Graco 332919C Gmax 3400 Ii 3900 5900 7900 And Texspray 5900Hd 7900Hd Users Manual 3400, 3900/5900/7900, 5900HD/7900HD Airless Sprayers Operation (English)

4af76202-da4b-4c1e-a455-9a706b20a3ac Graco Paint Sprayer 16W867 User Guide |

2015-04-02

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Operation

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

332919C
EN

For professional use only.
Not approved for use in European explosive atmosphere locations.
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

✓

Model:

Standard

16W865

✓

GMAX II 3900
ProContractor

Lo-Boy

RentalPro
360G

✓

16W866
✓

16W867

✓

16W984
GMAX II 5900
Model:

Standard

16W869

✓

ProContractor

Lo-Boy

Ironman

Convertible

✓

16W870
✓

16W871

✓

16W881

✓

16W873
GMAX II 7900
Model:

Standard

16W883

✓

ProContractor

Lo-Boy

Ironman

Roof Rig

✓

16W884
✓

16W885

ti23055a

✓

16W887

✓

16W987
TexSpray 5900HD
Model:

Standard

16W889

✓

ProContractor

Related Manuals:
✓

16W882

TexSpray 7900HD
Model:

Standard

16W890

✓

16W888
16X949

ProContractor

Ironman

✓
✓

Parts

332921

Table of Contents

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™ Guard Assembly . . . . . . . . . . . . . . 14
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clearing Tip Clogs . . . . . . . . . . . . . . . . . . . . . . . 15
WatchDog™ Protection System (ProContractor and
Ironman units only) . . . . . . . . . . . . . . . . . . . . . 15
Hose Reel
(ProContractor units only) . . . . . . . . . . . . . . . 16

2

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

332919C

Warning

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 identify 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, follow 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 containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.
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

Component Identification
Standard Models (3400, 3900, 5900, 5900HD, 7900, 7900HD)
OFF

A
L

ON

B
K
ON

C

ti22694a

OFF

J

D

H

E

G

F
M

A
B
C
D
E
F

Engine ON/OFF Switch
Grounding Clamp
Pump On/Off Switch
Pressure Control
Prime Valve
Gun Trigger Lock

332919C

G
H
J
K
L
M

Strainer
Pump
Engine Controls
Drain Hose
Easy Out Pump Filter
Hose

5

Component Identification

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

S

OFF

A

R

ON

B
P
C

ON
ti22742a

OFF

N

D
M

ti22742a

E
L

F

K
H

J

G

A
B
C
D
E
F
G
H
J

6

Grounding Coil
Smart Control 3.0 Display
Pump ON/OFF Switch
WatchDogTM Switch
Pressure Control
Prime Valve
Gun Trigger Lock
Strainer
Drain hose

K
L
M
N
P
R
S
T

Pump
Toolbox
Rod Pull Feature
Engine Controls
ProConnectTM II Pump Clamp
Filter
Engine ON/OFF Switch
Hose Reel

332919C

Component Identification

Ironman Models (5900, 7900, 7900HD)
S
OFF

A

R

ON

P

B

ON

C
N

OFF

D
M

E
L
ti22741a

H

J

F

K

G

A
B
C
D
E
F
G
H

Grounding Coil
Smart Control 3.0 Display
Pump ON/OFF Switch
WatchDogTM Switch
Pressure Control
Prime Valve
Gun Trigger Lock
Heavy Duty Strainer

332919C

J
K
L
M
N
P
R
S

Drain Hose
MaxLife Pump
Rod Pull Feature
Engine Controls
ProConnectTM II Pump Clamp
Easy Out Pump Filter
Engine ON/OFF Switch
Hose

7

Component Identification

Lo-Boy Models (3900, 5900, 7900)
OFF

A

O

ON

B
N

ON
ti22737a

C

M

OFF

D
L

K

E

G
J

F
H

A
B
C
D
E
F
G
H

8

Engine ON/OFF Switch
Grounding Coil
Pump ON/OFF Switch
Pressure Control
Prime Valve
Gun Trigger Lock
Hose
Pump

