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

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Page Count: 32

Manual Conventions
Warning
Maintenance
Troubleshooting
Bearing Housing and Connecting Rod
Drive Housing
Pinion Assembly/Clutch Armature/Clamp
Clutch Housing
Pressure Control
Displacement Pump
Parts
Parts Drawing and List - Pinion Housing, Drive Housing
LoBoy Suction Set Kits (Kits include suction set and drain hose)
Pressure Control and Filter Parts Drawing
Pressure Control and Filter Parts List
Parts - Sprayers, RAC™ X Tip, Gun & Hose
Technical Data
Graco Standard Warranty

310893P

Repair

GMAX™ II 3900/5900/7900

TexSpray™ 5900HD/7900HD

Airless Sprayers

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.

GMAX ll 3900

248683 ✓✓

248684 ✓✓

248685 ✓✓

248686 ✓✓

249335 ✓✓

GMAX ll 5900

248687 ✓✓

248688 ✓✓

248689 ✓✓

248690 ✓✓

249336 ✓✓

TexSpray 5900HD

248699 ✓✓

GMAX ll 7900

248700 ✓✓

248701 ✓✓

248702 ✓✓

248703 ✓✓

249337 ✓✓

TexSpray 7900HD

255632 ✓✓

ti5474a

ti5475a

ti5447a

Related Manuals

310892 311861

308491

310894 309640

ENG

Manual Conventions

2310893P

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

Note

WARNING

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.

Hazard Symbol

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or

destruction of equipment.

Additional helpful information.

Warning

310893P 3

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.

Warning

4310893P

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 mon-

oxide 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.

WARNING

Maintenance

310893P 5

Maintenance

Pressure Relief Procedure

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. 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.

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check that all hose fittings are secure.

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 pack-

ing 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.

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 ele-

ment. 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.

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4.

CAUTION

For detailed engine maintenance and specifications,

refer to separate Honda Engines Owner's Manual,

supplied.

ti6200a

OIL FUNNEL

Troubleshooting

6310893P

Troubleshooting

Problem Cause Solution

E=XX is displayed Fault condition exists Determine fault correction from table, page 15

Engine will not start Engine switch is OFF Turn engine switch ON

Engine is out of gasoline Refill gas tank. Honda Engines Owner's Man-

ual.

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

False tripping of WatchDog system.

EMPTY is displayed. Pump does not

run.

Operating conditions out of WatchDog

parameters

Pump output is low, page 7.

Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.

Operate without WatchDog active; Manual

310892.

Engine operates, but displacement

pump does not operate

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.

Tip or tip filter is clogged

Clean tip or tip filter. Manual 309639.

Displacement pump piston rod is stuck

due to dried paint

Repair pump. Manual 310894.

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

field

Check wiring connections. Page 12.

Reference

Digital Display Messages

. Page

Reference wiring diagram. Page 29.

With pump switch ON and pressure turned to MAXI-

MUM, 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

positioned

Adjust or replace clutch. Page 10.

Pinion assembly is worn or damaged Repair or replace pinion assembly. Page10.

Troubleshooting

310893P 7

Problem Cause Solution

Pump output is low 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

dirty

Clean filter. Manual 310892 or 309639.

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).

Excessive paint leakage into throat

packing nut

Throat packing nut is loose Remove throat packing nut spacer. Tighten

throat packing nut just enough to stop leak-

age.

Throat packings are worn or damaged

Replace packings. Manual 310894.

Displacement rod is worn or damaged

Replace rod. Manual 310894.

Fluid is spitting from gun Air in pump or hose

Check and tighten all fluid connections. Rep-

rime 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.

Pump is difficult to prime 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

when new and may cause noise

Clutch surfaces need to wear into each

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.

Displaced or missing magnet.

Check connections. Replace sensor or

wire. Reposition or replace magnet.

No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.

Bearing Housing and Connecting Rod

8310893P

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 alter-

nate part and item number.

Removal

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. Inspect crank (B) and connecting rod (43) for excessive

wear and replace parts as needed.

Installation

1. 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.

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.

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.

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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.

FIG. 1

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

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TIB



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1Oil

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

Drive Housing

310893P 9

Drive Housing

Removal

1. Relieve pressure; page 5.

2. Remove bearing housing. Refer to Bearing Housing and

Connecting Rod, Removal, page 8.

3. Premium sprayers: Remove two screws (108) and gallon

counter sensor (39).

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.

Installation

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).

7. Install bearing housing. Refer to Bearing Housing and

Connecting Rod, Installation, page 8.

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.

