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Repair
™
GMAX II 3900/5900/7900
™
TexSpray 5900HD/7900HD
Airless Sprayers
3A0243A
Korean patent: 10-0647761
ENG
- 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 Hi-Boy Lo-Boy Lo-Boy
Premium Standard Premium Standard
(QuikReel) (QuikReel)
248683 ✓
248684 ✓
249335 ✓
258731 ✓
258736 ✓
GMAX 5900
M
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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 pre- vent fire and explosion: • Use equipment only in well ventilated area. � Do not fill fuel tank while engine is running or hot; shut off engine
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Warning WARNING 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. � 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
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Maintenance Maintenance AFTER THE FIRST 20 HOURS OF OPERATION: Pressure Relief Procedure 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 1. Lock gun trigger safety. replace, if necessary. 2. Turn engine ON/OFF switch to OFF. Replacement elements can be purchased from your
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Troubleshooting 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 l
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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- Clean intake valve (see pump manual). rial. Engine speed is too low. Incre
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Troubleshooting Fluid Pump Runs Constantly 1. Perform Pressure Relief Procedure (page 4), turn prime valve forward to SPRAY position, and turn power switch OFF. 2. Remove control box cover. Troubleshooting Procedure: Pump problem. See the proper fluid pump With a pressure gauge plumbed into the paint manual for the sprayer for further trouble- hose, start the engine. Turn pump switch ON. NO shooting procedures. Does sprayer exceed maximum pressure? YES Disconnect clutch wires from control b
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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. Go to step 1. No light Replace the Does switch NO switch. Once Normal operation test positive? Red light on Control board continuously commanding engine to run Green light on WatchDog continuously enabled YES Check wiring Flashing See error code from J1 and J2 section for further for prope
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+ + + - - Troubleshooting Control Board Malfunction (Steps) STEP 3. STEP 2. STEP 1. 10-12 DC 12 -20 AC Leave engine Turn engine Turn engine BEEP V running and turn ON. Set meter OFF and set V switch ON. Turn to AC volts and meter to - potentiometer to connect wires continuity. - high and set to control ti14940a - meter to DC board. ti14939a ti14938a volts. Control + Board Pump Clutch On/Off Control Field Engine Switch Board Generator To Clutch Field Pinion Drive Assembly +
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Troubleshooting Convertible Electric Motor Will Not Run Troubleshooting Procedure (see following page for actual steps): See step 2. Is there Repair or replace See Step 1. Is there NO NO over 100 AC volts? the power cord. over 100 AC volts? YES Replace the power switch. YES If engine is hot, let See Step 4. Is there See Step 3. Is there cool and retest. If NO NO continuity through the over 100 DC volts? step 4 still shows an thermal sensor? open, replace engine. YES YES See engine test sec
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+ + - + - Troubleshooting Convertible Electric Motor Will Not Run (Steps) STEP 1. STEP 2. Plug in cord and turn Plug in cord and turn switch ON. Connect switch ON. Connect wires to control board wires to control board V V and turn meter to AC and turn meter to AC volts. volts. - - ti14921a Black to ti14920a power cord - White White Black Black L2 L1 L2 L1 Transformer Electric Engine Control Board Electric Engine Control Board Black Ground Black Black Jack Power Cord White to Barrel AC power
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Troubleshooting Convertible Electric Motor Runs - No AC Output to Sprayer Control Board Troubleshooting Procedure (see following page for actual steps): See step 1. See step 2. Repair or replace NO Is there over 10-20 NO Is there continuity? the power cord. AC volts? YES YES See step 3. Repair or replace See the sprayer NO Is there continuity? the power cord. control board trou- bleshooting in this manual. YES Repair or replace See step 4. wire splice(s) on Is there over 100 NO the powe
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+ - + Troubleshooting Convertible Electric Motor Runs - No AC Output to Sprayer Control Board (Steps) STEP 1. STEP 2. 10-20 AC Plug in cord and turn Check AC power cord BEEP switch ON. Connect for an open wire. Turn V wires to transformer meter to continuity and power cord. Turn test. Meter should - meter to AC volts. ti14926a read continuity. - ti14925a White to barrel White to barrel Jack Power Cord Power Cord AC power to Black to tips AC power to Black to tips Transformer control boa
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Digital Display Messages Digital Display Messages � 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 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. pressurized. 200 psi
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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 NOTICE 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. Align these nate part and item number. parts with locating pins, to avoid premature bearing wear. Removal 5. Instal
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Drive Housing Drive Housing 7. Install bearing housing. Refer to Bearing Housing Removal and Connecting Rod, Installation, page 15. NOTICE 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. 1. Relieve pressure; page 4. 8. Install screws (38) in drive housing. Torque evenly to 2. Remove bearing housing. Refer to Bearing Hous- note 3 value below. ing and Connecting Rod, Removal, page
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Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature/Clamp 6. Remove retaining ring (29b). Pinion Assembly/Clutch Armature Removal 7. Turn pinion assembly over and tap pinion shaft Pinion Assembly (29a) out with plastic mallet. If pinion assembly (29) is not removed from clutch hous- ing (19), do 1. through 3. Otherwise, start at 4. 27 29b 29a 1. Remove drive housing; page 16. 2. Disconnect clutch cable connectors from inside of 29d pressure control. a. Remove two screws (71)
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Pinion Assembly/Clutch Armature/Clamp Installation Clutch Armature Pinion Assembly 1. Lay two stacks of two dimes on smooth bench sur- 1. Check o-ring (29d) and replace if missing or dam- face. aged. 2. Lay armature (25) on two stacks of dimes. 2. Tap pinion shaft (29a) in with plastic mallet. 3. Press center of hub (26) down to bench surface. 3. Install retaining ring (29b) with beveled side facing up. 25 26 0.12+01 in (3.0+.25 mm) 4. Place pinion assembly on bench with rotor side up. 5. Appl
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Clutch Housing Clutch Housing Removal 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). 3. Pull off clutch housing (19). Installation 1. 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). 19 18 21 20 D ti5486a 35
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Clutch Housing Engine Removal 16 NOTE: All service to the engine must be performed by an authorized Honda dealer. 1. Remove Pinion Assembly/Clutch Arma- ture/Clamp and Clutch Housing, as instructed on pages 17, and 18. 2. Disconnect all necessary wiring. ti5487a 3. Remove two locknuts (17) and screws (16) from 17 base of engine. 4. Lift engine carefully and place on work bench. Installation 1 To the field 1. Lift engine carefully and place on cart. 2 To the engine 3 To gallon counter 2. In
