Graco Inc. 3A0243A Paint Sprayer User Manual
Contents
1. 1 Remove two screws 71 and swing down cover 130a 2 Connect pump ON OFF switch connector to control 2 Di t ON OFF switch 130f t isconnect pump switch connector board from control board 3 Swing up cover 130a and secure with two screws GROUND 129 3900 71 CLUTCH TO ENGINE 15 5900 7900 CLUTCH 39 GALLON COUNTER 130b 3A0243A 21 Pressure Control Control Board Removal 1 Remove two screws 71 and swing down cover 130a 2 Remove strain relief bushings 130r and 123 3 Disconnect at control board 130b e Lead from potentiometer 130d e Lead from transducer 66 e Lead from WatchDog switch 130g 4 Lead from pump ON OFF switch 130f 5 e Lead from gallon counter sensor 39 e Display connector 130m e Engine ground and clutch wires 4 Remove four screws 130c and control board 130b Installation Install control board 130b with four screws 130c Connect engine wires to control board 130b Connect at control board 130b e Ground and clutch wires e Display connector 130m e Lead from gallon counter sensor 39 e Lead from pump ON OFF switch 130f e Lead from WatchDog switch 130g e Lead from transducer 66 e 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 4 Remov2. DISPLAY SPRAYER OPERATION INDICATION ACTION No Display Sprayer may be Loss of power or display Check power source Relieve pressure before repair pressurized not connected or disassembly Verify display is connected Sprayer may be Pressure less than Increase pressure as needed nee pressurized 200 psi 14 bar 1 4 MPa 3000 psi ae i ieee Normal operation Spray cif bar Pressure varies with tip MPa size and pressure ti6315a control setting sa an tas Sprayer stops Engine is Exceeded pressure limit 1 Check fluid path for clogs such as clogged filter EL Ue running 2 Open prime valve and gun if running AutoClean 3 Use Graco paint hose 1 4 in x 50 ft minimum teanga 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 5 Sprayer stops Engine is Pressure transducer faulty 1 Check transducer connection L M a running bad connection or broken 2 Disconnect and reconnect transducer plug to Lu Wile ensure good connection with control board ti6317a 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 d Sprayer stops Engine is High clutch current 1 Check wiring connections C FE running 2 Measure 1 2 0 2 Q GMAX II 3900 Lud 1 7 0 2 Q GMAX II 5900 7900 amp TexSpray wesles 79
3. 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 THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as s
4. Replace rod See pump manual Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Rep rime pump see operation manual Tip is partially clogged Clear tip see gun manual Fluid supply is low or empty Refill fluid supply Prime pump see operation manual 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 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 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 Ch
5. to avoid premature bearing wear Be A 5 Install screws 41 and washers 42 in bearing housing Torque evenly to note 3 value below 6 Install pump Refer to Displacement Pump Installation page 14 1 Relieve pressure page 4 2 Remove four screws 45 and front cover 44 3 Remove pump Refer to Displacement Pump Removal page 23 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 con necting rod assembly off drive housing 6 Inspect crank B and connecting rod 43 for exces sive wear and replace parts as needed Installation 1 Evenly lubricate inside of bronze bearing C in bearing housing 40 with high quality motor oil Lib erally 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 hous ings 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 mal let 3A0243A ti5477b 68 A Oil A Pack with bearing grease 114819 A GMAX II 3900 Torque to
6. Malfunction Troubleshooting Procedure see following page for actual steps Remove control box cover Turn sprayer ON Observe control board Green and Red LED lights Go to step 1 No light 3 m Does switch NO as ine Once Normal operation test positive maples Red light on Control board continuously commanding engine to run Green light on WatchDog continuously enabled YES Flashing See error code Check wiring section for further from J1 and J2 troubleshooting y y for proper con Red light on Model not Cotest os Goto step 2 a proper continuously with selected i eae aN e pe ae ay sae potentiometer pias NO OOH AE NO wer eee ote ale OFF after a VDC proper engine or replace engine replacement present voltage generator board is installed YES YES Connect a test a ry 2 transducer to Go to step 4 If low resistance is L_ NO gt the board Is1 3Ohms _ NG present in step 4 clutch a Does the reading pres gt the problem is a engage clutch ent shorted field engage NO Replace pinion If an open in the YES wiring is present Replace YES check pinion VES the al ii Replace the control ea potentiometer board y y Mechanical Replace problem Repair the or replace transducer clutch pinion assembly 8 3A0243A Troubles
