Graco 16W884, 16W870, 16W871, 16W865, 16W887 User Manual

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Operation

GMAX™ 3400, GMAX™ II 3900/5900/7900, and TexSpray 5900HD/7900HD Airless Sprayers

332919C

Not approved for use in European explosive atmosphere locations.

For professional use only.

For the application of architectural paints and coatings.

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. Save these instructions.

GMAX 3400

Model: Standard

16W863 ✓

GMAX II 3900

Model: Standard ProContractor Lo-Boy RentalPro

360G

16W865 ✓

16W866 ✓

16W867 ✓

16W984 ✓

GMAX II 5900

Model: Standard ProContractor Lo-Boy Ironman Convertible

16W869 ✓

16W870 ✓

16W871 ✓

16W881 ✓

16W873 ✓

GMAX II 7900

Model: Standard ProContractor Lo-Boy Ironman Roof Rig

16W883 ✓

16W884 ✓

16W885 ✓

16W887 ✓

16W987 ✓

TexSpray 5900HD

Model: Standard ProContractor

16W889 ✓

16W882 ✓

TexSpray 7900HD

Model: Standard ProContractor Ironman

16W890 ✓

16W888 ✓

16X949 ✓

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Related Manuals:

Parts 332921

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Standard Models (3400, 3900, 5900, 5900HD,

7900, 7900HD) . . . . . . . . . . . . . . . . . . . . . . . 5

ProContractor Models (3900, 5900, 7900, 5900HD,

7900HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ironman Models (5900, 7900, 7900HD) . . . . . . . 7

Lo-Boy Models (3900, 5900, 7900) . . . . . . . . . . . 8

Convertible Models (5900) . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Convertible Models Only: . . . . . . . . . . . . . . . . . 12

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Switch Tip

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Clearing Tip Clogs . . . . . . . . . . . . . . . . . . . . . . . 15

WatchDog

Ironman units only) . . . . . . . . . . . . . . . . . . . . . 15

Hose Reel

(ProContractor units only) . . . . . . . . . . . . . . . 16

™

Guard Assembly . . . . . . . . . . . . . . 14

™

Protection System (ProContractor and

Digital Tracking System

(ProContractor and Ironman units) . . . . . . . . 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure . . . . . . . . . . . . . . . . 21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fluid Pump Runs Constantly . . . . . . . . . . . . . . . 24

Control Board Malfunction . . . . . . . . . . . . . . . . . 25

Control Board Malfunction (Steps) . . . . . . . . . . . 26

Convertible Electric Motor Will Not Run . . . . . . 27

Convertible Electric Motor Will Not Run (Steps) 28 Convertible Electric Motor Runs -

No AC Output to Sprayer Control Board . . . 29

Digital Display Messages . . . . . . . . . . . . . . . . . . . 31

Pinion Assembly/Clutch Armature/Clamp . . . . . . 32

Pinion Assembly/Clutch Armature Removal . . . 32

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Clamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . 33

Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . 33

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 38

2 332919C

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.

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. Do not use pail liners unless they are antistatic

or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you iden-

tify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. 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, fol-

low the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit

and follow the Pressure Relief Procedure for turning off the unit.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3300 psi (22.8 MPa, 228 bar). Use Graco replacement parts or accessories

that are rated a minimum of 3300 psi (22.8 MPa, 228 bar).

• 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.

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.

332919C 3

Warning

WARNING

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 Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment

manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS 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.

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 contain-

ing such solvents.

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

patibility.

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 MSDSs 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 is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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. This 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.

RECOIL HAZARD

Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.

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.

4 332919C

Component Identification

Standard Models (3400, 3900, 5900, 5900HD, 7900, 7900HD)

OFF

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OFF

A Engine ON/OFF Switch B Grounding Clamp C Pump On/Off Switch D Pressure Control E Prime Valve F Gun Trigger Lock

332919C 5

GStrainer HPump

J Engine Controls

K Drain Hose

L Easy Out Pump Filter

MHose

Component Identification

ProContractor Models (3900, 5900, 7900, 5900HD, 7900HD)

OFF

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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

J Drain hose

Switch

KPump

L Toolbox M Rod Pull Feature N Engine Controls

ProConnect

R Filter

S Engine ON/OFF Switch

T Hose Reel

II Pump Clamp

6 332919C

Ironman Models (5900, 7900, 7900HD)