FIG. 3

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

CAUTION

Premium models: Gallon counter sensor is connected to con-

trol board in pressure control. Pulling on the sensor wires could

cause damage.

CAUTION

Thrust washers may stick to grease inside of drive housing.

Do not lose or misplace.

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.

FIG. 2

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TIA





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B

A





Gallon counter sensor

Pack with grease 114819

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)



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Copper

Steel

Pinion Assembly/Clutch Armature/Clamp

10 310893P

Pinion Assembly/Clutch Armature/Clamp

Pinion Assembly/Clutch Armature Removal

Pinion Assembly

If pinion assembly (29) is not removed from clutch housing

(19), do 1. through 3. Otherwise, start at 4.

1. Remove drive housing; page 9.

2. FIG. 4. Disconnect clutch cable connectors from inside of

pressure control.

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.

FIG. 4

. Remove four screws (36) and pinion assembly (29).

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.

FIG. 5

6. FIG. 6. Remove retaining ring (29b).

7. Turn pinion assembly over and tap pinion shaft (29a) out

with plastic mallet.

FIG. 6

Clutch Armature

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).

10. Remove armature.

FIG. 7

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

ti5480a

ti5481a

ti5987b

29b

29a

ti5482a

29d

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TIA

Pinion Assembly/Clutch Armature/Clamp

310893P 11

Installation

Clutch Armature

1. FIG. 8. Lay two stacks of two dimes on smooth bench

surface.

2. Lay armature (25) on two stacks of dimes.

3. Press center of hub (26) down to bench surface.

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.

2. Drain gasoline from tank according to Honda manual.

FIG. 9

. Tip engine on side so gas tank is down and air

cleaner is up.

4. FIG. 10. Loosen two screws (24) on clamp (22),

5. Push screwdriver into slot in clamp (22) and remove

clamp.

FIG. 9

Clamp Installation

1. FIG. 10. Install engine shaft key (18)

2. Tap clamp (22) onto engine shaft (A). Maintain dimension

shown note 2. Chamfer must face engine.

3. 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)

Face of clutch housing

1.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3900

2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 & 7900

Torque to 125 ±.10 in-lb (14 ±1.1 N·m)

Chamfer this side

FIG. 10

0.12+01 in (3.0+.25 mm)

25 26

dimes

ti6321a

WARNING

Gasoline can spill and cause a fire or explosion if

engine is tipped on side.

ti6199a

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Clutch Housing

12 310893P

Clutch Housing

Removal

1. FIG. 11. 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. FIG. 11. 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).

FIG. 11

Engine

Removal

NOTE: All service to the engine must be performed by

an authorized HONDA dealer.

1. Remove Pinion Assembly/Clutch Armature/Clamp and

Clutch Housing, as instructed on pages 9, 10 and 11.

2. FIG. 12. Disconnect all necessary wiring.

3. FIG. 13. Remove two locknuts (17) and screws (16) from

base of engine.

4. Lift engine carefully and place on work bench.

FIG. 12

FIG. 13

Installation

1. Lift engine carefully and place on cart.

2. FIG. 13. Install two screws (16) in base of engine and

secure with locknuts (17). Torque to 26 ft-lb (22.6 N·m).

3. FIG. 12. Connect all necessary wiring.

4. Install Pinion Assembly/Clutch Armature/Clamp and

Clutch Housing, as instructed on pages 9, 10 and 11.

ti5486a

To the field

To the engine

3To gallon counter

4To ground

Green

ti5485b

Bottom View

5900/7900

Bottom View

3900

ti5487a

Pressure Control

310893P 13

Pressure Control

Pump ON/OFF Switch

Removal

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.

Installation

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).

FIG. 14

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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Pressure Control

14 310893P

Control Board

Removal

1. FIG. 14. Remove two screws (71) and swing down

cover (130a)

2. Remove strain relief bushings (130r and 123).

3. 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

4. Remove four screws (130c) and control board (130b).

Installation

FIG. 14

. Install control board (130b) with four screws (130c).

2. Connect engine wires to control board (130b).

3. 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)

4. Install new strain relief bushings (123 and 130r).

5. Swing up cover (130a) and secure with two screws (71).

Pressure Control Transducer

Removal

1. FIG. 14. Remove two screws (71) and swing down

cover (130a)

2. Disconnect transducer (66) lead from control board

(130b).

3. Pull transducer connector through rubber grommet (113).

4. Remove pressure control transducer (66) and o-ring (67)

from filter housing (72).

