Graco 332919C User's Manual
Contents
1. 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 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 u2. T 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 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 Short press to move to SOFTWARE REV ti22726a 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 4 Turn pump switch ON Turn prime valve forward to SPRAY position 1 tit4844a SAS ON hi NOTE Use water for water base paint mineral spir 227298 S its for oil base paint or other solvents recom mended by manufacturer 5 Increase pressure to 1 2 Hold gun against paint pail Disengage trigger lock Trigger gun until flush 2 Start Engine ing fluid appears a Move fuel valve to open ti5248a ti22730a _ ti14846a 6 Move gun to waste pail hold gun against pail trig ger gun to thoroughly flush system Release trigger and engage trigger lock C ti14847a 7 Turn prime valve down to DRAIN position and a
3. YES a 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 i 0 Troubleshooting Go to step 1 Does switch test positive Replace the Switch YES Check wiring from J1 and J2 for proper con nection If proper connection is detected repair or replace engine generator Go to step 2 Do you have proper engine voltage YES Connect a test transducer to the board Does the clutch engage Go to step 5 Does the clutch engage Replace the control board Replace the potentiometer Replace the transducer 25 Troubleshooting Control Board Malfunction Steps STEP 1 DM STEP 2 WYW STEP 3 Turn engine 2 20AC Turn engine wp Leave engine OFF and set 32 22 ON Set meter running and turn meter to Y to AC volts and v switch ON Turn continuity KR connect wires y potentiometer to i to control 3 high and set i ti14939a board meter to DC ti14938a ti14940a volts Pump Board A J2 J1 Clutch rae Engine S f Field Generator Control Board To Clutch Field Pinion Drive Assembly Housing To Ground PDC JE Clutch Test Points c J10 g al To Engine LED TT
4. iM MD 12 a K J J2 J1 LO 7 Control OC ON nasisa Board WatchDog SY Premium Display Board Potentiometer wf STEPS JS N 3 ohms Turn engine T SR lt o OFF and urn engine 54 ON and turn Re J5 wie switch ON clutchwires h 19 ae ti14942a Set meter to V Ohms ti14941a RON Control i Board Clutch Field a lt i Clutch Test Points 26 332919C Troubleshooting Convertible Electric Motor Will Not Run Troubleshooting Procedure see following page for actual steps See step 2 Is there over 100 AC volts See Step 1 Is there over 100 AC volts Repair or replace NO the power cord YES Replace the power switch YES If engine is hot let cool and retest If step 4 still shows an open replace engine see Step 4 Is there continuity through the thermal sensor See Step 3 Is there over 100 DC volts YES YES See engine test section Replace engine control board 332919C 27 Troubleshooting Convertible Electric Motor Will Not Run Steps STEP 1 STEP 2 Plug in cord and turn Plug in cord and turn switch ON Connect switch ON Connect wires to control board wires to control board and turn meter to AC and turn meter to AC volts volts ti14920a Black to power cord Black Transformer Electric Engine Control Board T Black Jack Power Cord A ARII AC power to con
5. Be thoroughly familiar with the controls MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e 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
6. 0 cm zinc and nickel plated carbon steel PTFE nylon polyurethane UHMW Wetted parts 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 1m GO 6 332919C 7900 Models D o gt gt o S Oo o D Honda GX200 Engine ANSI Power Rating 3600 rpm Sprayer Maximum Working Pressure O O 7 6 5 Horsepower 3300 psi 228 bar 22 8 MPa Maximum Delivery Rating 2 2 gpm 8 33 Ipm 8 mesh 2589 micron 8 mesh 2589 micron Inlet Paint Strainer stainless steel screen reusable stainless steel screen reusable Outlet Paint Filter 60 mesh 250 micron 60 mesh 250 micron stainless steel screen reusable 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 Maximum Tip Size a i ee 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 Weight Height Length 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 zinc
7. and nickel plated carbon steel PTFE nylon polyurethane UHMW Wetted parts 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 1m N 332919C 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 op