Component Identification

OFF

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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

332919C 7

Switch

J Drain Hose

K MaxLife Pump

L Rod Pull Feature

M Engine Controls

ProConnect P Easy Out Pump Filter R Engine ON/OFF Switch SHose

II Pump Clamp

Component Identification

Lo-Boy Models (3900, 5900, 7900)

OFF

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OFF

A Engine ON/OFF Switch B Grounding Coil C Pump ON/OFF Switch D Pressure Control E Prime Valve F Gun Trigger Lock GHose HPump

8 332919C

J Drain Hose K Rod Pull Feature LStrainer

M Engine Controls

ProConnectTM II Pump Clamp

O Easy Out Pump Filter

Convertible Models (5900)

OFF

Component Identification

ti22696a

A Engine ON/OFF Switch B Grounding Coil C Pump On/Off Switch D Pressure Control E Prime Valve F Gun Trigger Lock GHose

HStrainer

JPump

K Engine Controls

L Drain Hose

M Easy Out Pump Filter

NPower Pack

332919C 9

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 engine ON/OFF switch to OFF.

3. Move pump switch to OFF and turn pressure control knob fully counterclockwise.

4. Disengage trigger lock. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure.

5. Engage gun trigger lock.

6. Turn prime valve down to DRAIN position. Leave prime valve down until ready to spray again.

7. If you suspect the spray tip or hose is 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. Clear hose or tip obstruction.

Grounding

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.

ti5787a

Air and fluid hoses: Use only electrically conductive hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground exceeds 29 megohms, replace hose immediately.

Spray gun: Ground through connection to a properly

grounded fluid hose and pump.

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 nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: Hold metal part of the spray gun

firmly to the side of a grounded metal pail, then trigger the gun.

10 332919C

Setup

All sprayers except ProContractor:

appropriate Graco high-pressure hose to sprayer.

Select Units:

Install whip hose to fluid inlet of spray

gun and tighten securely.

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Connect

Setup

5. Fill throat packing nut with TSL to prevent premature packing wear. Do this each time you spray.

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6. Check engine oil level. Add SAE 10W-30 (summer) or 5W-20 (winter), if necessary.

3. Engage gun trigger lock.

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4. When spraying texture, remove inlet strainer and filter bowl screen when spraying materials.

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7. Fill fuel tank.

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8. Attach sprayer grounding clamp to earth ground.

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332919C 11

Setup

Convertible Models Only:

Change Engine to Motor

1. Disconnect engine power cord.

5. Look through side vent holes and ensure drive belt is in motor pulley.

ti5772a

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2. Release tension bar.

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3. Remove engine; tilt and slide back.

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6. Secure motor with tension bar.

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7. Plug in pressure control power cord.

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4. Install motor; drop in and push forward.

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12 332919C

Startup

c. Set throttle to fast.

1. Place suction tube and drain tube in grounded metal pail partially filled with flushing fluid. Attach ground wire to pail and to earth ground.

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2. Turn prime valve down to DRAIN position. Turn

pressure control counterclockwise to lowest pressure.

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3. Set pump switch OFF.

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d. Set engine switch to ON.

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5. Pull rope to start engine.

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6. Increase pressure enough to start pump stroking and allow fluid to circulate for 15 seconds; turn pressure down and turn prime valve forward to SPRAY position.

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4. Start Engine

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a. Move fuel valve to open.

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7. Disengage spray gun trigger lock.

b. Move choke to closed.

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332919C 13

Startup

8. Hold gun against grounded metal flushing pail. Trigger gun and increase fluid pressure slowly until pump runs smoothly.

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Inspect fittings for leaks. Do not stop leaks with your hand or a rag! If leaks occur, turn sprayer OFF immediately. Perform Pressure Relief Procedure steps 1-3, page 10. Tighten leaky fittings. Repeat Startup procedure steps 1 - 5. If no leaks, continue to trigger gun until system is thoroughly flushed. Proceed to step 6.

9. Place siphon tube in material pail.

Switch Tip™ Guard Assembly

1. Perform Pressure Relief Procedure, page 10.

2. Engage gun trigger lock. Insert Switch Tip. Insert

seat and OneSeal

3. Insert Switch Tip.

4. Screw assembly onto gun. Tighten.

™

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ti13024a

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10. Trigger gun again into flushing fluid pail until material appears.