J
K
L
M

Drain Hose
Rod Pull Feature
Strainer
Engine Controls

N

ProConnectTM II Pump Clamp
Easy Out Pump Filter

O

332919C

Component Identification

Convertible Models (5900)
OFF

A
M

ON

N
B
L
ON

C
ti22696a

OFF

K

D

J

E

G

H

F

A
B
C
D
E
F
G

Engine ON/OFF Switch
Grounding Coil
Pump On/Off Switch
Pressure Control
Prime Valve
Gun Trigger Lock
Hose

332919C

H
J
K
L
M
N

Strainer
Pump
Engine Controls
Drain Hose
Easy Out Pump Filter
Power Pack

9

Pressure Relief Procedure

Pressure Relief Procedure

Grounding

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.

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.

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.

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

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

1. All sprayers except ProContractor: Connect
appropriate Graco high-pressure hose to sprayer.
2. Select Units: Install whip hose to fluid inlet of spray
gun and tighten securely.

ti22743a

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

ti22698a

3. Engage gun trigger lock.

ti5952a

7. Fill fuel tank.

ti22700a

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

ti5953a

8. Attach sprayer grounding clamp to earth ground.

ti22701a
ti5787a

332919C

11

Setup

Convertible Models Only:
5. Look through side vent holes and ensure drive belt
is in motor pulley.

Change Engine to Motor
1. Disconnect engine power cord.

ti5772a

6. Secure motor with tension bar.
ti5774a

2. Release tension bar.

ti5775a

3. Remove engine; tilt and slide back.

ti5775a

7. Plug in pressure control power cord.

ti22702a

ti5779a

4. Install motor; drop in and push forward.

ti22703a

12

332919C

Startup

Startup
c.

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.

Set throttle to fast.

ti5250a

d. Set engine switch to ON.

ti5262a
ti14844a

2. Turn prime valve down to DRAIN position. Turn
pressure control counterclockwise to lowest pressure.

5. Pull rope to start engine.

ti5263a

ti14842a

3. Set pump switch OFF.

ti22708a

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.

ti5790a

4. Start Engine

ti22709a

a. Move fuel valve to open.

ti14845a
ti5248a

7. Disengage spray gun trigger lock.
b. Move choke to closed.

ti22818a
ti5249a

332919C

13

Startup

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

Switch Tip™ Guard Assembly

1. Perform Pressure Relief Procedure, page 10.
2. Engage gun trigger lock. Insert Switch Tip. Insert
seat and OneSeal™.
C

A

B

ti22710a

ti13243a

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.

ti13023a

3. Insert Switch Tip.

ti13024a

9. Place siphon tube in material pail.

4. Screw assembly onto gun. Tighten.

ti2710a

ti5797a

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

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

ti13030a

ti13243a

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.

ti13025a

14

332919C

WatchDog™ Protection System (ProContractor and Ironman units only)

Clearing Tip Clogs

WatchDog™ Protection System
(ProContractor and Ironman units only)
Pump stops automatically when material pail is empty.

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

To Activate:
1. Perform Startup.

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

ti10166a

ti13033a
ti13033a

ti10167a

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

ti10166a

ti13034a

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

ti10167a

ti22711a

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.

ti22712a

332919C

15

Hose Reel (ProContractor units only)

Hose Reel
(ProContractor units only)
3. Pull reel handle down and turn clockwise to reel in
hose.
To avoid injury, keep your head clear of hose reel
while winding up hose.
1. Make sure hose is routed through hose guide.

ti22745a

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

(A)

(B)

ti13504a

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

ti22746a

ti22744a

16

332919C

Digital Tracking System (ProContractor and Ironman units)

Digital Tracking System
(ProContractor and Ironman units)
Operation Main Menu

Job Gallons

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

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

ti22713a

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

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).
ti22714a
ti13243a

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

2. Turn power ON. Pressure display appears. Dashes
will not appear unless pressure is less than 200 psi
(14 bar, 1,4 MPa).
OFF
ti22718a

ON
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.

