate to digital messages. 1. 2. Remove two screws (71) and swing down cover (130). Start engine. Blink count is the same as error code(E=0X). 310893P After a fault, follow these steps to restart sprayer: 1. Correct fault condition 2. Turn sprayer OFF 3. Turn sprayer ON 15 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. If pump door is stuck, do steps e., f. and 8., otherwise go to step 9. FIG. 16 FIG. 19 16 310893P 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. Slide pump into connecting rod. Push pump pin until it is fully retained. Note: Pin will snap into position. ti6378a FIG. 25 310893P 17 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. 27 18 310893P Displacement Pump 310893P 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!), ! 2EF TID 2EF 20 310893P 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 310893P Description Qty FRAME, cart (3900) 1 WASHER, flat 2 WHEEL, pneumatic (3900) 2 CLIP, retaining 2 SLEEVE, cart (3900) 2 WASHER 2 PIN, spring straight 2 SCREW, mach, pnh 4 WASHER, lock 4 BUTTON, snap 2 HANDLE, cart 1 WIRE, ground assembly w/ clamp 1 SCREW, thread forming, hex hd 1 CAP, leg 2 ENGINE, gas, 4.0 hp, (3900) 1 SCREW, flange, hex 2 NUT, lock 2 KEY, parallel 1 HOUSING, clutch, mach (3900) 1 SCREW, cap, hex hd 4 WASHER, lock 4 COLLAR, shaft 1 SCREW, hex, socket head 6 WASHER, lock, spring (hi-collar) 10 ARMATURE, clutch, 4in. (3900) 1 HUB, armature 1 ROTOR, clutch, 4 in. (3900) 1 SCREW, cap, sch 4 HOUSING, pinion, (3900) 1 WASHER, thrust (brass) 1 WASHER, thrust (steel) 1 GEAR, combination (3900) 1 HOUSING, drive (3900) 1 MAGNET 1 SCREW, cap, flnghd 1 SCREW, hex washer hd (3900) 10 SWITCH, reed w/connector 1 HOUSING, bearing (3900) 1 SCREW, cap, socket hd 4 WASHER, lock spring 4 ROD, connecting (3900) 1 COVER, front, includes 45 (3900) 1 SCREW, mach hex wash hd 4 Ref 47 67 68 69 72 76 82 83 84 86 87 89 90 93* 94* 99 100 101 107 108* 115 119 120▲ 121▲ 122 125▲ 127 129 130 * 132 133 134* 143 164 ▲ * † Part Description Qty 287512 PUMP, displacement, (3900) 1 includes 86, 89, 90 111457 O-RING 1 244240 HOSE, coupled, includes 69 1 241920 DEFLECTOR, threaded 1 15F250 WASHER, thrust (3900) 1 114678 BUSHING, strain relief 1 189920 STRAINER, (1-11 1/2 npsm) 1 114271 STRAP, retaining 1 238049 FLUID, TSL, 4 oz (not shown) 1 15E802 FITTING, pump, quick disconnect 1 287419 HOSE, coupled 1 15E807 TUBE, INTAKE (3900) 1 118494 O-RING 1 287253 TOOL BOX, includes 94 1 118852 SCREW, machine, hex washer hd 3 113161 SCREW, flange, hex hd 3 15E736 BRACKET, holder, manual 1 119510 HOLDER, manual 1 15F109 PIN, pump (3900) 1 114528 SCREW, MACH, PHILLIPS, PNHD 2 15F755 LABEL, identification 1 15E851 LABEL, identification 1 15F638 LABEL, danger, English 1 194126 LABEL, warning 1 290228 LABEL, caution 1 195119 LABEL, warning 1 119569 BUSHING, strain relief 1 119579 CONDUCTOR, ground 1 BOX, control 1 287648 Premium 1 287649 Standard 1 119676 SPRING, RETAINING (3900) 1 114687 CLIP, RETAINER 1 15F354 FUNNEL, OIL (shown on page 5) 1 116038 WASHER, wave spring 2 119790 O-RING 1 Replacement Danger and Warning labels, tags, and cards are available at no cost. Premium sprayers only Included in Clutch Replacement Kit 241109 21 Parts GMAX ll 5900/5900HD Parts Drawing $%4!), ! 