Installation

1. FIG. 14. Install o-ring (67) and pressure control transducer

(66) in filter housing (72). Torque to 35 - 45 ft-lb.

2. Install transducer connector and rubber grommet in

control housing.

3. Connect transducer (66) lead to control board (130b).

4. Swing up cover (130a) and secure with two screws (71).

Pressure Adjust Potentiometer

Removal

1. FIG. 14. Remove two screws (71) and swing down

cover (130a)

2. Disconnect potentiometer (130d) lead from control board

(130b).

3. Loosen set screws on potentiometer knob (130h) and remove

knob, shaft nut, lock washer and potentiometer (130d).

4. Remove shaft spacer (130e) from potentiometer.

Installation

1. Install shaft spacer (130e) on potentiometer (130d).

2. 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.

3. Connect potentiometer lead to control board (130b).

4. Swing up cover (130a) and secure with two screws (71).

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

Pressure Control

310893P 15

Digital Display Messages

* Error codes also appear on control board as a blinking red

LED. LED is an alternate to digital messages.

1. Remove two screws (71) and swing down cover (130).

2. Start engine. Blink count is the same as error code(E=0X).

After a fault, follow these steps to restart sprayer:

1. Correct fault condition

2. Turn sprayer OFF

3. Turn sprayer ON

WARNING

Relieve pressure before repair, page 5.

DISPLAY* SPRAYER OPERATION INDICATION ACTION

No Display 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. Check fluid path for clogs, such as clogged

filter

2. Open prime valve and gun if running

AutoClean

3. Use Graco paint hose, 1/4 in. x 50 ft

minimum. Smaller hose or metal braid

hose may result in pressure spikes.

4. Replace transducer if fluid path is not

clogged and proper hose is used.

Sprayer stops. Engine is running. Pressure transducer faulty,

bad connection or broken

wire

1. Check transducer connection

2. Disconnect and reconnect transducer plug

to ensure good connection with control

board socket

3. 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.

Sprayer stops. Engine is running. High clutch current 1. Check wiring connections.

Measure: 1.2 +0.2

(GMAX II 3900);

1.7 +0.2Ω (GMAX II 5900/ 7900 &

TexSpray 7900HD)

across clutch field at 70°F

3. Replace clutch field assembly

Sprayer stops. Engine is running. Loss of paint to pump or

severe pressure loss

1. Check for empty paint condition, clogged inlet

strainer, failed pump or severe leak

2. Reduce pressure and turn pump switch

OFF and ON to restart pump

3. WatchDog function can be deactivated by

turning WatchDog switch OFF

Sprayer stops. Engine is running. Pressure greater than

2000 psi (138 bar, 14 MPa)

while in Flush Timer Mode

1. Open prime valve and gun

2. Verify no flow obstructions or clogged filter

ti6314a

psi

bar

MPa

ti6315a

ti6316a

ti6317a

ti6318a

ti6320a

• 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

(with constant

green LED)

Displacement Pump

16 310893P

Displacement Pump

Removal

1. Flush pump.

2. Stop pump with piston rod in its lowest position.

3. Do Pressure Relief, page 5.

4. Separate drain hose from sprayer

FIG. 15

5. Disconnect material hose from pump.

FIG. 16

6. Raise latch lock. Push latch open.

FIG. 17

7. FIG. 18. Ratchet open pump door.

a. Ratchet pump door forward.

FIG. 18

b. Twist latch u-bolt out of pump door recess.

c. Place u-bolt on pump door outer edge.

d. If pump door is stuck, do steps e., f. and 8., otherwise

go to step 9.

FIG. 19

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

Displacement Pump

310893P 17

e. Twist latch u-bolt back from pump door outer edge

f. Place u-bolt on pump door protrusion

FIG. 20

8. Ratchet pump door forward.

FIG. 21

9. Open pump door.

FIG. 22

10. FIG. 23. Pull out pump pin and place in pin holder

FIG. 23

Installation

1. FIG. 24. 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.

FIG. 24

FIG. 25

. Slide pump into connecting rod. Push pump pin until it

is fully retained.

Note: Pin will snap into position.

FIG. 25

ti6325a

ti6378a

Displacement Pump

18 310893P

4. FIG. 26. Close pump door and rotate latch into position.

Do not tighten latch.

5. FIG. 26. Rotate pump to align with material hose. Connect

material hose and hand tighten to 70 in-lb

FIG. 26

FIG. 27

. Tighten latch and rotate latch lock into locked position.

FIG. 27

7. FIG. 28. Attach drain hose to sprayer.

FIG. 28

8. FIG. 29. Fill pump with Graco TSL until fluid flows onto top

of seal.