FT
M

ti22716a

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.

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

ti22719a

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

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%.

ti22720a

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

ti22725a

9. Short press to move to SOFTWARE REV.
ti22721a

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.

ti22726a

ti22722a

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

ti22723a

18

332919C

Cleanup

Cleanup
3. Pull rope to start engine.

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.

ti5263a

4. Turn pump switch ON. Turn prime valve forward to
SPRAY position.
OFF
ti14844a

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

ON
ti22729a

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.

ti5248a

b. Move choke to closed.

ti22730a

ti14846a

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

ti5249a

c.

Set throttle to fast.

ti14847a

7. Turn prime valve down to DRAIN position and allow
flushing fluid to circulate until flushing fluid appears
clear.
ti5250a

8. Turn prime valve forward to SPRAY position. Trigger
gun into flushing pail to purge fluid from hose.
d. Set engine switch to ON.

ti14845a

ti14847a

ti5262a

332919C

19

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

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.

ti22731a

10. Turn prime valve down DRAIN position.

ti2776a

ti14842a

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

ti15018a

20

332919C

Maintenance

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 operation.
DAILY: Check and fill the gas tank.
OIL FUNNEL
ti23054a

332919C

21

Troubleshooting

Troubleshooting

Problem
E=XX is displayed
Engine will not start

Cause
Fault condition exists.
Engine switch is OFF.
Engine is out of gasoline.
Engine oil level is low.
Spark plug disconnected or damaged.
Engine is cold.
Fuel shutoff lever is OFF.
Oil is seeping into combustion chamber.

False tripping of WatchDog system.
EMPTY is displayed. Pump does not
run.
Engine operates, but displacement
pump does not operate

Operating conditions out of WatchDog
parameters.
Pump output is low, page 23.
Error code displayed.
Pump switch is OFF.
Pressure setting too low.

Solution
Determine fault correction from table, page 31.
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.
Use choke.
Move lever to ON position.
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 Operation manual).
See Digital Display Messages, page 31.
Turn pump switch ON.
Turn pressure adjusting knob clockwise to
increase pressure.
Clean filter.
Clean tip or tip filter (see gun manual).
Repair pump (see pump manual).

Fluid filter is dirty.
Tip or tip filter is clogged.
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 See Parts manual.
field.
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 Adjust or replace clutch. See page 32.
positioned.
Pinion assembly is worn or damaged.
Repair or replace pinion assembly. Page 32.

22

332919C

Troubleshooting

Problem
Pump output is low

Excessive paint leakage into throat
packing nut

Fluid is spitting from gun

Pump is difficult to prime

Cause
Strainer is clogged.
Piston ball is not seating.
Piston packings are worn or damaged.
O-ring in pump is worn or damaged.
Intake valve ball is not seating properly.
Intake valve ball is packed with material.
Engine speed is too low.

Pump packings are worn.
Paint is too thick.
Engine speed is too high.

High engine speed at no load
Gallon counter not working
No display, sprayer operates

332919C

Clean strainer.
Service piston ball (see pump manual).
Replace packings (see pump manual).
Replace o-ring (see pump manual).
Clean intake valve (see pump manual).
Clean intake valve (see pump manual).
Increase throttle setting (see operation manual).
Adjust or replace clutch. Page 32.
Increase pressure (see operation manual).
Clean filter (see gun manual).

Clutch is worn or damaged.
Pressure setting is too low.
Fluid filter, tip filter or tip is clogged or
dirty.
Large pressure drop in hose with heavy Use larger diameter hose and/or reduce overall
materials.
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 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. Replace rod (see pump manual).
Air in pump or hose.
Check and tighten all fluid connections. Reprime 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.
Air in pump or hose.
Check and tighten all fluid connections.

Intake valve is leaking.