2EF ,ABEL 3EE PAGE FOR PARTS 3EE MANUAL FOR PARTS 3EE PAGE FOR PARTS 3EE PAGE FOR PARTS 5SED ON (IGH BOYS SEE PAGE FOR ,OW BOY .OT USED ON ($ 2EF "OTTOM 6IEW A 2EF B 2EF $%4!), ! 2EF TIE 2EF 22 310893P 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 310893P Description Qty FRAME, cart (5900/7900) 1 WASHER, flat 2 WHEEL, pneumatic (5900/7900) 2 CLIP, retaining 2 SLEEVE, cart (5900/7900) 2 WASHER 2 PIN, spring straight 2 SCREW, mach, pnh 5 BUTTON, snap 2 HANDLE, cart 1 WIRE, ground assembly w/ clamp 1 SCREW, thread forming, hex hd 1 CAP, leg 2 ENGINE, gas, 5.5 hp, (5900) 1 SCREW, flange, hex 2 NUT, lock 2 KEY, parallel 1 HOUSING, clutch, mach (5900/7900) 1 SCREW, cap, hex hd 4 WASHER, lock 4 COLLAR, shaft 1 SCREW, hex, socket head 6 WASHER, lock, spring (hi-collar) 10 ARMATURE, clutch, 5 in. (5900/7900) 1 HUB, armature 1 ROTOR, clutch, 5 in. (5900/7900) 1 SCREW, cap, sch 4 HOUSING, pinion, 5900 1 WASHER, thrust (brass) 2 WASHER, thrust (steel) 1 GEAR, combination (5900) 1 HOUSING, drive (5900) 1 MAGNET 1 SCREW, cap, flnghd 1 SCREW, cap sch (5900/7900) 4 WASHER, lock, spring (5900/7900) 4 SCREW, mach hex hd (5900/7900) 6 SWITCH, reed w/connector 1 HOUSING, bearing (5900) 1 SCREW, cap, socket hd 4 WASHER, lock spring (hi-collar) 4 ROD, connecting (5900) 1 COVER, front, (5900), includes 45 1 SCREW, mach hex wash hd 4 Ref 47 Part 287513 287579 67 111457 68 244240 69 241920 76 114678 82 189920 83 114271 84 238049 86 15E802 87 287419 89 15E806 90 118494 93* 287253 94* 118852 99 113161 100 15E736 101 119510 107 15F110 108* 114528 115 15E854 119 15E852 15E980 120▲ 15F638 121▲ 194126 122 290228 125▲ 195119 127 119569 130 * 287648 287649 132 119778 133 114687 134* 15F354 143 116038 164 119790 165 15G584 ▲ * † Description Qty PUMP, displacement (5900), includes 86, 89, 90 1 (5900HD), includes 86, 164 1 O-RING 1 HOSE, coupled, includes 69 1 DEFLECTOR, threaded 1 BUSHING, strain relief 1 STRAINER, (1-11 1/2 npsm) 1 STRAP, retaining 1 FLUID, TSL, 4 oz (not shown) 1 FITTING, pump, quick disconnect 1 HOSE, coupled 1 TUBE, INTAKE 1 O-RING 1 TOOL BOX, includes 94 1 SCREW, machine, hex washer hd 3 SCREW, flange, hex hd 3 BRACKET, holder, manual 1 HOLDER, manual 1 PIN, pump (5900) 1 SCREW, MACH, PHILLIPS, PNHD 2 LABEL, identification 1 LABEL, identification (5900) 1 (5900HD) 1 LABEL, warning 1 LABEL, warning 1 LABEL, caution 1 LABEL, warning 1 BUSHING, strain relief 1 BOX, control 1 Premium 1 Standard 1 SPRING, RETAINING (5900) 1 CLIP, RETAINER 1 FUNNEL, OIL (shown on page 5) 1 WASHER, wave spring 2 O-RING 1 RECEIVER, clamp 1 Replacement Danger and Warning labels, tags, and cards are available at no cost. Premium sprayers only Included in Clutch Replacement Kit 241113 23 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!), ! TexSpray 7900HD Only 2EF TID 2EF 24 310893P 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 310893P Description FRAME, cart (5900/7900) WASHER, flat WHEEL, pneumatic (5900/7900) CLIP, retaining SLEEVE, cart (5900/7900) WASHER PIN, spring straight SCREW, mach, pnh BUTTON, snap HANDLE, cart WIRE, ground assembly w/ clamp SCREW, thread forming, hex hd CAP, leg ENGINE, gas, 6.5 hp, (7900) SCREW, flange, hex NUT, lock KEY, parallel HOUSING, clutch, mach (5900/7900) SCREW, cap, hex hd WASHER, lock COLLAR, shaft SCREW, hex, socket head WASHER, lock, spring (hi-collar) ARMATURE, clutch, 5 in. (5900/7900) HUB, armature ROTOR, clutch, 5 in. (5900/7900) SCREW, cap, sch HOUSING, pinion, 7900 WASHER, thrust (brass) WASHER, thrust (steel) GEAR, combination (7900) HOUSING, drive (7900) MAGNET SCREW, cap, flnghd SCREW, cap sch (5900/7900) WASHER, lock, spring (5900/7900) SCREW, mach hex hd(5900/7900) SWITCH, reed w/connector HOUSING, bearing (7900) SCREW, cap, socket hd WASHER, lock spring (hi-collar) ROD, connecting (7900) COVER, front, (7900), includes 45 SCREW, mach hex wash hd PUMP, displacement (7900), includes 86, 89, 90 PUMP, displacement (TexSpray 7900HD), includes 86, 164 O-RING Qty 1 2 2 2 2 2 2 4 2 1 1 1 2 1 2 2 1 1 4 4 1 6 10 1 1 1 4 1 2 1 1 1 1 1 4 4 6 1 1 4 4 1 1 5 1 1 Ref 68 69 75 76 82 83 84 86 87 89✿ 90✿ 93✿ 94✿ 99 100 101 107 108* 109* 115 119 Part 109450 244240 241920 15F584 114678 189920 114271 238049 15E802 15G509 287419 289282 248215 118494 287253 118852 113161 15E736 119510 15F097 114528 15F947 15E854 15E853 15M962 120▲ 15F638 121▲ 194126 122 290228 125▲ 195119 127 119569 130 * 287648 287649 132 119677 133 114687 134* 15F354 143 116038 164 119790 109450 Description O-RING (TexSpray 7900HD only) HOSE, coupled, includes 69 DEFLECTOR, threaded LABEL, ProConnect BUSHING, strain relief STRAINER, (1-11 1/2 npsm) STRAP, retaining FLUID, TSL, 4 oz (not shown) FITTING, pump, quick disconnect FITTING, pump, quick disconnect (TexSpray 7900HD only) HOSE, coupled HOSE, coupled (TexSpray 7900HD only) TUBE, INTAKE O-RING TOOL BOX, includes 94 SCREW, machine, hex washer hd SCREW, flange, hex hd BRACKET, holder, manual HOLDER, manual PIN, pump (7900) SCREW, MACH, PHILLIPS, PNHD SHIELD, magnetic LABEL, identification LABEL, identification LABEL, front (TexSpray 7900HD only) LABEL, danger, English LABEL, warning LABEL, caution LABEL, warning BUSHING, strain relief BOX, control Premium Standard SPRING, RETAINING (7900) CLIP, RETAINER FUNNEL, OIL (shown on page 5) WASHER, wave spring O-RING O-RING (TexSpray 7900HD only) Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. * Premium sprayers only † Included in Clutch Replacement Kit 241113 ✿ Not used on TexSpray 7900HD 1 25 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 7900HD GEAR, driving, first 3900 5900/7900/TexSpray 7900HD RING, retaining, large 3900 5900/7900/TexSpray 7900HD PIN, dowel O-RING 3900 5900/7900/TexSpray 7900HD WASHER, thrust, steel 3900 5900/7900/TexSpray 7900HD Qty 1 1 1 Ref 33 33a Part 116191 116192 33b 107089 194173 1 1 Description DRIVE HOUSING WASHER, thrust, steel 3900 5900/7900/TexSpray 7900HD WASHER, thrust, brass 3900 5900/7900/TexSpray 7900HD Qty 1 1 1 1 1 1 1 2 1 1 1 1 28 Ref 24 Ref 27 Ref 29b 29a 29c 29 33a 33b 