Graco Inc 3A0243A User Manual

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 3900

Model Hi-Boy

Premium

(QuikReel) 248683 ✓ 248684 ✓ 249335 ✓ 258731 ✓ 258736 ✓

Model Hi-Boy

Premium

(QuikReel) 248687 ✓ 248688 ✓ 258732 ✓ 258737 ✓

Model Hi-Boy

Premium

(QuikReel) 258734 ✓

Model Hi-Boy

Premium

(QuikReel) 248700 ✓ 248701 ✓ 258733 ✓ 258738 ✓

Model Hi-Boy

Premium

(QuikReel) 258735 ✓

Hi-Boy

Standard

GMAX 5900

Hi-Boy

Standard

TexSpray 5900 HD

Hi-Boy

Standard

GMAX 7900

Hi-Boy

Standard

GMAX 7900

Hi-Boy

Standard

Lo-Boy

Premium

(QuikReel)

Lo-Boy

Premium

(QuikReel)

Lo-Boy

Premium

(QuikReel)

Lo-Boy

Premium

(QuikReel)

Lo-Boy

Premium

(QuikReel)

Lo-Boy

Standard

Lo-Boy

Standard

Lo-Boy

Standard

Lo-Boy

Standard

Lo-Boy

Standard

3A0243A

ENG

ti14916a

Related Manuals: Operation 3A0242

Parts 3A0244 Gun 311861

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.

• 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 all equipment in the 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.

• Keep a working fire extinguisher in the work area.

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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

2 3A0243A

Warning

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

SUCTION HAZARD

Powerful suction could cause serious injury.

• Never place hands near the pump fluid inlet when pump is operating or pressurized.

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.

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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A0243A 3

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.

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.

NOTE: 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.

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.

ti6200a

OIL FUNNEL

4 3A0243A

Troubleshooting

Problem Cause Solution

E=XX is displayed Fault condition exists. Determine fault correction from table, page 14.

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

Engine is out of gasoline. Refill gas tank. Honda Engine Manual. Engine oil level is low. Try to start engine. Replenish oil, if necessary.

Honda Engine Manual.

Spark plug disconnected or damaged. Connect spark plug cable or replace spark

plug. Engine is cold. 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.

Engine operates, but displacement pump does not operate

Operating conditions out of WatchDog parameters.

Pump output is low, page 6. Error code displayed. Reference Pressure Control repair, page 21. Pump switch is OFF. Turn pump switch ON. Pressure setting too low. Turn pressure adjusting knob clockwise to

Fluid filter is dirty. Clean filter. Tip or tip filter is clogged. Clean tip or tip filter (see gun manual). Displacement pump piston rod is stuck

due to dried paint. Connecting rod is worn or damaged. Replace connecting rod. Page 15. Drive housing is worn or damaged. Replace drive housing. Page 16. Electrical power is not energizing clutch

field.

Turn pressure down. Contact Graco Technical

Assistance to adjust WatchDog parameters.

Operate without WatchDog active (see Opera-

tion manual).

increase pressure.

Repair pump (see pump manual).

Check wiring connections. Page 21.

Reference Digital Display Messages.

Page 14.

Reference wiring diagram. Page 21.

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 + 0.2 Ω; if

not, replace pinion housing.

Have pressure control checked by authorized

Graco dealer. Clutch is worn, damaged, or incorrectly

positioned. Pinion assembly is worn or damaged. Repair or replace pinion assembly. Page 17.

3A0243A 5

Adjust or replace clutch. Page 19.

Troubleshooting

Problem Cause Solution

Pump output is low Strainer is clogged. Clean strainer.

Piston ball is not seating. Service piston ball (see pump manual). Piston packings are worn or damaged. Replace packings (see pump manual). O-ring in pump is worn or damaged. Replace o-ring (see pump manual). Intake valve ball is not seating properly. Clean intake valve (see pump manual). Intake valve ball is packed with mate-

rial. Engine speed is too low. Increase throttle setting (see operation man-

Clutch is worn or damaged. Adjust or replace clutch. Page 17. Pressure setting is too low. Increase pressure (see operation manual). Fluid filter, tip filter or tip is clogged or

dirty. Large pressure drop in hose with heavy

materials.

Excessive paint leakage into throat packing nut

Fluid is spitting from gun Air in pump or hose. Check and tighten all fluid connections. Rep-

Pump is difficult to prime Air in pump or hose. Check and tighten all fluid connections.

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

Throat packings are worn or damaged. Replace packings (see pump manual). Displacement rod is worn or damaged. Replace rod (see pump manual).

Tip is partially clogged. Clear tip (see gun manual). Fluid supply is low or empty. Refill fluid supply. Prime pump (see operation

Clean intake valve (see pump manual).

ual).