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Spray

1. Spray test pattern. Increase pressure to eliminate heavy edges. Use smaller tip size if pressure adjustment can not eliminate heavy edges.

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2. Hold gun perpendicular, 10-12 in. (25-30 cm) from surface. Spray back and forth. Overlap by 50%. Trigger gun after moving and release before stopping.

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14 332919C

WatchDog™ Protection System (ProContractor and Ironman units only)

Clearing Tip Clogs

To avoid injury, never point gun at your hand or into a rag!

1. Release trigger, engage trigger lock. Rotate Switch Tip. Disengage trigger lock. Trigger gun to clear clog.

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2. Engage trigger lock. Return Switch Tip to original position. Disengage trigger lock and continue spraying.

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WatchDog™ Protection System

(ProContractor and Ironman units only)

Pump stops automatically when material pail is empty.

To Activate:

1. Perform Startup.

2. Turn WatchDog switch ON and WD ON displays. EMPTY displays/flashes and pump stops when Watchdog protection system detects an empty material pail.

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3. Turn WatchDog switch OFF. Add material or reprime sprayer. Turn pump switch OFF and ON to reset WatchDog protection system. Turn WatchDog switch back ON to continue to monitor material level.

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332919C 15

Hose Reel (ProContractor units only)

Hose Reel

(ProContractor units only)

To avoid injury, keep your head clear of hose reel while winding up hose.

1. Make sure hose is routed through hose guide.

3. Pull reel handle down and turn clockwise to reel in hose.

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NOTE: The hose reel can be locked into two positions: Usage (A) and Storage (B).

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2. Lift and turn pivot lock 90 to unlock hose reel. Pull on hose to remove it from hose reel.

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(A)

(B)

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16 332919C

Digital Tracking System

(ProContractor and Ironman units)

Digital Tracking System (ProContractor and Ironman units)

Operation Main Menu

Short press to move to next display. Press and hold (5 seconds) to change units or reset data.

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1. Turn pressure to lowest setting. Trigger gun to relieve pressure. Turn prime valve down to DRAIN position.

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2. Turn power ON. Pressure display appears. Dashes will not appear unless pressure is less than 200 psi (14 bar, 1,4 MPa).

Job Gallons

1. Short press DTS button to move to Job Gallons (or liters x 10).

ti22717a

NOTE: JOB scrolls past, then the number of gallons sprayed above 1000 psi (70 bar, 7 MPa) displays.

Lifetime Gallons

1. Short press DTS button to move to Lifetime Gallons (or liters x 10).

NOTE: LIFE scrolls briefly, then the number of gallons sprayed above 1000 psi (70 bar, 7 MPa) displays.

OFF

ti22715a

Change Display Units

Press and hold DTS button for 5 seconds to change pressure units (psi, bar, MPa) to desired units. Selection of bar or MPa changes gallons to liters x 10. To change display units DTS must be in pressure display mode and pressure must be at zero.

ti22716a

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332919C 17

Digital Tracking System (ProContractor and Ironman units)

Secondary Menu - Stored Data and WatchDog Pump Protection Modes

1. Perform Pressure Relief, steps 1 - 4 if they have

not already been done.

2. Turn power switch on while holding DTS button down.

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3. The sprayer model briefly displays (e.g. 5900), SERIAL NUMBER scrolls past and then serial number (e.g. 00001) displays.

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4. Short press DTS button and MOTOR ON scrolls past and then total motor run hours are displayed.

7. Short press DTS button. W-DOG scrolls past then OFF displays if watchdog switch is OFF. ON dis- plays if Watchdog switch is ON.

ti22724a

8. Press and hold (8 seconds) DTS button to move to WatchDog Trigger % menu. Continue to hold DTS button and Watchdog can be set to trigger at 30, 40, 50, or 60% of current sprayer pressure setting. Release DTS button when desired % is displayed. default is 50%.

ti22725a

9. Short press to move to SOFTWARE REV.

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5. Short press DTS button. LAST ERROR CODE

scrolls by and last error code is displayed; e.g. E=07. See sprayer Repair manual for additional information.

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6. Press and hold DTS button to clear error code to zero.