33 30,72 Ref 29d 30 Ref 38 Ref 34 Ref * 1 38 Ref 32 Ref 31 Ref 109 Ref ti5494c 1 * Pinion housing (29) includes clutch field ✬ Premium models 26 * 39 Ref 108 Ref * 310893P 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 3900/5900 287988 288038 includes 82, 109 (suction hose), 1 110, 111, 112, 114, 115 HOSE, suction 7900 288114 288039 includes 82, 109 (suction hose), 1 110, 111, 112, 114, 115 15C980 NUT, jam 1 15H854 O-RING 2 15C981 WASHER, suction, swivel 1 118505 RING, retaining, external 1 CLIP, drain line 15D000 3900/5900 1 196723 7900 1 SCREW 108795 3900/5900 2 NONE 7900 TUBE 15E952 3900/5900 1 NONE 7900 241920 DEFLECTOR 1 HOSE, drain, includes 155 287654 3900/5900 1 246331 7900 1 TUBE, suction 15F149 3900/5900 1 15F171 7900 1 15F909 TUBE, angle 1 120330 CLAMP, hose 2 HOSE, suction 15H393 3900/5900 1 15H787 7900 1 176450 GUARD, hose 1 310893P 159 157 109 115 82 161 156 155 153 1 154 1 111 114 159 ti5755b 1 90 112 110 158 Used on 3900 5900 27 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 A 3TANDARD 0REMIUM -ODELS -ODELS 4EX3PRAY ($ 0ART .UMBER 3TANDARD 0ART .UMBER A R B C G K F D E A J D H 28 TID 310893P 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 119541 116167 195428 15E857 287515 15E855 15E858 119545 245103 150a†◆ 193710 310893P DESCRIPTION QTY Filter Replacement Kit 3900/5900 7900 CAP, filter 1 O-RING 1 TUBE, diffusion 1 FILTER, fluid 1 HANDLE 1 PIN, grooved 1 BASE, valve 1 VALVE, drain, replacement kit 1 SEAT, valve 1 GASKET, seat, valve 1 ADAPTER (3900/5900) 1 (7900/TexSpray 5900HD/7900HD) 1 TRANSDUCER, pressure contl 1 O-RING 1 SCREW, mach, pnh, sems 6 HOUSING, filter 1 HOSE, coupled 1 HOSE, coupled 1 (TexSpray 7900HD) VALVE, auto clean, includes 91a 1 GASKET 1 KIT, repair, clamp, trigger 1 PLUG, pipe 1 GASKET, TRANSDUCER 1 BUSHING, strain, relief 1 CONTROL BOX BOX, premium 1 BOX, standard 1 CONTROL, board 1 SCREW, pan head 4 POTENTIOMETER 1 SPACER, shaft 1 SWITCH, rocker 1 SWITCH, toggle 1 KNOB, potentiometer 1 BOOT, toggle 1 LABEL, identification 1 DISPLAY, LCD, GMAX 1 LABEL 1 LABEL, identification 1 BUSHING, strain relief 1 DRAIN VALVE (7900/TexSpray 7900HD) SEAL, valve 1 REF PART 150b†◆ 193709 150c†◆ 114797 150d†◆ 150e†◆ 114708 150f†◆ 15G563 150g†◆ 116424 151 248314 152 15D541 DESCRIPTION SEAT, valve GASKET VALVE ASSEMBLY SPRING, compression HANDLE, valve NUT, cap, hex, hd PLUG, (Standard) includes 152 O-RING, Standard) 160* 287648 161 287649 CONTROL, premium, complete (includes 130b-130r) CONTROL, standard, complete (includes 130b-130r) ★ † ‡ ◆ * Included in Filter Replacement Kit 287510 Included in Filter Replacement Kit 287517 Included in Drain Valve Replacement Kit 235014 Included in Drain Valve Replacement Kit 245103 Premium models only QTY 1 1 1 1 1 1 1 1 1 1 DRIVE PINON Pressure Control Wiring Diagram ti5496a CLUTCH TEST POINTS TO GROUND 3900 CONTROL BOARD TO ENGINE PUMP STROKE COUNTER 5900/7900 LED D12 J10 J2 J1 J3 J4 J5 J9 ON/ OFF SWITCH TRANSDUCER WATCHDOG POTENTIOMETER PREMIUM DISPLAY BOARD 29 Parts - Sprayers, RAC™ X Tip, Gun & Hose Parts - Sprayers, RAC™ X Tip, Gun & Hose Ref 