Clutch squeaks each time clutch
engages

Solution

Clutch surfaces are not matched to
each other when new and may cause
noise.
Misadjusted throttle setting.
Worn engine governor.
Bad sensor, broken or disconnected
wire. Displaced or missing magnet.
Display damaged or has bad connection.

Reduce engine speed and cycle pump as
slowly as possible during priming.
Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well. Reassemble valve.
Replace pump packings (see pump manual).
Thin the paint according to the supplier's recommendations.
Decrease throttle setting before priming pump
(see operation manual).
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
Reset throttle to 3300 engine rpm at no load.
Replace or service engine governor.
Check connections. Replace sensor or wire.
Reposition or replace magnet.
Check connections. Replace display.

23

Troubleshooting

Fluid Pump Runs Constantly
1. Perform Pressure Relief Procedure (page 21),
turn prime valve forward to SPRAY position, and
turn power switch OFF.
2. Remove control box cover.

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

NO

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

NO

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

NO

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

NO

Replace the control board.

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

Unplug transducer from control board.

YES

Bad transducer.
Replace and test with a new one.

24

332919C

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.
Does switch
test positive?

No light
Once

Normal operation

Red light on
continuously

Control board
commanding
engine to run

Green light on
continuously

WatchDog
enabled

Flashing

See error code
section for further
troubleshooting

YES

Model not
Red light on
continuously with selected
potentiometer
OFF after a
replacement
board is installed

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

YES

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

YES

Mechanical
problem. Repair
or replace
clutch/pinion
assembly.

332919C

NO

Replace the
switch.

NO

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.

NO

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

NO

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

YES
Go to step 5.
Does the
clutch
engage?

NO

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

NO

YES

Replace the
potentiometer.

YES

Replace
the
control
board.

Replace
the
transducer.

25

Troubleshooting

Control Board Malfunction (Steps)
STEP 1.
Turn engine
OFF and set
meter to
continuity.

BEEP

V

-

-

ti14939a

ti14938a

J2

10-12 DC
V

ti14940a

-

Clutch
Field

J1

Engine
Generator

+

-

Control
Board

STEP 3.
Leave engine
running and turn
switch ON. Turn
potentiometer to
high and set
meter to DC
volts.

+

Pump
On/Off
Switch

+

-

STEP 2.
Turn engine
ON. Set meter
to AC volts and
connect wires
to control
board.

12 -20 AC

Control
Board
To Clutch
Pinion
Field
Assembly

+

To Ground

Drive
Housing

Clutch Test Points
J10

To Engine

LED
D12
J2

J1

Control
Board
J3 J4

ti14943a
J5
J9

On/Off Switch

WatchDog

Transducer
Premium Display Board
Potentiometer

1-3 ohms

ti14942a

STEP 4.
Turn engine
OFF and
unplug
clutch wires.
Set meter to
Ohms.

STEP 5.
Turn engine
ON and turn
switch ON.

Control
Board J5

+

-

ti14941a

Control
Board
Clutch
Field

Clutch Test Points

26

332919C

Troubleshooting

Convertible Electric Motor Will Not Run
Troubleshooting Procedure
(see following page for actual steps):
See Step 1. Is there
over 100 AC volts?

NO

See step 2. Is there
over 100 AC volts?

NO

Repair or replace
the power cord.

YES

Replace the power switch.

YES

See Step 3. Is there
over 100 DC volts?
YES

See engine test section.

332919C

NO

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

NO

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

YES

Replace engine
control board.

27

Troubleshooting

Convertible Electric Motor Will Not Run (Steps)
STEP 2.
Plug in cord and turn
switch ON. Connect
wires to control board
and turn meter to AC
volts.

STEP 1.
Plug in cord and turn
switch ON. Connect
wires to control board
and turn meter to AC
volts.