Clean filter (see gun manual).

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 just enough to stop leakage.

rime pump (see operation manual).

manual). Check fluid supply often to prevent running pump dry.

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. Reas-

semble valve. Pump packings are worn. Replace pump packings (see pump manual). Paint is too thick. Thin the paint according to the supplier's rec-

ommendations. Engine speed is too high. Decrease throttle setting before priming pump

(see operation manual).

Clutch squeaks each time clutch engages

High engine speed at no load Misadjusted throttle setting. Reset throttle to 3300 engine rpm at no load.

Gallon counter not working Bad sensor, broken or disconnected

No display, sprayer operates Display damaged or has bad connec-

Clutch surfaces are not matched to each other when new and may cause noise.

Worn engine governor. Replace or service engine governor.

wire. Displaced or missing magnet.

tion.

Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time.

Check connections. Replace sensor or wire.

Reposition or replace magnet.

Check connections. Replace display.

6 3A0243A

Fluid Pump Runs Constantly

Troubleshooting Procedure:

Troubleshooting

1. Perform Pressure Relief Procedure (page 4), turn

prime valve forward to SPRAY position, and turn power switch OFF.

2. Remove control box cover.

With a pressure gauge plumbed into the paint hose, start the engine. Turn pump switch ON. Does sprayer exceed maximum pressure?

YES

Disconnect clutch wires from control board (see diagram, page 12). Does the pump stop running?

YES

Make sure clutch wires are plugged in (see diagram, page 12). Do the clutch test points read 10-18 DC volts?

YES

Pump problem. See the proper fluid pump manual for the sprayer for further troubleshooting procedures.

Mechanical problem in the clutch pinion assembly (clutch may be close to the rotor).

Check for a short from the two clutch wires to the frame. If shorted, repair or replace faulty wire.

Unplug transducer from control board.

YES

Bad transducer. Replace and test with a new one.

3A0243A 7

Replace the control board.

Troubleshooting

Control Board Malfunction

Troubleshooting Procedure (see following page for actual steps):

Remove control box cover. Turn sprayer ON. Observe control board Green and Red LED lights.

No light Once Normal operation Red light on

continuously

Green light on continuously

Flashing See error code

Red light on continuously with potentiometer OFF after a replacement board is installed

Go to step 4. Is 1-3 Ohms reading present?

YES

Control board commanding engine to run

WatchDog enabled

section for further troubleshooting

Model not selected

YES

If low resistance is

present in step 4, the problem is a shorted field. Replace pinion. If an open in the wiring is present, check pinion wiring connections.

Go to step 3. Is 10-12 VDC present?

Go to step 1. Does switch test positive?

YES

Go to step 2. Do you have proper engine voltage?

YES

Go to step 5. Does the clutch engage?

YES

Replace the potentiometer.

Replace the switch.

Check wiring from J1 and J2 for proper connection. If proper connection is detected, repair or replace engine generator.

Connect a test transducer to the board. Does the clutch engage?

Replace

YES

the control board.

Mechanical problem. Repair or replace clutch/pinion assembly.

8 3A0243A

Replace the transducer.

Control Board Malfunction (Steps)

Troubleshooting

BEEP

STEP 1.

Turn engine OFF and set meter to continuity.

ti14938a

Pump On/Off Switch

To Ground

To Engine

5900/7900

On/Off Switch

3900

ti14939a

Engine Generator

J1J2

J4J3

12 -20 AC

Control Board

STEP 2.

Turn engine ON. Set meter to AC volts and connect wires to control board.

Control Board

Clutch Test Points

LED D12

J10

To Clutch Field

Pinion Assembly

ti14943a

ti14940a

Control Board

10-12 DC

Drive Housing

STEP 3.

Leave engine running and turn switch ON. Turn potentiometer to high and set meter to DC volts.

Clutch Field

WatchDog

Transducer

Premium Display Board

1-3 ohms

STEP 4.

Turn engine

Potentiometer

OFF and unplug

ti14942a

Control Board

Clutch Test Points

clutch wires.

Set meter to

Ohms.

Clutch Field

3A0243A 9

STEP 5.

Turn engine ON and turn switch ON.

Control Board

ti14941a

Troubleshooting

Convertible Electric Motor Will Not Run

Troubleshooting Procedure (see following page for actual steps):

See Step 1. Is there over 100 AC volts?

YES

See Step 3. Is there over 100 DC volts?

YES

See engine test section.

See step 2. Is there over 100 AC volts?

YES

Replace the power switch.

See Step 4. Is there continuity through the thermal sensor?

YES

Replace engine control board.

Repair or replace the power cord.

If engine is hot, let cool and retest. If step 4 still shows an open, replace engine.

10 3A0243A

+ 22 hidden pages