FIG. 29

Displacement Pump

310893P 19

Parts

20 310893P

Parts

GMAX ll 3900 Parts Drawing

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Parts

310893P 21

GMAX ll 3900 Parts List

Ref Part Description Qty

1 287411 FRAME, cart (3900) 1

2 156306 WASHER, flat 2

3 119420 WHEEL, pneumatic (3900) 2

4 15E891 CLIP, retaining 2

5 192027 SLEEVE, cart (3900) 2

6 183350 WASHER 2

7 108068 PIN, spring straight 2

8 109032 SCREW, mach, pnh 4

8a 100020 WASHER, lock 4

9 112827 BUTTON, snap 2

10 245245 HANDLE, cart 1

11 237686 WIRE, ground assembly w/ clamp 1

12 112798 SCREW, thread forming, hex hd 1

14 15C871 CAP, leg 2

15 108879 ENGINE, gas, 4.0 hp, (3900) 1

16 110837 SCREW, flange, hex 2

17 110838 NUT, lock 2

18 183401 KEY, parallel 1

19 15E535

HOUSING, clutch, mach (3900)

20 108842 SCREW, cap, hex hd 4

21 100214 WASHER, lock 4

22 193680 COLLAR, shaft 1

23† 108803 SCREW, hex, socket head 6

24† 105510 WASHER, lock, spring (hi-collar) 10

25† ARMATURE, clutch, 4in. (3900) 1

26† HUB, armature 1

27† ROTOR, clutch, 4 in. (3900) 1

28† 101682 SCREW, cap, sch 4

29 287463 HOUSING, pinion, (3900) 1

30 114672 WASHER, thrust (brass) 1

31 114699 WASHER, thrust (steel) 1

32 287653 GEAR, combination (3900) 1

33 287467 HOUSING, drive (3900) 1

34* 116618 MAGNET 1

35 112395 SCREW, cap, flnghd 1

36 119426 SCREW, hex washer hd (3900) 10

39* 119562 SWITCH, reed w/connector 1

40 287932

HOUSING, bearing (3900)

41 113467 SCREW, cap, socket hd 4

42 104008 WASHER, lock spring 4

43 287471 ROD, connecting (3900) 1

44 287521 COVER, front, includes 45 (3900) 1

45 118444 SCREW, mach hex wash hd 4

47 287512 PUMP, displacement, (3900)

includes 86, 89, 90

67 111457 O-RING 1

68 244240 HOSE, coupled, includes 69 1

69 241920 DEFLECTOR, threaded 1

72 15F250 WASHER, thrust (3900) 1

76 114678 BUSHING, strain relief 1

82 189920 STRAINER, (1-11 1/2 npsm) 1

83 114271 STRAP, retaining 1

84 238049 FLUID, TSL, 4 oz (not shown) 1

86 15E802 FITTING, pump, quick disconnect 1

87 287419 HOSE, coupled 1

89 15E807 TUBE, INTAKE (3900) 1

90 118494 O-RING 1

93* 287253 TOOL BOX, includes 94 1

94* 118852 SCREW, machine, hex washer hd 3

99 113161 SCREW, flange, hex hd 3

100 15E736 BRACKET, holder, manual 1

101 119510 HOLDER, manual 1

107 15F109 PIN, pump (3900) 1

108* 114528 SCREW, MACH, PHILLIPS, PNHD 2

115 15F755 LABEL, identification 1

119 15E851 LABEL, identification 1

120▲15F638 LABEL, danger, English 1

121▲194126 LABEL, warning 1

122 290228 LABEL, caution 1

125▲195119 LABEL, warning 1

127 119569 BUSHING, strain relief 1

129 119579 CONDUCTOR, ground 1

130 BOX, control 1

* 287648 Premium 1

287649 Standard 1

132 119676 SPRING, RETAINING (3900) 1

133 114687 CLIP, RETAINER 1

134* 15F354 FUNNEL, OIL (shown on page 5) 1

143 116038 WASHER, wave spring 2

164 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

Ref Part Description Qty

Parts

22 310893P

GMAX ll 5900/5900HD Parts Drawing

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Parts

310893P 23

GMAX ll 5900/5900HD Parts List

Ref Part Description Qty

1 287370 FRAME, cart (5900/7900) 1

2 156306 WASHER, flat 2

3 119509 WHEEL, pneumatic (5900/7900) 2

4 15E891 CLIP, retaining 2

5 187604 SLEEVE, cart (5900/7900) 2

6 183350 WASHER 2

7 108068 PIN, spring straight 2

8 108795 SCREW, mach, pnh 5

9 112827 BUTTON, snap 2

10 245245 HANDLE, cart 1

11 237686 WIRE, ground assembly w/ clamp 1

12 112798 SCREW, thread forming, hex hd 1

14 276974 CAP, leg 2

15 114530 ENGINE, gas, 5.5 hp, (5900) 1

16 110837 SCREW, flange, hex 2

17 110838 NUT, lock 2

18 183401 KEY, parallel 1

19 15E277

HOUSING, clutch, mach (5900/7900)