8. conductive hoses with a maximum of 500 ft 150 m combined hose length to ensure grounding continuity Check elec trical 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 sur face 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 332919C Setup 5 Fill throat packing nut with TSL to prevent prema ture 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 ti5952a 7 Fill fuel tank 4 When spraying texture remove inlet strainer and fil ter bowl screen when spraying materials ti5797a 332919C 11 Setup Convertible Models Only 5 Look through side vent holes and ensure drive belt is in motor pulley Ch
9. 32919C Pressure Relief Procedure 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 Engage trigger lock 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 follow ing 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 10 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
10. AC power cord for an open wire Turn meter to continuity test Meter should read continuity White to barrel Ae White to barrel Y AC power to Black to tips AC power to control board control board X Transformer gt Black to tips Transformer D STEP 3 Check AC power Ooo cord for an open x wire Turn meter to P continuity test Meter should read continuity Ground ab White to barrel wer Cord SA 0 AC power to X control board Black to tips White to barrel i AN ti14927a AC power to White Y Black to tips ti14930a Electric Engine STEP 4 STEP 5 C Plug in cord and turn 10 20 AC Plug in cord and 7000 switch ON Partially ET turn switch ON Ve connect wires to ave Partially connect ner y splice Turn meter to wires to splice LU das AC volts Turn meter to AC i volts Transformer Power yee A Cord o s White Black Black Dn 3 Electric Engine Control Board 30 332919C Digital Display Messages Digital Display Messages e Digital messages are not available on all sprayers ZA e Blinking LED total count equals digital error code i e two blinks is the same as E 02 DISPLAY SPRAYER OPERA INDICATION ACTION TION No Display Sprayer may be Loss of power or display Check power source Relieve pressure bef
11. Display M Rod Pull Feature LP WatchDog swith Pressure Control BE ProConnect II Pump Clamp F uu CF Prime Vave TT R Ffr Gun Trigger Lock Engine ON OFF Switch Drain hose 6 332919C Component Identification 7900HD ironman Models 5900 7900 ti22741a Drain Hose MaxLife Pump BY Smart Control 3 0 Display Pump ON OFF Switch Rod Pull Feature Engine Controls D warnoog nw ProConnect M Pump Clamp OP Easy Out Pump Filter OR Engine ON OFF Switch a 332919C Component Identification Lo Boy Models 3900 5900 7900 A Engine ON OFF Switch Drain Hose C Pump ON OFF Switch Strainer Pressure Control M Engine Controls BroConnec I Pump Clamp Gun Trigger Lock O Easy Out Pump Filter BR E E i A Ea ES 8 332919C Component Identification Convertible Models 5900 2 8 5 g 2 G l J gS 9 lt VE aT 5 A N Y M A S V Co N 4 IS N7 aj tan MW A ANO YEAR Ate Y ti22696a v T e Strainer Engine ON OFF Switch Grounding Coil er Engine Controls Pump On Off Switch D Pressure Control Prime Valve Easy Out Pump Filter Power Pack Gun Trigger Lock Hose 3
12. FACTURED 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 r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concernees 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 reflec
13. 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 O for 5900 7900 1 7 0 2 O 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 Clean siramer a valve ball is packed with mate Clean intake a see pump cr rial Engine speed is too low Increase throttle setting see operation man ual 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 Clean filter See gun manual 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 perfor mance 50 ft minimum packing nut throat packing nut enough to leakage Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Rep rime pump see operation manual Tip is partially cl
14. Operation gt g GRACO GMAX 3400 GMAX II 3900 5900 7900 and aon TexSpray 5900HD 7900HD Airless Sprayers 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 wos Sad Cd prowess vf TTC GMAX II 3900 Standard ProContractor Lo Boy ELLA EEN TJ RentalPro UM 360G a EO EL T awer v T GMAX II 5900 ELE EL HI 1 mw WW 1 7 ewes prewar EL waf 7 1 Tower 7 T 7 UU i 16W88 TGWBB7 TexSpray 5900HD J Ironman Convertible Ironman Model ProContractor EL NR HEER KLEE AU TexSpray 7900HD Model Standard ProContractor Ironman wm 7 E R Related Manuals Parts 332921 CE PROVEN QUALITY LEADING TECHNOLOGY Table of Contents Table of Contents Table of Contents 2 WAarnind aea te Ea doy tea hain A dod de bess 3 Component ldentification 5 Standard Models 3400 3900 5900 5900HD 1900 7900HD Lee WN YO 5 ProContractor Models 3900 5900 7900 5900HD Y HID Y EFE Gc Ske We wh erates ele 6 Ironman Models 5900 7900 7900HD 7 Lo Boy Models 3900 5900 7900 8 Convertib
