Graco GMAX II 3900 Repair Manual

Airless sprayers

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Page 1 Repair ™ GMAX II 3900/5900/5900HD/7900 ™ TexSpray 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.
Page 2: Table Of Contents
Parts ........20 GMAX II 3900 Parts Drawing ....20 GMAX II 5900/5900HD Parts Drawing .
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. 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 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.
Page 5: Maintenance
Pressure Relief Procedure WARNING Read Injection Hazard, page 3; Burn Hazard, page 4. 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.
Page 6: 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 Troubleshooting Cause Fault condition exists Engine switch is OFF Engine is out of gasoline Engine oil level is low Spark plug is disconnected or damaged Connect spark plug cable or replace spark plug Cold engine...
Page 7 Problem Pump output is low Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime Clutch squeaks each time clutch engages High engine speed at no load Gallon counter not working No display, sprayer operates 310893L Cause Strainer (82) is clogged...
Page 8: Bearing Housing & Connecting Rod
Install pump. Refer to Displacement Pump, Installation, page 14. 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)
Page 9: Drive Housing
Install pump. Refer to Displacement Pump, Installation, page14. 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)
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 9. .
Page 11: Clamp Removal
Installation Clutch Armature . 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. 0.12+01 in (3.0+.25 mm) ti6321a dimes Clamp Removal Do Engine Removal.
Page 12: 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: Pump On/Off Switch
Removal WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 . 14. Remove two screws (71) and swing down cover (130a). Disconnect pump ON/OFF switch (130f) connector from control board. Press in on two retaining tabs on each side of pump ON/OFF switch (130f) and remove switch from cover.
Page 14: Pressure Control
Removal WARNING Read Injection Hazard, page 3; Burn Hazard, page 4 . 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) •...
Page 15: Digital Display Messages
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...
Page 16: Displacement Pump
Removal 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 . 15 Disconnect material hose from pump. . 16 Displacement Pump Raise latch lock.
Page 17 Twist latch u-bolt back from pump door outer edge Place u-bolt on pump door protrusion . 20 Ratchet pump door forward. . 21 Open pump door. . 22 310893L 10. F . 23. Pull out pump pin and place in pin holder .
Page 18 . 26. Close pump door and rotate latch into position. Do not tighten latch. . 26. Rotate pump to align with material hose. Connect material hose and hand tighten to 70 in-lb . 26 . 27. Tighten latch and rotate latch lock into locked position. .
Page 19 Displacement Pump 310893L...
Page 20: Parts
Parts Parts GMAX ll 3900 Parts Drawing 310893L...
Page 21 GMAX ll 3900 Parts List Part Description 287411 FRAME, cart (3900) 156306 WASHER, flat 119420 WHEEL, pneumatic (3900) 15E891 CLIP, retaining 192027 SLEEVE, cart (3900) 183350 WASHER 108068 PIN, spring straight 109032 SCREW, mach, pnh 100020 WASHER, lock 112827 BUTTON, snap 245245 HANDLE, cart 237686 WIRE, ground assembly w/ clamp 112798 SCREW, thread forming, hex hd...
Page 22: Gmax Ii 5900/5900Hd Parts Drawing
Parts GMAX ll 5900/5900HD Parts Drawing 310893L...
Page 23 GMAX ll 5900/5900HD Parts List Part Description 287370 FRAME, cart (5900/7900) 156306 WASHER, flat 119509 WHEEL, pneumatic (5900/7900) 15E891 CLIP, retaining 187604 SLEEVE, cart (5900/7900) 183350 WASHER 108068 PIN, spring straight 108795 SCREW, mach, pnh 112827 BUTTON, snap 245245 HANDLE, cart 237686 WIRE, ground assembly w/ clamp 112798 SCREW, thread forming, hex hd 276974 CAP, leg...
Page 24: Gmax Ii 7900/Texspray 7900Hd Parts Drawing
Parts GMAX ll 7900/TexSpray 7900 HD Parts Drawing TexSpray 7900HD Only 310893L...
Page 25 GMAX ll 7900/TexSpray 7900HD Parts List Part Description 287370 FRAME, cart (5900/7900) 156306 WASHER, flat 119509 WHEEL, pneumatic (5900/7900) 15E891 CLIP, retaining 191084 SLEEVE, cart (5900/7900) 183350 WASHER 108068 PIN, spring straight 108795 SCREW, mach, pnh 112827 BUTTON, snap 245245 HANDLE, cart 237686 WIRE, ground assembly w/ clamp...
Page 26: Parts Drawing And List - Pinion Housing
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 Part Description KIT, repair, field 287474 3900 287476 5900 287477 7900/TexSpray 7900HD GEAR, driving, first 287525 3900 241114 5900/7900/TexSpray 7900HD...
Page 27: Lo-Boy Suction Set
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 Part Description 189920 STRAINER, 1-11 1/2 npsm O-RING 115099 3900/5900 119566 7900 HOSE, suction 288038 3900/5900, includes 82, 110, 111, 112, 114, 288039 7900 15C980 NUT, jam...
Page 28: Pressure Control And Filter Parts Drawing
Pressure Control and Filter Parts Drawing Pressure Control and Filter Parts Drawing All Models 310893L...
Page 29: Pressure Control And Filter Parts List
Pressure Control and Filter Parts List PART DESCRIPTION Filter Replacement Kit 287510 3900/5900 287517 7900 ★ † 15C765 CAP, filter ★† 117285 O-RING ★† 15C766 TUBE, diffusion ★† 244067 FILTER, fluid ★ 15C780 HANDLE ★ 15C972 PIN, grooved ★ 224807 BASE, valve ★...
Page 30: Parts - Sprayers, Rac
™ Parts - Sprayers, RAC X Tip, Gun & Hose Premium Models and TexSpray 7900HD include items 202 to 204 or 205. Item 206 for TexSpray 7900HD only. Part Description 240794 HOSE, grounded, nylon; 1/4 in. ID; cpld 1/4 npsm(fbe); 50 ft (15 m); spring guards both ends;...
Page 31: 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 Maximum working pressure Noise Level Sound power Sound pressure Maximum delivery rating 3900 5900/5900HD 7900...
Page 32: Graco Standard Warranty
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.

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Graco GMAX II 3900 Repair Manual

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