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Repair
™
GMax
II
3900, 5900, 5900HD, 7900
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
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248684
248685
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248686
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249335
GMax ll 5900
248687
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248688
248689
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248690
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249336
GMax ll 5900HD
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248698
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248699
GMax ll 7900
248700
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248701
248702
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248703
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249337
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
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310893 rev. J
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309639
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309640
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Summary of Contents for Graco GMax ll 5900
- Page 1 GMax ll 7900 ✓ 248700 ✓ 248701 ✓ ✓ 248702 Related Manuals ✓ ✓ 248703 ✓ ✓ 249337 310892 309639 310894 309640 Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001...
- Page 2 Pressure Control ......14 Graco Standard Warranty ....32 Displacement Pump .
- Page 3 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: •...
- Page 4 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.
- Page 5 Maintenance Maintenance Pressure Relief Procedure AFTER THE FIRST 20 HOURS OF OPERATION: Drain engine oil and refill with clean oil. Reference Honda Engines Owner's Manual for correct oil viscosity. WARNING 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 Read Injection Hazard, page 3;...
- Page 6 Clean or replace spark plug. Start engine. Keep sprayer upright to avoid oil seepage False tripping of WatchDog system. Operating conditions out of WatchDog Turn pressure down. Contact Graco Technical EMPTY is displayed. Pump does not parameters Assistance to adjust WatchDog parameters.
- Page 7 Troubleshooting 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.
- Page 8 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 CAUTION may have different item numbers. Use the 5900 Hi-Boy DO NOT use bearing housing screws (41) to align or item number and part to find the corresponding alter- seat bearing housing with drive housing.
- Page 9 Drive Housing Drive Housing Removal CAUTION DO NOT use drive housing screws (38) to align or seat WARNING drive housing with pinion housing. Align these parts with locating pins, to avoid premature bearing wear. Install screws (38) in drive housing. Torque evenly to note Read Injection Hazard, page 3;...
- Page 10 Pinion Assembly/Clutch Armature/Clamp 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. WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 Remove drive housing;...
- Page 11 Pinion Assembly/Clutch Armature/Clamp Installation Clutch Armature Install armature (25) on engine drive shaft. Install four screws (23) and lock washers (24) with torque . 8. Lay two stacks of two dimes on smooth bench of 125 in-lb. surface. Pinion Assembly Lay armature (25) on two stacks of dimes.
- Page 12 Clutch Housing Clutch Housing Removal . 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 . 11. Push on clutch housing (19). Install four capscrews (20) and lock washers (21) and secure clutch housing (19) to engine.
- Page 13 Pressure Control Pressure Control Pump ON/OFF Switch Removal Installation Install new pump ON/OFF switch (130f) so tabs of switch snap into place on inside of cover. WARNING Connect pump ON/OFF switch connector to control board. Swing up cover (130a) and secure with two screws (71). Read Injection Hazard, page 3;...
- Page 14 Pressure Control Control Board Removal • Display connector (130m) • Engine, ground and clutch wires Remove four screws (130c) and control board (130b). WARNING Installation . 14. Install control board (130b) with four screws (130c). Connect engine wires to control board (130b). Connect at control board (130b): Read Injection Hazard, page 3;...
- Page 15 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.
- Page 16 Displacement Pump Displacement Pump Removal 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 Do Pressure Relief, page 5. Separate drain hose from sprayer .
- Page 17 Displacement Pump Twist latch u-bolt back from pump door outer edge 10. F . 23. Pull out pump pin and place in pin holder Place u-bolt on pump door protrusion . 20 Ratchet pump door forward. . 23 Installation . 24. Adjust piston rod with pin holder to pull out piston rod.
- Page 18 . 28. Attach drain hose to sprayer. Do not tighten latch. . 28 . 29. Fill pump with Graco TSL until fluid flows onto top . 26. Rotate pump to align with paint hose. Connect of seal. paint hose and hand tighten to 70 in-lb .
- Page 19 Displacement Pump 310893J...
- Page 20 Parts Parts GMax ll 3900 Parts Drawing 310893J...
- Page 21 Parts GMax ll 3900 Parts List Part Description 287253 TOOL BOX, includes 94 Part Description 118852 SCREW, machine, hex washer hd 287411 FRAME, cart (3900) 113161 SCREW, flange, hex hd 156306 WASHER, flat 15E736 BRACKET, holder, manual 119420 WHEEL, pneumatic (3900) 119510 HOLDER, manual 15E891 CLIP, retaining 15F109 PIN, pump (3900)
- Page 22 Parts GMax ll 5900/5900HD Parts Drawing 310893J...
- Page 23 Parts GMax ll 5900/5900HD Parts List Part Description Part Description PUMP, displacement 287513 (5900), includes 86, 89, 90 287370 FRAME, cart (5900/7900) 287579 (5900HD), includes 86 156306 WASHER, flat 111457 O-RING 119509 WHEEL, pneumatic (5900/7900) 244240 HOSE, coupled, includes 69...
- Page 24 Parts GMax ll 7900 Parts Drawing 310893J...
- Page 25 Parts GMax ll 7900 Parts List Part Description 287520 COVER, front, (7900), includes 45 Part Description 118444 SCREW, mach hex wash hd 249122 PUMP, displacement (7900), 287370 FRAME, cart (5900/7900) includes 86, 89, 90 156306 WASHER, flat 111457 O-RING 119509 WHEEL, pneumatic (5900/7900) 15E891 CLIP, retaining...
- Page 26 Parts Drawing and List - Pinion Housing, Drive Housing Ref 29: Pinion Housing Ref 33: Drive Housing GMax ll 3900: 287463 GMax ll 3900: 287467 GMax ll 5900: 287465 GMax ll 5900: 287469 GMax ll 7900: 287466 GMax ll 7900: 287470 Part...
- Page 27 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 Kit: 287631 GMax ll 7900 Kit: 287541 Part Description 189920 STRAINER, 1-11 1/2 npsm O-RING 115099 3900/5900 119566 7900 HOSE, suction...
- Page 28 Pressure Control and Filter Parts Drawing Pressure Control and Filter Parts Drawing All Models 310893J...
- Page 29 Pressure Control and Filter Parts List Pressure Control and Filter Parts List PART DESCRIPTION PART DESCRIPTION 150c 114797 GASKET †◆ Filter Replacement Kit 150d VALVE ASSEMBLY †◆ 287510 3900/5900 150e 114708 SPRING, compression †◆ 287517 7900 150f 15G563 HANDLE, valve †◆...
- Page 30 ™ Parts - Sprayers, RAC X Tip, Gun & Hose ™ Ref 40: Bearing Housing Parts - Sprayers, RAC X Tip, Gun & Hose Premium Models include items 202 to 204 or 205 Part Description HOUSING, bearing 118444 SCREW, mach hex wash hd 15E975 CLIP, spring PIN, housing, bearing...
- Page 31 Technical Data Technical Data Honda GX120 Engine ANSI Power Rating @ 3600 rpm 4.0 Horsepower (3.0 kW) Honda GX160 Engine ANSI Power Rating @ 3600 rpm 5.5 Horsepower (4.1 kW) Honda GX 200 Engine ANSI Power Rating @ 3600 rpm 6.5 Horsepower (4.8 kW) Maximum working pressure 3300 psi...
- Page 32 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.