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Graco 16W984 manual

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Table of contents for the manual

  • Page 1

    332919C Operation GMAX ™ 3400, GMAX ™ II 3900/5900/7900, and TexSpray 5900HD/7900HD Airless Sprayers For professional use only. Not approved for use in Eu ropean explosive atmosphere loca tions. For the application of architectural paints and coatin gs. 3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure Important Safety Instru ctions Read al[...]

  • Page 2

    Table of Contents 2 332919C Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component I dentifica tion . . . . . . . . . . . . . . . . . . . . 5 S t andard Mo dels (3400, 390 0, 5900, 5900HD, 7900, 7900HD) . . . . . . . . . . . . [...]

  • Page 3

    Warning 332919C 3 Warning The following warnings are for th e setup, use, grounding, mainte nance, and rep air of this equipment. The exclamation point symbol alert s you to a general war ning and the hazard symbol s refer to procedure-specific risks. Whe n these symbols appear in the body of this manual or on warnin g la bels, refer back to these [...]

  • Page 4

    Warning 4 332919C 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 temper ature rating of the lowest rate d system component. See Technical Data in all equipment manuals. • Use fluids and solven[...]

  • Page 5

    Component Identi fication 332919C 5 Component Identification Standard Models (3400, 390 0, 5900, 5900HD, 7900, 7900HD) OFF ON ON OFF ti22694a A B C D E F G H J L K M A Engine ON/OFF Switch B Grounding Clamp C Pump On/Of f Switch D Pressure Control E Prime V alve F Gun T rigger Lock GS t r a i n e r HP u m p J Engine Controls K Dra in Hose L Easy Ou[...]

  • Page 6

    Component Identification 6 332919C ProContractor Models (3900, 5900, 7900, 5900HD, 7900HD) OFF ON ON OFF ti22742a A B C D E F G HJ K P R N M L S T ti22742a A Grounding Coil B Smart Control 3.0 Display C Pump ON/OFF Switch D Wa t c h D o g TM Switch E Pressure Control F Prime V alve G Gun T rigger Lock HS t r a i n e r J Drain hose KP u m p L T ool [...]

  • Page 7

    Component Identi fication 332919C 7 Ironman Models (5900, 7900, 7900HD) OFF ON ON OFF ti22741a A B C D E F G HJ K L M N P R S A Grounding Coil B Smart Control 3.0 Display C Pump ON/OFF Switch D Wa t c h D o g TM Switch E Pressure Control F Prime V alve G Gun T rigger Lock H Heavy Duty Strainer J Drain Hose K MaxLife Pump L Rod Pull Feature M Engine[...]

  • Page 8

    Component Identification 8 332919C Lo-Boy Models (3900, 5900, 7900) OFF ON ON OFF ti22737a A B C D K G L J E F N O M H A Engine ON/OFF Switch B Grounding Coil C Pump ON/OFF Switch D Pressure Control E Prime V alve F Gun T rigger Lock GH o s e HP u m p J Drain Hose K Rod Pull Feature LS t r a i n e r M Engine Controls N ProConnect TM II Pump Clamp O[...]

  • Page 9

    Component Identi fication 332919C 9 Convertible Models (5900) OFF ON ON OFF ti22696a A B C D E G J K H N F L M A Engine ON/OFF Switch B Grounding Coil C Pump On/Off Switch D Pressure Control E Prime V alve F Gun T rigger Lock GH o s e HS t r a i n e r JP u m p K Engine Control s L Drain Hose M Easy Out Pump Filter NP o w e r P a c k[...]

  • Page 10

    Pressure Relief Procedure 10 332919C Pressure Relief Procedure Follow the Pressur e Relief Procedure whenever you see this symbol. 1. Engage trig ger lock. 2. T urn 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 grou[...]

  • Page 11

    Setup 332919C 11 Setup 1. All sprayers except ProContractor: Connect appropri ate Graco high -pressure ho se to sprayer . 2. Select Units: Install whip hose to fluid inlet of spray gun and tighten secu rely . 3. Engage gun t rigger lock. 4. When spray ing texture, re move inlet s trainer and fil- ter bowl screen wh en spraying materials. 5. Fill th[...]

  • Page 12

    Setup 12 332919C Convertible Models Only: Change Engine to Motor 1. Disconnect engin e power cord. 2. Release tension bar . 3. Remove engine; t ilt and slide back. 4. Install mo tor; drop in and push forward. 5. Look thro ugh side vent holes and ensu re drive belt is in motor pulley . 6. Secure motor with tension bar . 7. Plug in pressure control p[...]