20 108842 SCREW, cap, hex hd 4

21 100214 WASHER, lock 4

22 193680 COLLAR, shaft 1

23† 108803 SCREW, hex, socket head 6

24† 105510 WASHER, lock, spring (hi-collar) 10

25†

ARMATURE, clutch, 5 in. (5900/7900)

26† HUB, armature 1

27† ROTOR, clutch, 5 in. (5900/7900) 1

28† 101682 SCREW, cap, sch 4

29 287465 HOUSING, pinion, 5900 1

30 114672 WASHER, thrust (brass) 2

31 114699 WASHER, thrust (steel) 1

32 287460 GEAR, combination (5900) 1

33 287469 HOUSING, drive (5900) 1

34* 116618 MAGNET 1

35 112395 SCREW, cap, flnghd 1

36 102962 SCREW, cap sch (5900/7900) 4

37 104008 WASHER, lock, spring (5900/7900) 4

38 15C753 SCREW, mach hex hd (5900/7900) 6

39* 119562 SWITCH, reed w/connector 1

40 287933

HOUSING, bearing (5900)

41 114666 SCREW, cap, socket hd 4

42 106115 WASHER, lock spring (hi-collar) 4

43 287472 ROD, connecting (5900) 1

44 287511 COVER, front, (5900), includes 45 1

45 118444 SCREW, mach hex wash hd 4

47 PUMP, displacement

287513 (5900), includes 86, 89, 90 1

287579 (5900HD), includes 86, 164 1

67 111457 O-RING 1

68 244240 HOSE, coupled, includes 69 1

69 241920 DEFLECTOR, threaded 1

76 114678 BUSHING, strain relief 1

82 189920 STRAINER, (1-11 1/2 npsm) 1

83 114271 STRAP, retaining 1

84 238049 FLUID, TSL, 4 oz (not shown) 1

86 15E802 FITTING, pump, quick disconnect 1

87 287419 HOSE, coupled 1

89 15E806 TUBE, INTAKE 1

90 118494 O-RING 1

93* 287253 TOOL BOX, includes 94 1

94* 118852 SCREW, machine, hex washer hd 3

99 113161 SCREW, flange, hex hd 3

100 15E736 BRACKET, holder, manual 1

101 119510 HOLDER, manual 1

107 15F110 PIN, pump (5900) 1

108* 114528 SCREW, MACH, PHILLIPS, PNHD 2

115 15E854 LABEL, identification 1

119 LABEL, identification

15E852 (5900) 1

15E980 (5900HD) 1

120▲15F638 LABEL, warning 1

121▲194126 LABEL, warning 1

122 290228 LABEL, caution 1

125▲195119 LABEL, warning 1

127 119569 BUSHING, strain relief 1

130 BOX, control 1

* 287648 Premium 1

287649 Standard 1

132 119778 SPRING, RETAINING (5900) 1

133 114687 CLIP, RETAINER 1

134* 15F354 FUNNEL, OIL (shown on page 5) 1

143 116038 WASHER, wave spring 2

164 119790 O-RING 1

165 15G584 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

Ref Part Description Qty

Parts

24 310893P

GMAX ll 7900/TexSpray 7900 HD Parts Drawing

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TexSpray 7900HD

Only

Parts

310893P 25

GMAX ll 7900/TexSpray 7900HD Parts List

Ref Part Description Qty

1 287370 FRAME, cart (5900/7900) 1

2 156306 WASHER, flat 2

3 119509 WHEEL, pneumatic (5900/7900) 2

4 15E891 CLIP, retaining 2

5 191084 SLEEVE, cart (5900/7900) 2

6 183350 WASHER 2

7 108068 PIN, spring straight 2

8 108795 SCREW, mach, pnh 4

9 112827 BUTTON, snap 2

10 245245 HANDLE, cart 1

11 237686 WIRE, ground assembly w/ clamp 1

12 112798 SCREW, thread forming, hex hd 1

14 276974 CAP, leg 2

15 116080 ENGINE, gas, 6.5 hp, (7900) 1

16 110837 SCREW, flange, hex 2

17 110838 NUT, lock 2

18 183401 KEY, parallel 1

19 15E277

HOUSING, clutch, mach (5900/7900)