7. drain hose to sprayer material hose and hand tighten to 70 in Ib ti6299a zH l D Be EX 5 6 Tighten latch and rotate latch lock into locked posi 8 Fill pump with Graco TSL until fluid flows onto top tion of seal 3A0243A 25 Hose Reel Hose Reel Removal 4 Remove swivel cap Be sure to keep your head clear of hose reel while winding up hose ti13543a 1 Remove hose fitting from swivel cap and completely remove hose ti15023a ti13542a ti15024a 26 3A0243A Hose Reel Installation 1 Grease shaft 5 Install E clip ay Massa ti13538a 2 Make sure two washers and wave spring are on hub before hose reel is installed 6 Install hose to hose cap Make sure to route hose through side arm of hose reel ti13545a ti15023a 3 Install hose reel onto frame Place C clamp on reel and frame to allow snap ring to fit into place Install 7 Wrap up hose Make sure hose is routed through snap ring hose guide ti13536a ti13504a ti13543a 3A0243A 27 Pivot Replacement Pivot Replacement Removal Vi 1 Remove Hose Reel page 26 2 Remove rigid fluid tube from swivel shaft ti15025a 3 Remove two screws on pivot plate A swivel shaft B if necessary and remove coupling C from swivel shaft ti15022a 4 Remove pivot D 28 Installation 1 Install pivot D 2 Install pivot plat
8. engine shaft A Maintain dimension shown note 2 Chamfer must face engine 18 Pinion Assembly 1 Check o ring 29d and replace if missing or dam aged Tap pinion shaft 29a in with plastic mallet Install retaining ring 29b with beveled side facing up Place pinion assembly on bench with rotor side up 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 6 Install pinion assembly 29 with four screws 36 and washers 37 7 Connect clutch cable connectors to inside of pres sure control 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 Ib 14 1 1 N m A Face of clutch housing A 1 550 010 in 39 37 25 mm GMAX 3900 2 612 010 in 66 34 25 mm GMAX 5900 amp 7900 A Torque to 125 10 in Ib 14 1 1 N m A Chamfer this side ti5484a 3A0243A Clutch Housing Removal Aes 1 Remove four screws 20 and lock washers 21 which hold clutch housing 19 to engine 2 Remove screw 35 from under mounting plate D Pull off clutch housing 19 Installation 1 Push on clutch housing 19 2 Install four capscrew
9. part of the body fetes Do not put your hand over the spray tip e Do not stop or deflect leaks with your hand body glove or rag e Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses and couplings daily Replace worn or damaged parts immediately O n MOVING PARTS HAZARD E Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts Ko e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure and disconnect all power sources 2 3A0243A Warning WARNING A PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemi cal reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material sup plier for compatibility icf SUCTION HAZARD Powerful suction could cause serious injury e Never place hands near the pump fluid
10. 00HD across clutch field at 70 F 3 Replace clutch field assembly cCmotv Sprayer stops Engine is Loss of paint to pump or 1 Check for empty paint condition clogged inlet Li ii running severe pressure loss strainer failed pump or severe leak 2 Reduce pressure and turn pump switch OFF with and ON to restart pump constant 3 WatchDog function can be deactivated by green LED turning WatchDog switch OFF 5 Sprayer stops Engine is Pressure greater than 1 Open prime valve and gun Lift running 2000 psi 138 bar 14 MPa 2 Verify no flow obstructions or clogged filter Liu while in Flush Timer Mode ti6320a Error codes also appear on control board as a blinking red LED LED is an alternate to digital messages 1 1 Remove two screws 71 and swing down cover 130 2 2 Start engine Blink count is the same as error code E 0X 3 14 After a fault follow these steps to restart sprayer Correct fault condition Turn sprayer OFF Turn sprayer ON 3A0243A 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 alter nate part and item number Removal DO NOT use bearing housing screws 41 to align or seat bearing housing with drive housing Align these parts with locating pins