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18 332919C

Cleanup

1. Perform Pressure Relief Procedure (page 10),

steps 1 - 4. Remove siphon tube set from paint and place in flushing fluid. Remove tip guard from gun.

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NOTE: Use water for water-base paint, mineral spirits for oil-base paint, or other solvents recommended by manufacturer.

2. Start Engine

Cleanup

3. Pull rope to start engine.

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4. Turn pump switch ON. Turn prime valve forward to SPRAY position.

OFF

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5. Increase pressure to 1/2. Hold gun against paint pail. Disengage trigger lock. Trigger gun until flushing fluid appears.

a. Move fuel valve to open.

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b. Move choke to closed.

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c. Set throttle to fast.

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d. Set engine switch to ON.

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6. Move gun to waste pail, hold gun against pail, trigger gun to thoroughly flush system. Release trigger and engage trigger lock.

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7. Turn prime valve down to DRAIN position and allow flushing fluid to circulate until flushing fluid appears clear.

8. Turn prime valve forward to SPRAY position. Trigger gun into flushing pail to purge fluid from hose.

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332919C 19

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Cleanup

9. Raise siphon tube above flushing fluid and run sprayer for 15 to 30 seconds to drain fluid. Turn pump switch and engine OFF

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10. Turn prime valve down DRAIN position.

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11. Remove filters from gun and sprayer, if installed. Clean and inspect. Install filters.

12. If flushing with water, flush again with mineral spirits, or Pump Armor, to leave a protective coating to prevent freezing or corrosion.

13. Wipe sprayer, hose and gun with a rag soaked in water or mineral spirits.

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20 332919C

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.

NOTE: For detailed engine maintenance and specifications, refer to separate Honda Engines Owner's Manual, supplied.

DAILY: Check level of TSL in displacement pump packing 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 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.

Use the supplied engine oil funnel when draining oil.

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 opera-

tion.

DAILY: Check and fill the gas tank.

OIL FUNNEL

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332919C 21

Troubleshooting

Problem Cause Solution

E=XX is displayed Fault condition exists. Determine fault correction from table, page 31.

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.

False tripping of WatchDog system. EMPTY is displayed. Pump does not run.

Engine operates, but displacement pump does not operate

Oil is seeping into combustion chamber.

Operating conditions out of WatchDog parameters.

Pump output is low, page 23. Error code displayed. See Digital Display Messages, page 31. 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. See Parts manual. Drive housing is worn or damaged. See Parts manual. Electrical power is not energizing clutch

field.

Remove spark plug. Pull starter 3 to 4 times.

Clean or replace spark plug. Start engine.

Keep sprayer upright to avoid oil seepage.

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).

See Parts manual.

See Digital Display Messages, page 31.

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 for 3900 -

1.2 + 0.2 Ω, for 5900/7900 1.7 ± 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 32.

22 332919C

Adjust or replace clutch. See page 32.

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 32. 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.

332919C 23

Troubleshooting

Fluid Pump Runs Constantly

Troubleshooting Procedure:

1. Perform Pressure Relief Procedure (page 21),

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 29). Does the pump stop running?

YES

Make sure clutch wires are plugged in (see diagram, page 29). 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.

24 332919C

Replace the control board.

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.

Troubleshooting

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.

332919C 25

Replace the transducer.

Troubleshooting

Control Board Malfunction (Steps)

BEEP

STEP 1.

Turn engine OFF and set meter to continuity.

ti14938a

Pump On/Off Switch

To Engine

To Ground

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

To C l u tc h Field

Clutch Test Points

J10

LED D12

STEP 3.

10-12 DC

ti14940a

Clutch Field

Pinion Assembly

ti14943a

Drive Housing

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

Control Board

Clutch Field

On/Off Switch

1-3 ohms

ti14942a

Clutch Test Points

WatchDog

STEP 4.

Turn engine OFF and unplug clutch wires. Set meter to Ohms.

Control Board

Premium Display Board

Transducer

Potentiometer

STEP 5.

Turn engine ON and turn switch ON.

Control Board

ti14941a

26 332919C

Convertible Electric Motor Will Not Run

Troubleshooting Procedure (see following page for actual steps):

Troubleshooting

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.

332919C 27

Troubleshooting

Convertible Electric Motor Will Not Run (Steps)

STEP 1.