20 108842 SCREW, cap, hex hd 4

21 100214 WASHER, lock 4

22 193680 COLLAR, shaft 1

23† 108803 SCREW, hex, socket head 6

24† 105510 WASHER, lock, spring (hi-collar) 10

25†

ARMATURE, clutch, 5 in. (5900/7900)

26† HUB, armature 1

27† ROTOR, clutch, 5 in. (5900/7900) 1

28† 101682 SCREW, cap, sch 4

29 287466 HOUSING, pinion, 7900 1

30 114672 WASHER, thrust (brass) 2

31 114699 WASHER, thrust (steel) 1

32 287459 GEAR, combination (7900) 1

33 287470 HOUSING, drive (7900) 1

34* 116618 MAGNET 1

35 112395 SCREW, cap, flnghd 1

36 102962 SCREW, cap sch (5900/7900) 4

37 104008 WASHER, lock, spring (5900/7900) 4

38 15C753 SCREW, mach hex hd(5900/7900) 6

39* 119562 SWITCH, reed w/connector 1

40 287934 HOUSING, bearing (7900) 1

41 112599 SCREW, cap, socket hd 4

42 112600 WASHER, lock spring (hi-collar) 4

43 287473 ROD, connecting (7900) 1

44 287520 COVER, front, (7900), includes 45 1

45 118444 SCREW, mach hex wash hd 5

47 249122 PUMP, displacement (7900),

includes 86, 89, 90

289590 PUMP, displacement (TexSpray

7900HD), includes 86, 164

67 111457 O-RING 1

109450 O-RING (TexSpray 7900HD only) 1

68 244240 HOSE, coupled, includes 69 1

69 241920 DEFLECTOR, threaded 1

75 15F584 LABEL, ProConnect 1

76 114678 BUSHING, strain relief 1

82 189920 STRAINER, (1-11 1/2 npsm) 1

83 114271 STRAP, retaining 1

84 238049 FLUID, TSL, 4 oz (not shown) 1

86 15E802 FITTING, pump, quick disconnect 1

15G509 FITTING, pump, quick disconnect

(TexSpray 7900HD only)

87 287419 HOSE, coupled 1

289282 HOSE, coupled

(TexSpray 7900HD only)