11. 200 in lb 22 6 Nem GMAX II 5900 Torque to 25 ft lb 34 Nem GMAX II 7900 Torque to 40 ft lb 54 Nem TexSpray 5900HD Torque to 40 ft lb 54 Nem TexSpray 7900HD Torque to 40 ft lb 54 Nem 15 Drive Housing Drive Housing Removal 1 Relieve pressure page 4 2 Remove bearing housing Refer to Bearing Hous ing and Connecting Rod Removal page 15 Premium models Gallon counter sensor is connected to control board in pressure control Pulling on the sensor wires could cause damage 3 Premium sprayers Remove two screws 108 and gallon counter sensor 39 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 hous ing Be prepared to support combination gear 32 which may also come out Installation 1 Apply all grease supplied with replacement gear cluster to gear teeth and to areas called out by note 3 2 Ensure thrust washers 30 31 5900 7900 30 31 72 3900 are on combination gear 32 and wash ers 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 16
12. 7 Install bearing housing Refer to Bearing Housing and Connecting Rod Installation page 15 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 8 Install screws 38 in drive housing Torque evenly to note 3 value below 9 Install pump Refer to Displacement Pump Installation page 14 ti5478a GMAX II 3900 Torque to 140 10 in lb 15 8 1 1 Nem GMAX II 5900 Torque to 200 10 in Ib 22 6 1 1 Nem GMAX II 7900 Torque to 200 10 in Ib 22 6 1 1 Nem Texspray 5900HD Torque to 200 10 in Ib 22 6 1 1 Nem Texspray 7900HD Torque to 200 10 in lb 22 6 1 1 Nem Gallon counter sensor A Pack with grease 114819 30 72 A Copper A Steel ti6252a 3A0243A Pinion Assembly Clutch Armature Clamp Pinion Assembly Clutch Armature Clamp Pinion Assembly Clutch Armature Removal 6 Remove retaining ring 29b 7 Turn pinion assembly over and tap pinion shaft Pinion Assembly If pinion assembly 29 is not removed from clutch hous ing 19 do 1 through 3 Otherwise start at 4 Zed 1 Remove drive housing page 16 2 Disconnect clutch cable connectors from inside of pressure control a Remove two screws 71 and swing down cover 130a b Disconnect engine leads from board to engine c Remove strain reliefs 130r and 123 3 Remove four screws 36 and p
13. Barrel Il iu AC power to Black to Tips control board White Engine Control Board 0 0 White Blaci Li L2 ti14924a C O STEP 4 BEEP Check the engine ther ogo mal sensor meter should read continuity Note engine should be cooled down Turn meter to continuity test 11 Troubleshooting Convertible Electric Motor Runs No AC Output to Sprayer Control Board Troubleshooting Procedure see following page for actual steps 12 See step 1 Is there over 10 20 AC volts YES See the sprayer control board trou bleshooting in this manual NO See step 2 Is there continuity YES See step 3 Is there continuity NO NO Repair or replace the power cord YES See step 4 Is there over 100 AC volts YES See step 5 Repair or replace the power cord ai NO Is there over 10 20 AC volts YES Replace cord jack NO Repair or replace wire splice s on the power cord wires w Replace transformer 3A0243A Troubleshooting Convertible Electric Motor Runs No AC Output to Sprayer Control Board Steps STEP 1 ea 3 Plug in cord and turn TER switch ON Connect Ss ti14925a wires to transformer and power cord Turn meter to AC volts Jack Power Cord White to b
14. Repair G TM aZ GMAX lIl 3900 5900 7900 TexSpray 5900HD 7900HD Airless Sprayers rey Korean patent 10 0647761 ENG For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi 22 8 MPa 228 bar Maximum Working Pressure Read all warnings and instructions in this IMPORTANT SAFETY INSTRUCTIONS A manual Save these instructions GMAX 3900 Model Hi Boy Hi Boy Lo Boy Lo Boy Premium Standard Premium Standard QuikReel QuikReel 248683 y 248684 J 249335 y 258731 v 258736 v GMAX 5900 Model Hi Boy Hi Boy Lo Boy Lo Boy Premium Standard Premium Standard QuikReel QuikReel 248687 WA 248688 y 258732 v 258737 y TexSpray 5900 HD Model Hi Boy Hi Boy Lo Boy Lo Boy Premium Standard Premium Standard QuikReel QuikReel 258734 v ti14916a GMAX 7900 Model Hi Boy Hi Boy Lo Boy Lo Boy Premium Standard Premium Standard QuikReel QuikReel 248700 Related Manuals 248701 Operation 3A0242 258733 v Parts 3A0244 258738 J Gun 311861 GMAX 7900 Model Hi Boy Hi Boy Lo Boy Lo Boy Premium Standard Premium Standard QuikReel QuikReel 258735 y cE HO03 PROVEN QUALITY LEADING TECHNOLOGY 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 appl