40: Bearing Housing 141 40 163 106 165 166 104 105 79 142 TIA Ref 40 Part 287932 287933 287934 45 79 104 118444 15E975 Ref 202 Part 240794 240797 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, 22.8 MPa) (3900/5900) HOSE, grounded, nylon; 3/8 in. ID; cpld 1 1/4 npsm(fbe); 50 ft (15 m); spring guards both ends; 3300 psi (228 bar, 22.8 MPa) (5900HD/7900/TexSpray 7900HD) CONTRACTOR II SPRAY GUN 1 Includes RAC X 517-size SwitchTip and HandTite Guard. See 311861 for parts. (3900/5900/7900) TEXTURE SPRAY GUN 1 Includes LTX531 SwitchTip and Guard. See 308491 for parts. (5900HD/TexSpray 7900HD) BUSHING, 3/8 x 1/4 in. (5900HD/7900) 1 HOSE, whip 1/4 in. x 3 ft 1 (TexSpray 7900HD) 15E779 15E625 105 15G930 15G890 106 141 142 163 165 166 102040 111040 15F503 15F498 15F116 15G840 15G584 108859 116942 45 Description HOUSING, bearing (3900) HOUSING, bearing (5900) HOUSING, bearing (7900/TexSpray 7900HD) SCREW, mach hex wash hd CLIP, spring PIN, housing, bearing 3900 5900/7900/TexSpray 7900HD LATCH, housing, bearing 3900 5900/7900/TexSpray 7900HD NUT, lock hex 3900 5900/7900/TexSpray 7900HD SCREW, set, socket hd SCREW, adjustment LATCH RECEIVER, latch (3900) RECEIVER, latch (5900/7900/TexSpray 7900HD) SCREW, shoulder, sch (3900) SCREW, shoulder, sch (5900/7900/TexSpray 7900HD) Qty 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 310893P 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 (6.06 liter/min) 2.20 gpm (8.33 liter/min) 1 gun with 0. 036 in. tip 2 guns with 0. 023 in. tip 3 guns with 0. 018 in. tip 1 gun with 0. 043 in. tip 2 guns with 0. 029 in. tip 3 guns with 0. 023 in. tip 4 guns with 0. 019 in. tip 1 gun with 0. 048 in. tip 2 guns with 0. 035 in. tip 3 guns with 0. 027 in. tip 4 guns with 0. 023 in. tip 12 mesh (893 micron) stainless steel screen, reusable 60 mesh (250 micron) stainless steel screen, reusable 1-5/16–12 UN-2A ¼ npsm from fluid filter 3/8 npsm from fluid filter zinc-plated carbon steel, PTFE, nylon, polyurethane, UHMW polyethylene, fluoroelastomer, acetal, leather, aluminum, tungsten carbide, nickel- and zinc-plated carbon steel, stainless steel, chrome plating 5900/5900HD 7900 Inlet paint strainer Outlet paint filter Pump inlet size Fluid outlet size: 3900/5900 Fluid outlet size: 7900 Wetted parts Dimensions Sprayer (no hose and gun) 3900 5900 7900 TexSpray 7900HD 310893P Weight lb (kg) Height in. (cm) Width in. (cm) Length in. (cm) 109 (50) 139 (64) 146 (67) 157 (71) 31.5 (80.0) 32.25 (81.9) 32.25 (81.9) 32.25 (81.9) 22.25 (56.5) 24.5 (62.2) 24.5 (62.2) 24.5 (62.2) 32.0 (81.3) 32.25 (81.9) 33.0 (83.8) 33.0 (83.8) 31 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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program. TO PLACE AN ORDER, contact your Graco distributor, or call 1-800-690-2894 to identify the nearest distributor. All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 310893 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 Copyright 2005, Graco inc. is registered to ISO 9001 www.graco.com 2/2005 Rev. 05/2011 32 310893P
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