Plug in cord and turn switch ON. Connect

wires to control board and turn meter to AC volts.

ti14920a

Black

Electric Engine Control Board

White

Ground

Black

Transformer

White

Black

STEP 2.

Plug in cord and turn switch ON. Connect wires to control board and turn meter to AC volts.

power cord

Jack

Power Cord

AC power to control board

Black to

ti14921a

Black

Electric Engine Control Board

White to Barrel

Black to Tips

White

100 + DC

ti14923a

+M -M

STEP 3.

Plug in cord and turn switch ON. Turn meter to DC volts.

Engine

TS TS

Control Board

Engine Control Board

Black

+M -M

ti14924a

Electric Engine

White

TS TS

STEP 4.

BEEP

Check the engine thermal sensor (meter should read continuity). Note: engine should

ti14922a

be cooled down. Turn meter to continuity test.

Engine Control

-M TS

Board

Electric Engine

Yellow Yellow

Electric Engine

28 332919C

Convertible Electric Motor Runs No AC Output to Sprayer Control Board

Troubleshooting Procedure (see following page for actual steps):

Troubleshooting

See step 1. Is there over 10-20 AC volts?

YES

See the sprayer control board troubleshooting in this manual.

See step 2. Is there continuity?

YES

See step 3. Is there continuity?

YES

See step 4. Is there over 100 AC volts?

YES

See step 5. Is there over 10-20 AC volts.

Repair or replace the power cord.

Repair or replace wire splice(s) on the power cord wires.

Replace transformer.

YES

Replace cord jack.

332919C 29

Troubleshooting

Convertible Electric Motor Runs - No AC Output to Sprayer Control Board (Steps)

10-20 AC

ti14925a

Jack

Transformer

STEP 1.

Plug in cord and turn switch ON. Connect wires to transformer and power cord. Turn meter to AC volts.

Power Cord

AC power to control board

Ground

Black

White to barrel

Black to tips

Transformer

Black

White

Engine Control Board

Jack

Power Cord

AC power to control board

ti14926a

White to barrel

Black to tips

BEEP

STEP 2.

Check AC power cord for an open wire. Turn meter to continuity test. Meter should read continuity.

Power Cord

AC power to control board

STEP 3.

BEEP

Check AC power cord for an open wire. Turn meter to continuity test.

Meter should read continuity.

Power Cord

White to barrel

Black to tips

White to barrel

Power Cord

Black

Electric Engine

STEP 4.

Plug in cord and turn switch ON. Partially connect wires to splice. Turn meter to AC volts.

Transformer

White

ti14929a

+M -M

White

TS TS

ti14930a

ti14927a

AC power to control board

Black to tips

STEP 5.

10-20 AC

Plug in cord and turn switch ON.

Partially connect wires to splice.

Transformer

Turn meter to AC

ti14928a

volts.

Black

Jack

Black

Electric Engine Control Board

30 332919C

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 OPERA-

TION

No Display Sprayer may be

pressurized.

Sprayer may be pressurized.

Sprayer is pressurized. Power is applied. (Pressure varies with tip size and pressure control setting).

Sprayer stops. Engine is running.

(with constant

green LED)

Sprayer stops. Engine is running.

INDICATION ACTION

Loss of power or display not connected.

Pressure less than 200 psi (14 bar, 1.4 MPa).

Normal operation. Spray

Exceeded pressure limit. 1. Check fluid path for clogs, such as clogged filter.

Pressure transducer faulty, bad connection or broken wire.

High clutch current. 1. Check wiring connections.

Loss of paint to pump or severe pressure loss.

Pressure greater than 2000 psi (138 bar, 14 MPa) while in Flush Timer Mode.

Check power source. Relieve pressure before repair or disassembly. Verify display is connected.

Increase pressure as needed.

2. Open prime valve and gun if running AutoClean.

3. Use Graco paint hose, 1/4 in. x 50 ft minimum. 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.

1. Check transducer connection.

2. Disconnect and reconnect transducer plug to ensure good connection with control board 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.

Measure: 1.2 + 0.2 Ω (GMAX II 3900);

1.7 + 0.2 Ω (GMAX II 5900/ 7900 & TexSpray 7900HD) across clutch field at 70°F.