  • Page 13

    Startup 332919C 13 Startup 1. Place suction tube a nd drain tube in grounded met al pail p artially filled with flushi ng fluid. Attach ground wire to pail and to ear th ground. 2. T urn prime valve down to DRAIN position. Tu rn pressure control counterc lockwise to lowest pres- sure. 3. Set pump switch OFF . 4. S tart Engine a. Move fuel v alve to[...]

  • Page 14

    Startup 14 332919C 8. Hold gun against grounded met al flushing pail. T rig- ger gun a nd increase fluid pressure slo wly until pump runs smo othly . Inspect fittings for leaks. Do not stop leaks with your hand or a rag! If leaks occur , turn sprayer OFF immediately . Perform Pres sure Relief Pr ocedure steps 1-3, p age 10. T ighten leaky fittings.[...]

  • Page 15

    WatchDog ™ Protection System (ProContractor and Ironman units only) 332919C 15 Clearing Tip Clogs 1. Release trigger , engage tr igger lock. Rot ate Switch T ip. Disengage trigger lock. T rigger gun to clear clog. 2. Engage trigger loc k. Return Switch T ip to original position. Disengage trigg er lock and continue spray- ing. WatchDog ™ Protec[...]

  • Page 16

    Hose Reel (ProContractor units only) 16 332919C Hose Reel (ProContractor units only) 1. Make sure hose is routed through ho se guide. 2. Lift and turn pivot lock 90 to unlock hose reel. Pull on hose to remove it from hose reel. 3. Pull reel handle down and turn clockwise to reel in hose. NOTE: The hose reel can be locked into two posi- tions: Usage[...]

  • Page 17

    Digital Tracking System (ProC ontractor and Ironman uni ts) 332919C 17 Digital Tracking System (ProContractor and Ironman units) Operation Main Menu Short press to move to next display . Press and hold (5 seconds) to change uni ts or rese t data. 1. T u rn pressure to lowest setting. T rigger gun to relieve pres sure. Turn pr ime valve down to DRAI[...]

  • Page 18

    Digital Tracking System (ProC ontractor and Ironman units) 18 332919C Secondary Menu - Stored Data and WatchDog Pump Protection Modes 1. Perform Pressure Relief, step s 1 - 4 if they have not already been done. 2. T urn power switch on while holding DTS button down. 3. The sprayer model briefly displays (e.g. 5900 ), SERIAL NUMBER scrolls past and [...]

  • Page 19

    Cleanup 332919C 19 Cleanup 1. Perform Pressure Relief Procedure (page 10), steps 1 - 4. Remove sip hon tube set from p aint and place in flushing fluid. Remove tip guard from gun. NOTE : Use water for water-base paint, mineral spir- its for oil- base paint, or other solvent s recom- mended by manufacturer . 2. S tart Engine a. Move fuel v alve to o[...]

  • Page 20

    Cleanup 20 332919C 9. Raise siphon tube above flushing fluid and run sprayer for 15 to 30 seconds to drai n fluid. T urn pump switch and en gine OFF 10. Turn prime valve do wn DRAIN positio n. 1 1. Remove filters from gun and spra yer , if installed . Clean and inspect. Install filters. 12. If flushing with water , flush again with mineral spirits,[...]

  • Page 21

    Maintenance 332919C 21 Maintenance Pressure Relief Procedure 1. Lock gun trigger safety . 2. T urn 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 met a l pail, and trigger gun to relieve pressu re. 5. Lock g[...]

  • Page 22

    Troubleshooting 22 332919C Troubleshooting Problem Cause Solution E=XX is displayed Fault condition exists. Dete rmine fault correction from table, page 31. Engine will not start Engine switch is OFF . T urn engine switch ON. Engine is out of gaso line. Refill gas tank. Honda Engine Man ual. Engine oil level is low . T ry to start engine. Replenish[...]

  • Page 23

    Troubleshooti ng 332919C 23 Pump output is low S trainer is clogged. Clean strainer . Piston ball is not seating. Service piston ba ll (see pump manual). Piston packings are worn or damage d. Replace packings (see pump manua l). O-ring in pump is worn or damaged. Replace o-ring (see pump manual). Intake valve ball is not seating properly . Clean in[...]

  • Page 24

    Troubleshooting 24 332919C Fluid Pump Runs Constantly 1. Perform Pressure Relief Procedure (page 21), turn prime valve forward to SPRA Y position, and turn power switch OFF . 2. Remove contro l box co ver . Troubleshooting Procedure: With a pressure gauge plumbe d into the paint hose, start the engine. Turn pump switch ON. Does sprayer exceed maxim[...]