89✿248215 TUBE, INTAKE 1

90✿118494 O-RING 1

93✿287253 TOOL BOX, includes 94 1

94✿118852 SCREW, machine, hex washer hd 3

99 113161 SCREW, flange, hex hd 3

100 15E736 BRACKET, holder, manual 1

101 119510 HOLDER, manual 1

107 15F097 PIN, pump (7900) 1

108* 114528 SCREW, MACH, PHILLIPS, PNHD 2

109* 15F947 SHIELD, magnetic 1

115 15E854 LABEL, identification 1

119 15E853 LABEL, identification 1

15M962 LABEL, front (TexSpray 7900HD only) 1

120▲15F638 LABEL, danger, English 1

121▲194126 LABEL, warning 1

122 290228 LABEL, caution 1

125▲195119 LABEL, warning 1

127 119569 BUSHING, strain relief 1

130 BOX, control

* 287648 Premium 1

287649 Standard 1

132 119677 SPRING, RETAINING (7900) 1

133 114687 CLIP, RETAINER 1

134* 15F354 FUNNEL, OIL (shown on page 5) 1

143 116038 WASHER, wave spring 2

164 119790 O-RING 1

109450 O-RING (TexSpray 7900HD only) 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

Ref Part Description Qty

Parts Drawing and List - Pinion Housing, Drive Housing

26 310893P

Parts Drawing and List - Pinion Housing, Drive Housing

Ref 29: Pinion Housing

GMAX ll 3900: 287463

GMAX ll 5900: 287465

GMAX ll 7900: 287466

TexSpray 7900HD: 287466

Ref 33: Drive Housing

GMAX ll 3900: 287467

GMAX ll 5900: 287469

GMAX ll 7900: 287470

TexSpray 7900HD: 287470

Ref Part Description Qty

29 KIT, repair, field

287474 3900 1

287476 5900 1

287477 7900/TexSpray 7900HD 1

29a GEAR, driving, first

287525 3900 1

241114 5900/7900/TexSpray 7900HD 1

29b RING, retaining, large

113094 3900 1

112770 5900/7900/TexSpray 7900HD 1

29c 105489 PIN, dowel 2

29d O-RING

165295 3900 1

114683 5900/7900/TexSpray 7900HD 1

33a WASHER, thrust, steel

116191 3900 1

116192 5900/7900/TexSpray 7900HD 1

Ref Part Description Qty

33 DRIVE HOUSING 1

33a WASHER, thrust, steel

116191 3900 1

116192 5900/7900/TexSpray 7900HD 1

33b WASHER, thrust, brass

107089 3900 1

194173 5900/7900/TexSpray 7900HD 1

108 Ref*

34 Ref*

38 Ref

30,72 Ref

31 Ref

32 Ref

29c

29a

29b

27 Ref

28 Ref

ti5494c

38 Ref

39 Ref*

24 Ref

29d

30 Ref

33a

33b

109 Ref*

1Pinion housing (29) includes clutch field

✬ Premium models

LoBoy Suction Set Kits (Kits include suction set and drain hose)

310893P 27

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 Part Description Qty

82 189920 STRAINER, 1-11 1/2 npsm 1

90 O-RING

115099 3900/5900 1

119566 7900 1

109 HOSE, suction 3900/5900 287988

288038 includes 82, 109 (suction hose),

110, 111, 112, 114, 115

HOSE, suction 7900 288114

288039 includes 82, 109 (suction hose),

110, 111, 112, 114, 115

110 15C980 NUT, jam 1

111 15H854 O-RING 2

112 15C981 WASHER, suction, swivel 1

114 118505 RING, retaining, external 1

115 CLIP, drain line

15D000 3900/5900 1

196723 7900 1

153 SCREW

108795 3900/5900 2

NONE 7900

154 TUBE

15E952 3900/5900 1

NONE 7900

155 241920 DEFLECTOR 1

156 HOSE, drain, includes 155

287654 3900/5900 1

246331 7900 1

157 TUBE, suction

15F149 3900/5900 1

15F171 7900 1

158 15F909 TUBE, angle 1

159 120330 CLAMP, hose 2

160 HOSE, suction

15H393 3900/5900 1

15H787 7900 1

161 176450 GUARD, hose 1

ti5755b

109

115

114 112

111

153

154

156

110

1Used on 3900 5900

155

159

158

159

157

161

Pressure Control and Filter Parts Drawing

28 310893P

Pressure Control and Filter Parts Drawing

All Models

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-ODELS

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3TANDARD0ART.UMBER

0REMIUM0ART.UMBER

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-ODELS

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Pressure Control and Filter Parts List

310893P 29

Pressure Control and Filter Parts List

REF PART DESCRIPTION QTY

Filter Replacement Kit

287510 3900/5900

287517 7900

53★† 15C765 CAP, filter 1

54★†117285 O-RING 1

55★†15C766 TUBE, diffusion 1

56★†244067 FILTER, fluid 1

57★15C780 HANDLE 1

58★15C972 PIN, grooved 1

59★224807 BASE, valve 1

60★‡ 235014 VALVE, drain, replacement kit 1

61★‡ 15E022 SEAT, valve 1

62★‡ 111699 GASKET, seat, valve 1

65 ADAPTER

★164672 (3900/5900) 1

†162485 (7900/TexSpray 5900HD/7900HD) 1

66★†243222 TRANSDUCER, pressure contl 1

67★†111457 O-RING 1

71 116585 SCREW, mach, pnh, sems 6

72*†15E284 HOUSING, filter 1

87 287419 HOSE, coupled 1

289282 HOSE, coupled

(TexSpray 7900HD)

287293 VALVE, auto clean, includes 91a 1

91a

115524 GASKET 1

244346 KIT, repair, clamp, trigger 1

96★†104813 PLUG, pipe 1

113 15E925 GASKET, TRANSDUCER 1

123 119545 BUSHING, strain, relief 1

130 CONTROL BOX

130a*

249583 BOX, premium 1

130a 249584 BOX, standard 1

130b 287516 CONTROL, board 1

130c 117317 SCREW, pan head 4

130d 241443 POTENTIOMETER 1

130e 198650 SPACER, shaft 1

130f 116752 SWITCH, rocker 1

130g 119541 SWITCH, toggle 1

130h 116167

KNOB, potentiometer

130j 195428 BOOT, toggle 1

130k 15E857 LABEL, identification 1

130m*

287515 DISPLAY, LCD, GMAX 1

130n*

15E855 LABEL 1

130p

15E858 LABEL, identification 1

130r 119545 BUSHING, strain relief 1

150 245103 DRAIN VALVE (7900/TexSpray

7900HD)