15. arrel AC power to control board Transformer Black to tips Transformer til White Jack Power Con Black TS TS II NY AC power to control board STEP 4 Plug in cord and turn switch ON Partially connect wires to splice Turn meter to AC volts Electric Engine Control Board 3A0243A STEP 2 Check AC power cord for an open wire Turn meter to continuity test Meter should read continuity mee BEEP lt A OOo 4926a __ White to barrel Power Cord AC power to control board Black to tips ti14927a STEP 3 BEEP lt Check AC power OOo cord for an open wire Turn meter to to barrel continuity test Meter should read continuity Black to tips i Power Cord White to barrel AC power to Black to tips hite control board STEP 5 10 20 Ac Plug in cord and turn switch ON Partially connect Transformer wires to splice Turn meter to AC D Pi 0 0 volts ti14928a Black 13 Digital Display Messages Digital Display Messages E 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
16. e A on pivot and tighten two screws on pivot plate C 3 Install o ring and replace swivel shaft B if it was removed ti15022a _ti13544a EA 4 Replace coupling C 5 Replace rigid fluid tube to swivel shaft if it was removed SN _stit5025a 6 Replace Hose Reel page 27 3A0243A 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 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 stainles
17. e pressure control transducer 66 and o ring 67 from filter housing 72 N at Installation eee 1 Install o ring 67 and pressure control transducer 66 in filter housing 72 Torque to 35 45 ft lb 1 Remove two screws 71 and swing down 2 Install transducer connector and rubber grommet in con cover 130a trol housing 2 Disconnect transducer 66 lead from control board 3 Connect transducer 66 lead to control board 130b 130b 4 Swing up cover 130a and secure with two screws 71 3 Pull transducer connector through rubber grommet 113 Pressure Adjust Potentiometer Removal 1 2 1 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 3 remove knob shaft nut lock washer and potentiometer 4 130d f 4 Remove shaft spacer 130e from potentiometer 22 Installation Install shaft spacer 130e on potentiometer 130d Install potentiometer shaft nut lock washer and potenti ometer 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 After a fault follow these steps to restar
18. eck connections Replace sensor or wire Reposition or replace magnet No display sprayer operates Display damaged or has bad connec tion Check connections Replace display 3A0243A Fluid Pump Runs Constantly N 7 C cs MPabariPst Troubleshooting Procedure With a pressure gauge plumbed into the paint hose start the engine Turn pump switch ON Does sprayer exceed maximum pressure Troubleshooting Perform Pressure Relief Procedure page 4 turn prime valve forward to SPRAY position and turn power switch OFF YES Disconnect clutch wires from control board see diagram page 12 Does the pump stop run ning YES y Make sure clutch wires are plugged in see dia gram page 12 Do the clutch test points read 10 18 DC volts YES Y Unplug transducer from control board YES Bad transducer Replace and test with a new one 3A0243A 2 Remove control box cover Pump problem See the proper fluid pump NO p gt Manual for the sprayer for further trouble shooting procedures NO 3 Mechanical problem in the clutch pinion as sembly clutch may be close to the rotor Check for a short from the two clutch wires NO to the frame If shorted repair or replace faulty wire NO Replace the control board Troubleshooting Control Board
19. et 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 r dac
20. hooting Control Board Malfunction Steps STEP 3 Leave engine running and turn switch ON Turn potentiometer to STEP 2 Turn engine ON Set meter to AC volts and connect wires STEP 1 Turn engine OFF and set meter to continuity nog eae to control ti14940a high and set i board meter to DC i ti14939a ti14938a She Control Pump iad t t O Clutch On Off Control Field Switch Engine Board Generator To Clutch Field Pinion Drive To Ground o o Assembly Housing 3900 ae I DO Clutch Test Points J10 0 To Engine O 5900 7900 LED ii oe S J2 Ji c yi Control re 5 O S J Board EA ti14943a J3 J4 ss y On Off Switch Ja a WatchDog K S A Transducer 88888 Premium Display Board NS Em f STEP 4 Potentiometer Em in f 222 Turn engine f KO OFF and unplug A 14942a 4 clutch wires STEP De Set meter to Turn engine Control Ohms ON andturn Board switch ON Control Clutch Board Field SJ Wy ti14941a Clutch Test Points A 3A0243A 9 Troubleshooting Convertible Electric Motor Will Not Run Troubleshooting Procedure see follo