V

-

V

-

Black to
power cord

ti14920a

ti14921a

-

L2

L1

+

Black

+

-

White

Black

L1

L2

White

Transformer

Electric Engine Control Board

Electric Engine Control Board

Black
Ground

Black

Black

Jack

Power Cord

White to Barrel

AC power to
control board

Black to Tips

White

Black

Engine Control Board

White
Black

L1
+M

-M

L2
TS TS

ti14924a

STEP 3.
Plug in cord and turn
switch ON. Turn
meter to DC volts.

100 + DC
V

-

+

Electric
Engine

STEP 4.
Check the engine thermal sensor (meter
should read continuity).
Note: engine should
be cooled down. Turn
meter to continuity test.

BEEP

Engine
Control
Board

+M

-M
TS TS

+M

-M

ti14923a

TS

Engine
Control
Board
TS

-

ti14922a

Electric
Engine

28

Yellow

Electric
Engine

Yellow

332919C

Troubleshooting

Convertible Electric Motor Runs No AC Output to Sprayer Control Board
Troubleshooting Procedure
(see following page for actual steps):
See step 1.
Is there over 10-20
AC volts?

NO

See step 2.
Is there continuity?

YES

YES

See the sprayer
control board troubleshooting in this
manual.

See step 3.
Is there continuity?

NO

Repair or replace
the power cord.

NO

Repair or replace
the power cord.

YES

See step 4.
Is there over 100
AC volts?

NO

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

YES

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

NO

Replace transformer.

YES

Replace cord jack.

332919C

29

Troubleshooting

Convertible Electric Motor Runs - No AC Output to Sprayer Control Board (Steps)
STEP 1.
Plug in cord and turn
switch ON. Connect
wires to transformer
and power cord. Turn
meter to AC volts.

10-20 AC
V

-

STEP 2.
Check AC power cord
for an open wire. Turn
meter to continuity
test. Meter should
read continuity.

BEEP

ti14925a

ti14926a

Jack

-

Power Cord

-

White to barrel

White to barrel

AC power to
control board

Black to tips

+

Power Cord

Black to tips

AC power to
control board

Transformer

Transformer

STEP 3.
Check AC power
cord for an open
wire. Turn meter to
continuity test.
Meter should read
continuity.

BEEP
Black

Ground
Black

White to barrel
Jack

Black

AC power to
control board

White

Black

Power Cord

Black to tips
-

Engine Control Board

ti14927a

White

Black

L1
+M

-M

L2

White to barrel

Power Cord
AC power to
control board

Black to tips

TS TS

ti14930a

Electric
Engine

STEP 4.
Plug in cord and turn
switch ON. Partially
connect wires to
splice. Turn meter to
AC volts.

V

-

10-20 AC
V

-

STEP 5.
Plug in cord and
turn switch ON.
Partially connect
wires to splice.
Turn meter to AC
volts.

Transformer

Black

Transformer

White

-

+

ti14929a
ti14928a

+

-

Power
Cord

Black
Jack

Black

White
L1

Black

L2

Electric Engine Control Board

30

332919C

Digital Display Messages

Digital Display Messages

DISPLAY*
No Display

SPRAYER OPERATION

•

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

INDICATION

ACTION

Sprayer may be
pressurized.

Loss of power or display
not connected.

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

Sprayer may be
pressurized.

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

Increase pressure as needed.

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

Normal operation.

Spray

Sprayer stops. Engine
is running.

Exceeded pressure limit.

1.
2.
3.

4.
Sprayer stops. Engine
is running.

Pressure transducer faulty,
bad connection or broken
wire.

1.
2.

3.

Sprayer stops. Engine
is running.

High clutch current.

1.
2.

3.
Sprayer stops. Engine
is running.

Loss of paint to pump or
severe pressure loss.

1.
2.

(with constant
green LED)

3.
Sprayer stops. Engine
is running.

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

* Error codes also appear on control board as a blinking red
LED. LED is an alternate to digital messages.
1.
2.

Remove two screws (71) and swing down cover (130).
Start engine. Blink count is the same as error code(E=0X).

332919C

1.
2.