3. Replace clutch field assembly.

1. Check for empty paint condition, clogged inlet strainer, failed pump or severe leak.

2. Reduce pressure and turn pump switch OFF and ON to restart pump.

3. WatchDog function can be deactivated by turning WatchDog switch OFF.

1. Open prime valve and gun.

2. Verify no flow obstructions or clogged filter.

* Error codes also appear on control board as a blinking red LED. LED is an alternate to digital messages.

1. Remove two screws (71) and swing down cover (130).

2. Start engine. Blink count is the same as error code(E=0X).

332919C 31

After a fault, follow these steps to restart sprayer:

1. Correct fault condition

2. Turn sprayer OFF

3. Turn sprayer ON

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.

1. Remove drive housing.

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 pinion assembly (29).

6. Remove retaining ring (29b).

7. Turn pinion assembly over and tap pinion shaft (29a) out with plastic mallet.

29b

29a

29d

ti5482a

Clutch Armature

8. Use an impact wrench or wedge something between clutch armature (25) and clutch housing to hold engine shaft during removal.

9. Remove four screws (23) and lock washers (24).

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.

ti5481a

ti5987b

10. Remove armature.







TIA

32 332919C

Installation

Pinion Assembly/Clutch Armature/Clamp

Clutch Armature

1. Lay two stacks of two dimes on smooth bench surface.

2. Lay armature (25) on two stacks of dimes.

3. Press center of hub (26) down to bench surface.

ti6321a

0.12+01 in (3.0+.25 mm)

dimes

4. Install armature (25) on engine drive shaft.

5. Install four screws (23) and lock washers (24) with torque of 125 in-lb.

Pinion Assembly

1. Check o-ring (29d) and replace if missing or damaged.

2. Tap pinion shaft (29a) in with plastic mallet.

3. Install retaining ring (29b) with beveled side facing up.

4. Place pinion assembly on bench with rotor side up.

5. 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 pressure control.

4. Loosen two screws (24) on clamp (22),

5. Push screwdriver into slot in clamp (22) and remove clamp.

ti6199a

Clamp Installation

1. Install engine shaft key (18).

2. Tap clamp (22) onto engine shaft (A). Maintain dimension shown note 2. Chamfer must face engine.

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-lb (14 ±1.1 N•m).

Face of clutch housing

1.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3400 and 3900

2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 and 7900

Torque to 125 ±.10 in-lb (14 ±1.1 N•m)

Chamfer this side







Clamp Removal







1. Remove engine.

2. Drain gasoline from tank according to Honda manual.

3. Tip engine on side so gas tank is down and air

TIA





cleaner is up.

332919C 33

Technical Data

3400 Models

U.S. Metric

Engine

Honda GX120 Engine

ANSI Power Rating @ 3600 rpm 4.0 Horsepower 3.0 kW

Sprayer

Maximum Working Pressure 3300 psi 228 bar, 22.8 MPa

Maximum Delivery Rating 0.75 gpm 2.84 lpm

Inlet Paint Strainer

Outlet Paint Filter

Pump Inlet Size 1 1/4-12 UNF-2A 1 1/4-12 UNF-2A

Fluid Outlet Size 1/4 npsm from fluid filter 1/4 npsm from fluid filter

Maximum Tip Size: 1 Gun with 0.027 in. tip 1 Gun with 0.027 in. tip

Dimensions

Weight: 89 lb 40.5 kg

Height (handle extended): 40.8 in. 103.6 cm

Length (handle extended): 35.0 in. 88.9 cm

Width: 22.3 in. 56.6 cm

12 mesh (1523 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

12 mesh (1523 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,

Wetted parts

Noise Level:

Sound Power 100 dBa per ISO 3744 100 dBa per ISO 3744

Sound Pressure 86 dBa measured at 3.1 ft 86 dBa measured at 1 m

fluoroelastomer, acetal, leather, aluminum, tungsten carbide,

stainless steel, chrome plating

34 332919C

3900 Models

U.S. Metric

Engine

Honda GX120 Engine

ANSI Power Rating @ 3600 rpm 4.0 Horsepower 3.0 kW

Sprayer

Maximum Working Pressure 3300 psi 228 bar, 22.8 MPa

Maximum Delivery Rating 1.25 gpm 4.73 lpm

Inlet Paint Strainer

Outlet Paint Filter

Pump Inlet Size 1-5/16-12 UN-2A 1-5/16-12 UN-2A

Fluid Outlet Size 1/4 npsm from fluid filter 1/4 npsm from fluid filter

Maximum Tip Size:

Dimensions

Weight:

GMAX 3900 Standard 106 lb 48.2 kg

GMAX 3900 Lo-Boy 123 lb 55.9 kg

GMAX 3900 ProContractor 133 lb 60.5 kg

GMAX 3900 Rental Pro 360G 106 lb 48.2 kg

Height:

GMAX 3900 Standard 40.8 in. 103.6 cm

GMAX 3900 Lo-Boy 26.4 in. 67.1 cm

GMAX 3900 ProContractor 38.3 in. 97.3 cm

GMAX 3900 Rental Pro 360G 40.8 in. 103.6 cm

Length:

GMAX 3900 Standard 38.3 in. 97.3 cm

GMAX 3900 Lo-Boy 46.9 in. 119.1 cm

GMAX 3900 ProContractor 32.3 in. 82.0 cm

GMAX 3900 Rental Pro 360G 38.3 in. 97.3 cm

Width:

GMAX 3900 Standard 22.3 in. 56.6 cm

GMAX 3900 Lo-Boy 24.4 in. 62.0 cm

GMAX 3900 ProContractor 22.3 in. 56.6 cm

GMAX 3900 Rental Pro 360G 22.3 in. 56.6 cm

8 mesh (2589 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

1 Gun with 0.036 in. tip 1 Gun with 0.036 in. tip

2 Guns with 0.023 in. tip 2 Guns with 0.023 in. tip

3 Guns with 0.018 in. tip 3 Guns with 0.018 in. tip

8 mesh (2589 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

Technical Data

Wetted parts

Noise Level:

Sound Power 105 dBa per ISO 3744 105 dBa per ISO 3744

Sound Pressure 96 dBa measured at 3.1 ft 96 dBa measured at 1 m

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,

fluoroelastomer, acetal, leather, aluminum, tungsten carbide,

stainless steel, chrome plating

332919C 35

Technical Data

5900 Models

U.S. Metric

Engine

Honda GX160 Engine

ANSI Power Rating @ 3600 rpm 5.5 Horsepower 4.1 kW

Sprayer

Maximum Working Pressure 3300 psi 228 bar, 22.8 MPa Maximum Delivery Rating 1.6 gpm 6.06 lpm

Inlet Paint Strainer

Outlet Paint Filter

Pump Inlet Size 1-5/16-12 UN-2A 1-5/16-12 UN-2A Fluid Outlet Size 1/4 npsm from fluid filter 1/4 npsm from fluid filter Fluid Outlet Size (5900 IronMan and 5900HD) 3/8 npsm from fluid filter 3/8 npsm from fluid filter

Maximum Tip Size:

Dimensions

Weight:

GMAX 5900 Standard 138 lb 62.7 kg GMAX 5900 Lo-Boy 144 lb 65.5 kg GMAX 5900 ProContractor 160 lb 72.7 kg GMAX 5900 Convertible, Standard 167 lb 75.9 kg GMAX 5900 IronMan 160 lb 72.7 kg TexSpray 5900HD ProContractor 164 lb 74.5 kg TexSpray 5900HD Standard 142 lb 64.5 kg

Height:

GMAX 5900 Standard 40.5 in. 102.9 cm GMAX 5900 Lo-Boy 27.2 in. 69.1 cm GMAX 5900 ProContractor 38.0 in. 96.5 cm GMAX 5900 Convertible, Standard 43.8 in. 111.3 cm GMAX 5900 IronMan 38.8 in. 98.6 cm TexSpray 5900HD ProContractor 38.0 in. 98.6 cm TexSpray 5900HD Standard 40.5 in. 102.9 cm

Length:

GMAX 5900 Standard 37.7 in. 95.8 cm GMAX 5900 Lo-Boy 46.9 in. 119.1 cm GMAX 5900 ProContractor 32.7 in. 83.1 cm GMAX 5900 Convertible, Standard 33.0 in. 83.8 cm GMAX 5900 IronMan 40.4 in. 102.6 cm TexSpray 5900HD ProContractor 32.7 in. 83.1 cm TexSpray 5900HD Standard 37.7 in. 95.8 cm

Width: 24.4 in. 62.0 cm

8 mesh (2589 micron) stainless steel screen, reusable 60 mesh (250 micron) stainless steel screen, reusable