21. icable A WARNING FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre vent fire and explosion D e Use equipment only in well ventilated area e 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 e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Keep work area free of debris including solvent rags and gasoline e Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present e Ground all equipment in the work area See Grounding instructions e Use only grounded hoses e Hold gun firmly to side of grounded pail when triggering into pail e If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e 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 e Do not spray without tip guard and trigger guard installed e Engage trigger lock when not spraying A e Do not point gun at anyone or at any
22. inion assembly 29 8 ti5480a 4 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 ti5987b 3A0243A 10 29a out with plastic mallet IGEN 27 OD T ti5482a Clutch Armature Use an impact wrench or wedge something between clutch armature 25 and clutch housing to hold engine shaft during removal Remove four screws 23 and lock washers 24 Remove armature ti5483a 17 Pinion Assembly Clutch Armature Clamp Installation Clutch Armature 1 Lay two stacks of two dimes on smooth bench sur face 2 Lay armature 25 on two stacks of dimes 3 Press center of hub 26 down to bench surface 26 0 12 01 in 3 0 25 mm N ee Bes W A ed I Pe ii Td dimes j 4 Install armature 25 on engine drive shaft 5 Install four screws 23 and lock washers 24 with torque of 125 in lb Clamp Removal Tal C MPabar PSI 1 Remove engine 2 Drain gasoline from tank according to Honda man ual 3 Tip engine on side so gas tank is down and air cleaner is up 4 Loosen two screws 24 on clamp 22 Push screwdriver into slot in clamp 22 and remove clamp i Clamp Installation 1 Install engine shaft key 18 2 Tap clamp 22 onto
23. inlet when pump is operating or pressurized Be CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon mon oxide can cause death e Do not operate in an enclosed area Be 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 e Read MSDS s to know the specific hazards of the fluids you are using e 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 e 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 inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufac turer 3A0243A Maintenance Maintenance Pressure Relief Procedure A Za C 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 counterclockw
24. ise 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 NOTE For detailed engine maintenance and specifica tions 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 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 necessar
25. n Contact Graco Technical Assistance to adjust WatchDog parameters Operate without WatchDog active see Opera tion manual Engine operates but displacement pump does not operate Error code displayed Pump switch is OFF Reference Pressure Control repair page 21 Turn pump switch ON Pressure setting too low Turn pressure adjusting knob clockwise to increase pressure 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 Repair pump see pump manual 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 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 Q 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 19 Pinion assembly is worn or damaged Repair or
26. replace pinion assembly Page 17 3A0243A 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 O ring in pump is worn or damaged Replace packings see pump manual 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 Clean intake valve see pump manual Engine speed is too low Increase throttle setting see operation man ual 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 Clean filter see gun manual 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 perfor mance 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 leakage Throat packings are worn or damaged Replace packings see pump manual Displacement rod is worn or damaged