  • Page 25

    Troubleshooti ng 332919C 25 Control Board Malfunction Troubleshooting Procedure (see following page for actual steps): Go to step 5. Does the clutch engage? Go to step 2. Do you have proper engine voltag e? Go to step 4. Is 1-3 Ohms reading pres- ent? Mechanical problem. Repair or replac e clutch/pinion assembly . Replace the potentiometer . Go to [...]

  • Page 26

    Troubleshooting 26 332919C Control Board Malfunction (Steps) - BEEP + - J1 J2 12 -20 AC V - + - 10-12 DC V - - + + J1 0 J 5 J 9 J 4 J 3 J1 J2 LED D 12 J 5 - 1-3 ohms - + STEP 1. T urn engine OFF and set meter to continuity . T o Ground STEP 3 . Leave eng ine running and turn switch ON. T urn potentiometer to high and set meter to DC volt s. STEP 2 [...]

  • Page 27

    Troubleshooti ng 332919C 27 Convertible Electric Motor Will Not Run Troubleshooting Procedure (see following page for actual steps): See Step 1. Is th ere over 100 AC volts? See step 2. Is there over 100 AC volts? Replace the power switch. See Step 3. Is there over 100 D C volts? See engine test section . Replace engine control board. YES NO YES YE[...]

  • Page 28

    Troubleshooting 28 332919C Convertible Electric Motor Will Not Run (Steps) V - - L 2 L 1 + V - - L 2 L 1 + TS TS +M -M L 2 L 1 TS TS +M -M - BEEP - TS TS +M -M 100 + DC V - - + STEP 1. Plug in cord and turn switch ON. Connect wires to control board and turn meter to AC volts. STEP 2. Plug in cord and turn switch ON. Connect wires to control b oard [...]

  • Page 29

    Troubleshooti ng 332919C 29 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? YES NO YES YES YES NO NO NO YES See step 2. Is there continuity? Repair or replace the power cord. See the sprayer control boar d trou- bleshoo[...]

  • Page 30

    Troubleshooting 30 332919C Convertible Electric Motor R uns - No AC Output to Sp rayer Control Board (Steps) 10-20 AC V - - + - BEEP - TS TS +M -M L 2 L 1 10-20 AC V - - + L 2 L 1 V - - + - BEEP - STEP 1. Plug in cord and turn switch ON. Connect wires to transfor mer and power cord. T urn meter to AC volts. White to barrel Power Cord Engine Control[...]

  • Page 31

    Digital Display Messages 332919C 31 Digital Display Messages • Digital messages ar e not available on all sprayers • Blinking LED tota l count equals digit al error code i.e., two blinks is the same as E=02 * 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 sw[...]

  • Page 32

    Pinion Assembly/Clutch Armature/Clamp 32 332919C Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clut ch Armature Removal Pinion Assembly If pinion assembly (29) is not removed from clutch hous- ing (19), do 1. through 3. Othe rwise, start at 4. 1. Remove driv e housing. 2. Disconnect clutch ca ble connectors from inside of pressure co ntrol.[...]

  • Page 33

    Pinion Assembly/Clutch Armature /Clamp 332919C 33 Installation Clutch Armature 1. Lay two stacks of two dimes on smooth bench sur- face. 2. Lay armature (25) on two st acks of dimes. 3. Press center of hub (26) down to bench surface. 4. Install ar mature (25) on engine dr ive shaft. 5. Install four screws (23) and lock washers (24) with torque of 1[...]

  • Page 34

    Technica l Data 34 332919C 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 S trainer 12 mesh (1523 micron) stainless steel screen, reusable 12 mesh (1523 micron) stain[...]

  • Page 35

    Technical Data 332919C 35 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 S trainer 8 mesh (2589 micron) stainless steel screen, reusable 8 mesh (2589 micron) stainless steel screen,[...]

  • Page 36

    Technica l Data 36 332919C 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 S trainer 8 mesh (2589 micron) stainless steel screen, reusable 8 mesh (2589 micron) stainless steel screen,[...]

  • Page 37

    Technical Data 332919C 37 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 S trainer 8 mesh (2589 micron) stainless steel screen, reusable 8 mesh (2589 micron) stainless steel screen, [...]

  • Page 38

    All written and visual data contained in this document reflects the latest product info r mation available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. Original instructions. T his manual contains English. MM 332919 Graco Headquarters: Minne apolis International Offices: Belgium, China, Japan, K[...]