1 Gun with 0.043 in. tip 1 Gun with 0.043 in. tip 2 Guns with 0.029 in. tip 2 Guns with 0.029 in. tip 3 Guns with 0.023 in. tip 3 Guns with 0.023 in. tip 4 Guns with 0.019 in. tip 4 Guns with 0.019 in. tip

8 mesh (2589 micron) stainless steel screen, reusable 60 mesh (250 micron) stainless steel screen, reusable

Wetted parts

Noise Level:

Sound Power 105 dBa per ISO 3744 105 dBa per ISO 3744 Sound Pressure 96 dBa measured at 3.1 ft 96 dBa measured at 1 m

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,

fluoroelastomer, acetal, leather, aluminum, tungsten carbide,

stainless steel, chrome plating

36 332919C

7900 Models

U.S. Metric

Engine

Honda GX200 Engine

ANSI Power Rating @ 3600 rpm 6.5 Horsepower 6.5 kW

Sprayer

Maximum Working Pressure 3300 psi 228 bar, 22.8 MPa

Maximum Delivery Rating 2.2 gpm 8.33 lpm

Inlet Paint Strainer

Outlet Paint Filter

Pump Inlet Size 1-5/16-12 UN-2A 1-5/16-12 UN-2A

Fluid Outlet Size 3/8 npsm from fluid filter 3/8 npsm from fluid filter

Maximum Tip Size:

Dimensions

Weight:

GMAX 7900 Standard 148 lb 67.3 kg

GMAX 7900 Lo-Boy 154 lb 70.0 kg

GMAX 7900 ProContractor 167 lb 75.9 kg

GMAX 7900 IronMan 168 lb 76.4 kg

TexSpray 7900HD Pro 182 lb 82.7 kg

TexSpray 7900HD Standard 153 lb 69.5 kg

TexSpray 7900HD IronMan 175 lb 79.5 kg

Height:

GMAX 7900 Standard 40.5 in. 102.9 cm

GMAX 7900 Lo-Boy 27.2 in. 69.1 cm

GMAX 7900 ProContractor 38.0 in. 96.5 cm

GMAX 7900 IronMan 38.8 in. 98.6 cm

TexSpray 7900HD Pro 38.0 in. 96.5 cm

TexSpray 7900HD Standard 40.5 in. 102.9 cm

TexSpray 7900HD IronMan 38.8 in. 98.6 cm

Length:

GMAX 7900 Standard 38.1 in. 96.8 cm

GMAX 7900 Lo-Boy 46.9 in. 119.1 cm

GMAX 7900 ProContractor 33.3 in. 84.6 cm

GMAX 7900 IronMan 40.4 in. 102.6 cm

TexSpray 7900HD Pro 33.3 in. 84.6 cm

TexSpray 7900HD Standard 38.1 in. 96.8 cm

TexSpray 7900HD IronMan 40.4 in. 102.6 cm

Width: 24.4 in. 62.0 cm

8 mesh (2589 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

1 Gun with 0.048 in. tip 1 Gun with 0.048 in. tip

2 Guns with 0.035 in. tip 2 Guns with 0.035 in. tip

3 Guns with 0.027 in. tip 3 Guns with 0.027 in. tip

4 Guns with 0.023 in. tip 4 Guns with 0.023 in. tip

8 mesh (2589 micron) stainless steel screen, reusable

60 mesh (250 micron) stainless steel screen, reusable

Technical Data

Wetted parts

Noise Level:

Sound Power 105 dBa per ISO 3744 105 dBa per ISO 3744

Sound Pressure 96 dBa measured at 3.1 ft 96 dBa measured at 1 m

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,

fluoroelastomer, acetal, leather, aluminum, tungsten carbide,

stainless steel, chrome plating

332919C 37

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.

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 set 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 332919

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised July 2014

Graco 16W884, 16W870, 16W871, 16W865, 16W887 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Warning

Component Identification

Pressure Relief Procedure

Grounding

Setup

Startup

WatchDog™ Protection System (ProContractor and Ironman units only)

Hose Reel (ProContractor units only)

Digital Tracking System (ProContractor and Ironman units)

Cleanup

Maintenance

Troubleshooting

Digital Display Messages

Pinion Assembly/Clutch Armature/Clamp

Technical Data

Graco Standard Warranty