Check fluid path for clogs, such as clogged filter.
Open prime valve and gun if running AutoClean.
Use Graco paint hose, 1/4 in. x 50 ft minimum.
Smaller hose or metal braid hose may result in
pressure spikes.
Replace transducer if fluid path is not clogged
and proper hose is used.
Check transducer connection.
Disconnect and reconnect transducer plug to
ensure good connection with control board
socket.
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.
Check wiring connections.
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.
Replace clutch field assembly.
Check for empty paint condition, clogged inlet
strainer, failed pump or severe leak.
Reduce pressure and turn pump switch OFF
and ON to restart pump.
WatchDog function can be deactivated by
turning WatchDog switch OFF.
Open prime valve and gun.
Verify no flow obstructions or clogged filter.

After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON

31

Pinion Assembly/Clutch Armature/Clamp

Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch Armature Removal

6. Remove retaining ring (29b).

Pinion Assembly
If pinion assembly (29) is not removed from clutch housing (19), do 1. through 3. Otherwise, start at 4.

7. Turn pinion assembly over and tap pinion shaft
(29a) out with plastic mallet.
27

29b

1. Remove drive housing.

29a

2. Disconnect clutch cable connectors from inside of
pressure control.

29d

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.

ti5482a

3. Remove four screws (36) and pinion assembly (29).

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

36
37

19
29

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

36



37



ti5480a

4. Place pinion assembly (29) on bench with rotor side
up.

TIA

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.
28
24

29

E

E

ti5481a

ti5987b

32

332919C

Pinion Assembly/Clutch Armature/Clamp

Installation
Clutch Armature

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

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

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

2. Lay armature (25) on two stacks of dimes.
3. Press center of hub (26) down to bench surface.
25

26

0.12+01 in (3.0+.25 mm)

ti6199a

ti6321a

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.

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).

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).

1 Face of clutch housing
2

1.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3400 and 3900
2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 and 7900

3 Torque to 125 ±.10 in-lb (14 ±1.1 N•m)
4 Chamfer this side




19

7. Connect clutch cable connectors to inside of pressure control.



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
cleaner is up.

332919C





TIA

!

33

Technical Data

Technical Data
3400 Models
U.S.

Metric

Engine
Honda GX120 Engine
ANSI Power Rating @ 3600 rpm

4.0 Horsepower

3.0 kW

Maximum Working Pressure

3300 psi

228 bar, 22.8 MPa

Maximum Delivery Rating

0.75 gpm

2.84 lpm

Inlet Paint Strainer

12 mesh (1523 micron)
stainless steel screen, reusable

12 mesh (1523 micron)
stainless steel screen, reusable

Outlet Paint Filter

60 mesh (250 micron)
stainless steel screen, reusable

60 mesh (250 micron)
stainless steel screen, reusable

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

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

Sprayer

Dimensions

Wetted parts

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,
fluoroelastomer, acetal, leather, aluminum, tungsten carbide,
stainless steel, chrome plating

Noise Level:

34

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

332919C

Technical Data

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

8 mesh (2589 micron)
stainless steel screen, reusable

8 mesh (2589 micron)
stainless steel screen, reusable

Outlet Paint Filter

60 mesh (250 micron)
stainless steel screen, reusable

60 mesh (250 micron)
stainless steel screen, reusable

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

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

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

Wetted parts

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,
fluoroelastomer, acetal, leather, aluminum, tungsten carbide,
stainless steel, chrome plating

