Graco GMAX 3400, GMAX II 3900, GMAX II 7900, TexSpray 5900HD, TexSpray 7900HD Operation
...
Operation
ti23055a
GMAX™ 3400, GMAX™ II 3900/5900/7900, and
3A6400A
TexSpray 5900HD/7900HD Airless Sprayers
For the application of architectural paints and coatings. For professional use only.
Not approved for use in European explosive atmosphere locations.
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual and in gas engine manual before using
the equipment. Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals:
Parts 3A6417
Honda Engine Manuals
EN
Model Standard ProContractor Lo-Boy Ironman
GMAX 3400 17E825
GMAX II 3900 17E827 17E826
GMAX II 5900 17E831 17E829
GMAX II 5900
Convertible
GMAX II 7900 17E836 17E834
TexSpray 5900HD 17E839
TexSpray 7900HD 17E841
GMAX 3400 17G997
GMAX II 3900 17G999 17E828 17G998
GMAX II 5900 17H810 17E832 17H808 17E833
GMAX II 7900 17H818 17E837 17H817 17E838
GMAX II 7900
Roof Rig
TexSpray 5900HD 17H819 17E840
TexSpray 7900HD 17H820 17E842 17E843
17E830
17E835
Contents
Contents
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electric Motor Warnings . . . . . . . . . . . . . . . . . . . 4
Internal Combustion Engine Warnings . . . . . . . . 5
Electric Motor/Internal Combustion Engine
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 8
Standard Models (3400, 3900, 5900, 5900HD,
7900, 7900HD) . . . . . . . . . . . . . . . . . . . . . . . 8
ProContractor Models (3900, 5900, 7900, 5900HD,
7900HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ironman Models (5900, 7900, 7900HD) . . . . . . 10
Lo-Boy Models (3900, 5900, 7900) . . . . . . . . . . 11
Convertible Models (5900) . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding Procedure for Internal Combustion
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding of Pails . . . . . . . . . . . . . . . . . . . . . . 14
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Convertible Models Only . . . . . . . . . . . . . . . . . . 16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Switch Tip
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Clearing Tip Clogs . . . . . . . . . . . . . . . . . . . . . . 19
WatchDog
™
Guard Assembly . . . . . . . . . . . . . . 18
™
Protection System (ProContractor and
Ironman units only) . . . . . . . . . . . . . . . . . . . 19
QuikReel
LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LED Display Messages . . . . . . . . . . . . . . . . . . . . . 38
Pinion Assembly/Clutch Armature/Clamp . . . . . . 39
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 45
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46
™
(ProContractor units only) . . . . . . . . . . . . . . . 20
(ProContractor and Ironman units) . . . . . . . . . . 21
Fluid Pump Runs Constantly . . . . . . . . . . . . . . . 31
Control Board Malfunction . . . . . . . . . . . . . . . . . 32
Control Board Malfunction (Steps) . . . . . . . . . . 33
Convertible Electric Motor Will Not Run . . . . . . 34
Convertible Electric Motor Will Not Run (Steps) 35
Convertible Electric Motor Runs -
No AC Output to Sprayer Control Board . . . 36
Pinion Assembly/Clutch Armature Removal . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Clamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . 40
Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . 40
2 3A6400A
Warning
WARNING
120V US
Warning
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet
that is properly installed and grounded in accordance with all local codes and ordinances.
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to
either flat blade terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a
qualified electrician.
• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plugs
illustrated in the figure below.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
• Extension Cords:
• Use only a 3-wire extension cord that has a grounding plug and a grounding receptacle that accepts
the plug on the product.
• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG (2.5
2
mm
) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.
3A6400A 3
Warning
WARNING
Electric Motor Warnings
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:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as
cigarettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity
creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray
system, including the pump, hose assembly, spray gun, and objects in and around the spray area
shall be properly grounded to protect against static discharge and sparks. Use Graco conductive or
grounded high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge. Do not
use pail liners unless they are anti-static or conductive.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Do not spray flammable or combustible liquids in a confined area.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area.
• Sprayer generates sparks. Keep pump assembly in a well-ventilated area at least 20 feet (6.1 m)
from the spray area when spraying, flushing, cleaning, or servicing. Do not spray pump assembly.
• Do not smoke in the spray area or spray where sparks or flame is present.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Safety Data Sheets (SDSs)
and container labels provided with the paints and solvents. Follow the paint and solvent
manufacturer’s safety instructions.
• Keep a working fire extinguisher in the work area.
4 3A6400A
Internal Combustion Engine Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death.
Warning
• Do not operate internal combustion engine in an enclosed area.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
3A6400A 5
Warning
WARNING
Electric Motor/Internal Combustion Engine Warnings
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious injury that can result in
amputation. In the event that injection occurs, get immediate surgical treatment.
• Do not aim the gun at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks
with any part of the body.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Graco nozzle tips.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure
before removing the nozzle tip to clean.
• Equipment maintains pressure after power is shut off. Do not leave the equipment energized or
under pressure while unattended. Follow the Pressure Relief Procedure when the equipment is
unattended or not in use, and before servicing, cleaning, or removing parts.
• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
• This system is capable of producing 3300 psi (228 bar, 22.8 MPa). Use Graco parts or accessories
that are rated a minimum of 3300 psi (228 bar, 22.8 MPa).
• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
6 3A6400A
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.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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 Safety Data Sheets (SDSs) 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.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously
injured.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective 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.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause
cancer, birth defects or other reproductive harm.
This product contains a chemical known to the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
3A6400A 7
Component Identification
Component Identification
Standard Models (3400, 3900, 5900, 5900HD, 7900, 7900HD)
A Engine ON/OFF Switch
B Grounding Clamp
C Pump On/Off Switch
D Pressure Control
E Prime Valve
F Gun Trigger Lock
8 3A6400A
GStrainer
HPump
J Engine Controls
K Drain Hose
L Easy Out Pump Filter
MHose
Component Identification
ProContractor Models (3900, 5900, 7900, 5900HD, 7900HD)
A Grounding Coil
B Smart Control 3.0 Display
C Pump ON/OFF Switch
D
WatchDog
E Pressure Control
F Prime Valve
G Gun Trigger Lock
HStrainer
3A6400A 9
TM
Switch
JDrain hose
KPump
L Rod Pull Feature
M Engine Controls
N
ProConnect
P Filter
R Engine ON/OFF Switch
S QuikReel
TM
II Pump Clamp
Component Identification
Ironman Models (5900, 7900, 7900HD)
A Grounding Coil
B Smart Control 3.0 Display
C Pump ON/OFF Switch
D
WatchDog
E Pressure Control
F Prime Valve
G Gun Trigger Lock
H Heavy Duty Strainer
10 3A6400A
TM
Switch
J Drain Hose
K MaxLife Pump
L Rod Pull Feature
M Engine Controls
N
ProConnect
P Easy Out Pump Filter
R Engine ON/OFF Switch
S Hose (not shown)
TM
II Pump Clamp
Lo-Boy Models (3900, 5900, 7900)
Component Identification
A Engine ON/OFF Switch
B Grounding Coil
C Pump ON/OFF Switch
D Pressure Control
E Prime Valve
F Gun Trigger Lock
GHose
3A6400A 11
H Pump
J Drain Hose
K Rod Pull Feature
LStrainer
M Engine Controls
N
ProConnect
O Easy Out Pump Filter
TM
II Pump Clamp
Component Identification
Convertible Models (5900)
A Engine ON/OFF Switch
B Grounding Coil
C Pump On/Off Switch
D Pressure Control
E Prime Valve
F Gun Trigger Lock
GHose
12 3A6400A
HStrainer
JPump
K Engine Controls
L Drain Hose
M Easy Out Pump Filter
NPower Pack
Pressure Relief Procedure
ti5787a
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Engage trigger lock.
2. Turn gas engine ON/OFF siwtch to OFF. For
Convertible Models with electric motor, turn electric
motor ON/OFF switch to OFF, and unplug power
cord to electric motor.
3. Disengage trigger lock. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
4. Engage gun trigger lock.
5. Turn prime valve down to DRAIN position. Leave
prime valve down until ready to spray again.
6. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved:
Grounding
Grounding Procedure for
Internal Combustion Engine
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
To ground sprayer: Attach sprayer grounding clamp to
earth ground.
Air and fluid hoses: Use only electrically conductive
hoses with a maximum of 500ft. (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses. If total resistance to ground
exceeds 29 megaohms, replace hose immediately.
Spray gun: Ground through connection to a properly
grounded fluid hose and pump.
a. VERY SLOWLY loosen the tip guard retaining
nut or the hose end coupling to relieve pressure
gradually.
b. Loosen the nut or the coupling completely.
c. Clear the obstruction in the hose or tip.
3A6400A 13
Grounding
Grounding Procedure for
Electric Motor (Convertible
Models only)
The equipment must be grounded to reduce the risk
of static sparking and electric shock. An electric or
static spark can cause fumes to ignite or explode. An
improper ground can cause electric shock. A good
ground provides an escape wire for the electric
current.
This sprayer is equipped with a power cord that has a
ground wire and an appropriate grounding plug.
If using the electric motor, plug must be plugged into an
actual outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Do not modify the plug provided; if it does not fit the
outlet, have the proper outlet installed by a qualified
electrician.
Grounding of Pails
Solvent pails used when flushing: Follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which interrupts
grounding continuity.
ti25360a
Always ground a metal pail: connect a ground wire to
the pail. Clamp one end to the pail and the other end to
a true earth ground such as a water pipe.
To maintain ground continuity when sprayer is
flushed or pressure is relieved: hold metal part of
spray gun firmly to the side of a grounded metal pail
then trigger the gun.
Power Requirements
Convetible is only in USA or Canada.
• 100-120 VAC, 50/60 Hz, 15A, 1 phase.
Extension Cords
Use an extension cord with an undamaged ground
contact. If an extension cord is necessary, use a 3-wire,
12 AWG (2.5 mm²) minimum.
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
ti24585a
14 3A6400A
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