150a†◆193710 SEAL, valve 1

150b†◆193709 SEAT, valve 1

150c†◆114797 GASKET 1

150d†◆VALVE ASSEMBLY 1

150e†◆114708 SPRING, compression 1

150f†◆15G563 HANDLE, valve 1

150g†◆116424 NUT, cap, hex, hd 1

151 248314 PLUG, (Standard) includes 152 1

152 15D541 O-RING, Standard) 1

160* 287648 CONTROL, premium, complete 1

(includes 130b-130r)

161 287649 CONTROL, standard, complete 1

(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

REF PART DESCRIPTION QTY

Pressure Control

Wiring Diagram

ti5496a

TO ENGINE

5900/7900

TO GROUND

3900

CLUTCH TEST POINTS

CONTROL

BOARD

PINON

DRIVE

TRANSDUCER

POTENTIOMETER

PREMIUM DISPLAY BOARD

ON/ OFF SWITCH

WATCHDOG

PUMP STROKE

COUNTER

D12

LED

J5J4J3

J10

Parts - Sprayers, RAC™ X Tip, Gun & Hose

30 310893P

Parts - Sprayers, RAC™ X Tip, Gun & Hose Ref 40: Bearing Housing

Ref Part Description Qty

202 240794 HOSE, grounded, nylon; 1/4 in. ID; cpld

1/4 npsm(fbe); 50 ft (15 m); spring

guards both ends; 3300 psi (228 bar,

22.8 MPa) (3900/5900)

240797 HOSE, grounded, nylon; 3/8 in. ID; cpld

1/4 npsm(fbe); 50 ft (15 m); spring

guards both ends; 3300 psi (228 bar,

22.8 MPa)

(5900HD/7900/TexSpray 7900HD)

204 288420 CONTRACTOR II SPRAY GUN

Includes RAC X 517-size SwitchTip and

HandTite Guard. See 311861 for parts.

(3900/5900/7900)

241705 TEXTURE SPRAY GUN

Includes LTX531 SwitchTip and Guard.

See 308491 for parts. (5900HD/Tex-

Spray 7900HD)

205 159841 BUSHING, 3/8 x 1/4 in. (5900HD/7900) 1

206 241735 HOSE, whip 1/4 in. x 3 ft

(TexSpray 7900HD)

TIA







Ref Part Description Qty

40 287932 HOUSING, bearing (3900) 1

287933 HOUSING, bearing (5900) 1

287934 HOUSING, bearing

(7900/TexSpray 7900HD)

45 118444 SCREW, mach hex wash hd 1

79 15E975 CLIP, spring 1

104 PIN, housing, bearing

15E779 3900 1

15E625 5900/7900/TexSpray 7900HD 1

105 LATCH, housing, bearing

15G930 3900 1

15G890 5900/7900/TexSpray 7900HD 1

106 NUT, lock hex

102040 3900 2

111040 5900/7900/TexSpray 7900HD 2

141 15F503 SCREW, set, socket hd 1

142 15F498 SCREW, adjustment 1

163 15F116 LATCH 1

165 15G840 RECEIVER, latch (3900) 1

15G584 RECEIVER, latch

(5900/7900/TexSpray 7900HD)

166 108859 SCREW, shoulder, sch (3900) 1

116942 SCREW, shoulder, sch

(5900/7900/TexSpray 7900HD)

141 40

142

105

104

106

163

165

166

Technical Data

310893P 31

Technical Data

Dimensions

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 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

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 2.20 gpm (8.33 liter/min)

Maximum tip size

3900 1 gun with 0. 036 in. tip

2 guns with 0. 023 in. tip

3 guns with 0. 018 in. tip

5900/5900HD 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

7900 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

Inlet paint strainer 12 mesh (893 micron)

stainless steel screen, reusable

Outlet paint filter 60 mesh (250 micron)

stainless steel screen, reusable

Pump inlet size 1-5/16–12 UN-2A

Fluid outlet size: 3900/5900 ¼ npsm from fluid filter

Fluid outlet size: 7900 3/8 npsm from fluid filter

Wetted parts zinc-plated carbon steel, PTFE, nylon, polyurethane, UHMW

polyethylene, fluoroelastomer, acetal, leather, aluminum, tung-

sten carbide, nickel- and zinc-plated carbon steel, stainless steel,

chrome plating

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 (83.8)

Graco Standard Warranty

32 310893P

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

www.graco.com

2/2005 Rev. 05/2011

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

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