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

332919C

35

Technical Data

5900 Models
U.S.
Engine
Honda GX160 Engine
ANSI Power Rating @ 3600 rpm
Sprayer
Maximum Working Pressure
Maximum Delivery Rating
Inlet Paint Strainer
Outlet Paint Filter
Pump Inlet Size
Fluid Outlet Size
Fluid Outlet Size (5900 IronMan and 5900HD)
Maximum Tip Size:
Dimensions
Weight:
GMAX 5900 Standard
GMAX 5900 Lo-Boy
GMAX 5900 ProContractor
GMAX 5900 Convertible, Standard
GMAX 5900 IronMan
TexSpray 5900HD ProContractor
TexSpray 5900HD Standard
Height:
GMAX 5900 Standard
GMAX 5900 Lo-Boy
GMAX 5900 ProContractor
GMAX 5900 Convertible, Standard
GMAX 5900 IronMan
TexSpray 5900HD ProContractor
TexSpray 5900HD Standard
Length:
GMAX 5900 Standard
GMAX 5900 Lo-Boy
GMAX 5900 ProContractor
GMAX 5900 Convertible, Standard
GMAX 5900 IronMan
TexSpray 5900HD ProContractor
TexSpray 5900HD Standard
Width:

Wetted parts
Noise Level:
Sound Power
Sound Pressure

36

Metric

5.5 Horsepower

4.1 kW

3300 psi
1.6 gpm
8 mesh (2589 micron)
stainless steel screen, reusable
60 mesh (250 micron)
stainless steel screen, reusable
1-5/16-12 UN-2A
1/4 npsm from fluid filter
3/8 npsm from fluid filter
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

228 bar, 22.8 MPa
6.06 lpm
8 mesh (2589 micron)
stainless steel screen, reusable
60 mesh (250 micron)
stainless steel screen, reusable
1-5/16-12 UN-2A
1/4 npsm from fluid filter
3/8 npsm from fluid filter
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

138 lb
144 lb
160 lb
167 lb
160 lb
164 lb
142 lb

62.7 kg
65.5 kg
72.7 kg
75.9 kg
72.7 kg
74.5 kg
64.5 kg

40.5 in.
27.2 in.
38.0 in.
43.8 in.
38.8 in.
38.0 in.
40.5 in.

102.9 cm
69.1 cm
96.5 cm
111.3 cm
98.6 cm
98.6 cm
102.9 cm

37.7 in.
46.9 in.
32.7 in.
33.0 in.
40.4 in.
32.7 in.
37.7 in.
24.4 in.

95.8 cm
119.1 cm
83.1 cm
83.8 cm
102.6 cm
83.1 cm
95.8 cm
62.0 cm
zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,
fluoroelastomer, acetal, leather, aluminum, tungsten carbide,
stainless steel, chrome plating

105 dBa per ISO 3744
96 dBa measured at 3.1 ft

105 dBa per ISO 3744
96 dBa measured at 1 m

332919C

Technical Data

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

8 mesh (2589 micron)
stainless steel screen, reusable

8 mesh (2589 micron)
stainless steel screen, reusable

Outlet Paint Filter

60 mesh (250 micron)
stainless steel screen, reusable

60 mesh (250 micron)
stainless steel screen, reusable

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

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

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

24.4 in.

62.0 cm

Width:

Wetted parts

zinc- and nickel-plated carbon steel, PTFE, nylon, polyurethane, UHMW,
fluoroelastomer, acetal, leather, aluminum, tungsten carbide,
stainless steel, chrome plating

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

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 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
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised July 2014



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Web Statement                   : 332919C - GMAX 3400, GMAX II 3900/5900/7900, and TexSpray 5900HD/7900HD Airless Sprayers Operation (English)
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Title                           : 332919C - GMAX 3400, GMAX II 3900/5900/7900, and TexSpray 5900HD/7900HD Airless Sprayers Operation (English)
Description                     : GMAX 3400, GMAX II 3900/5900/7900, and TexSpray 5900HD/7900HD Airless Sprayers Operation (English)
Creator                         : Cindy Schmitz
Subject                         : 332919, 332919C, 332919EN, 332919EN-C, MM 332919, GMAX 3400, GMAX II, 3900/5900/7900, TexSpray 5900HD/7900HD, Airless Sprayers, 16W863; 16W865; 16W866; 16W867; 16W984; 16W869; 16W870; 16W871; 16W881; 16W873; 16W883; 16W884; 16W885; 16W887; 16W987; 16W889
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Author                          : Cindy Schmitz
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