27. s 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 ti5486a 3 5 3A0243A Clutch Housing 19 Clutch Housing Engine Removal W NOTE All service to the engine must be performed by an authorized Honda dealer I 20 Remove Pinion Assembly Clutch Arma ture Clamp and Clutch Housing as instructed on pages 17 and 18 Disconnect all necessary wiring Remove two locknuts 17 and screws 16 from base of engine Lift engine carefully and place on work bench A To the field To the engine A To gallon counter To ground a Bottom View 2 5900 7900 Installation 1 2 Lift engine carefully and place on cart Install two screws 16 in base of engine and secure with lock nuts 17 Torque to 26 ft lb 22 6 N m Connect all necessary wiring Install Pinion Assembly Clutch Armature Clamp and Clutch Housing as instructed on pages 17 and 18 3A0243A Pressure Control Pressure Control Pump ON OFF Switch Removal 3 Press in on two retaining tabs on each side of pump ON OFF switch 130f and remove switch from cover Ma fA Installation 1 Install new pump ON OFF switch 130f so tabs of switch snap into place on inside of cover
28. s steel screen reusable Pump inlet size 1 5 16 12 UN 2A Fluid outlet size 3900 5900 Fluid outlet size 7900 14 npsm from fluid filter 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 3A0243A 29 Technical Data Dimensions Sprayer Weight Ib kg Height in cm Width in cm Length in cm no hose and gun 31 5 80 0 22 25 56 5 32 0 81 3 32 25 81 9 24 5 62 2 32 25 81 9 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 30 3A0243A Notes Notes 3A0243A 31 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
29. t sprayer 1 2 3 Correct fault condition Turn sprayer OFF Turn sprayer ON 3A0243A Displacement Pump Displacement Pump Removal 6 Raise latch lock Push latch open ti6369a fo e 1 Flush pump 2 Stop pump with piston rod in its lowest position 3 Do Pressure Relief page 4 ti6370a 4 Separate drain hose from sprayer 7 Ratchet open pump door a Ratchet pump door forward ti14904a ti6373a 5 Disconnect material hose from pump b Twist latch u bolt out of pump door recess amn c Place u bolt on pump door outer edge ti6300a d If pump door is stuck do steps e f and 8 oth erwise go to step 9 e Twist latch u bolt back from pump door outer edge ti6374a 3A0243A 23 Displacement Pump f Place u bolt on pump door protrusion Installation ti6375a 9 Open pump door 24 1 4 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 a ti5492a 3 Slide pump into connecting rod Push pump pin until it is fully retained NOTE Pin will snap into position ti14907a Close pump door and rotate latch into position Do not tighten latch gt ti6313a 3A0243A Displacement Pump 5 Rotate pump to align with material hose Connect 7 Attach
30. tion du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es For the latest information about Graco products visit www graco com 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 This manual contains English MM 3A0243 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2009 Graco Inc is registered to ISO 9001 www graco com 2009
31. wing page for actual steps See Step 1 Is there See step 2 Is there over 100 AC volts B YES Y t See Step 3 Is there NO over 100 AC volts YES Replace the power switch See Step 4 Is there over 100 DC volts YES See engine test section 10 continuity through the thermal sensor NO P the power cord Repair or replace YES Replace engine control board NO If engine is hot let cool and retest If step 4 still shows an open replace engine 3A0243A Troubleshooting Convertible Electric Motor Will Not Run Steps STEP 1 Plug in cord and turn switch ON Connect y wires to control board and turn meter to AC volts ti14920a Black Electric Engine Control Board Ground Black eE STEP 3 400 0 Plug in cord and turn switch ON Turn meter to DC volts 3A0243A Mi AL D STEP 2 e Plug in cord and turn switch ON Connect 3 OOO wires to control board 37 and turn meter to AC volts Black to ti14921a power cord Ad Black T A White Transformer Electric Engine Control Board Black Power Cord White to
32. y 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 3A0243A Troubleshooting Troubleshooting TA 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 Engine is out of gasoline Engine oil level is low Spark plug disconnected or damaged Turn engine switch ON Refill gas tank Honda Engine Manual Try to start engine Replenish oil if necessary Honda Engine Manual 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 Operating conditions out of WatchDog parameters Pump output is low page 6 Turn pressure dow
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