15. a 332919C Digital Tracking System ProContractor and Ironman units 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 gal lons sprayed above 1000 psi 70 bar 7 MPa dis plays ti22718a 17 Digital Tracking System ProContractor and Ironman units Secondary Menu Stored Data and WatchDog Pump Protection Modes 1 18 Perform Pressure Relief steps 1 4 if they have not already been done Turn power switch on while holding DTS button down ti22719a The sprayer model briefly displays e g 5900 SERIAL NUMBER scrolls past and then serial num ber e g 00001 displays ti22720a Short press DTS button and MOTOR ON scrolls past and then total motor run hours are displayed ti22721a 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 ti22722a Press and hold DTS button to clear error code to zero ti22723a
16. ange Engine to Motor 1 Disconnect engine power cord ti5775a 3 Remove engine tilt and slide back ti5775a N Plug in pressure control power cord 4 12 332919C Startup Startup c Set throttle to fast 1 Place suction tube and drain tube in grounded metal ti5250a pail partially filled with flushing fluid Attach ground lt WN wire to pail and to earth ground d Set engine switch to ON TY ti5262a i 5 Pull rope to start engine 2 Turn prime valve down to DRAIN position Turn pressure control counterclockwise to lowest pres sure 6 Increase pressure enough to start pump stroking and allow fluid to circulate for 15 seconds turn pres sure down and turn prime valve forward to SPRAY 3 Set pump switch OFF position PS O ti14842a ti22708a ti5790a 4 Start Engine ti22709a a Move fuel valve to open ti5248a ti22818a ti5249a 332919C 13 Startup 8 Hold gun against grounded metal flushing pail Trig ger 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 ti22710a 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 3 steps 1 3 page 10 Tigh
17. ble 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 0 5 kg Height handle extended 103 6 cm Length handle extended 88 9 cm Width 66 om zinc and nickel plated carbon steel PTFE nylon polyurethane UHMW Wetted parts fluoroelastomer acetal leather aluminum tungsten carbide stainless steel chrome plating Noise Level 100 dBa per ISO 3744 100 dBa per ISO 3744 86 dBa measured at 3 1 ft 86 dBa measured at 1 m 34 332919C Technical Data 3900 Models Honda GX120 Engine ANSI Power Rating 3600 rpm 3 0 kW Sprayer Maximum Working Pressure 228 bar 22 8 MPa Maximum Delivery Rating 4 73 lpm 8 mesh 2589 micron 8 mesh 2589 micron Inlet Paint Strainer stainless steel screen reusable stainless steel screen reusable Outlet Paint Filter 60 mesh 250 micron 60 mesh 250 micron stainless steel screen reusable stainless steel screen reusable 2 Guns with 0 023 in tip 3 Guns with 0 018 in tip Maximum Tip Size Weight GMAX 3900 Standard 48 2 kg GMAX 3900 Lo Boy 55 9 kg GMAX 3900 ProContractor Height Length Width E zinc and nickel plated carbon steel PTFE nylon polyurethane UHMW Wetted parts fluoroelastomer acetal leather aluminum tungsten carbide stainless steel chrome plating 105 dBa per ISO 3744 105 dBa per ISO 3744 96 dBa meas
18. d pinion assembly 29 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 29 ti5481a ti5987b 32 6 Remove retaining ring 29b 7 Turn pinion assembly over and tap pinion shaft 29a out with plastic mallet 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 10 Remove armature ti5483a 332919C Installation Clutch Armature 1 Lay two stacks of two dimes on smooth bench sur face 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 Neer 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 dam aged 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 9 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
19. d retaining nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose NOTE For detailed engine maintenance and specifica tions refer to separate Honda Engines Owner s Manual supplied 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 332919C Maintenance DAILY Check level of TSL in displacement pump pack ing 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 ele ment 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 sup
20. eration 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 MANU
21. hold rotor 6 Install pinion assembly 29 with four screws 36 and washers 37 7 Connect clutch cable connectors to inside of pres sure control Clamp Removal ARA 1 Remove engine 2 Drain gasoline from tank according to Honda man ual 3 Tip engine on side so gas tank is down and air cleaner is up 332919C Pinion Assembly Clutch Armature Clamp 4 Loosen two screws 24 on clamp 22 5 Push screwdriver into slot in clamp 22 and remove clamp 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 Nem N Face of clutch housing A 1 550 010 in 39 37 25 mm GMAX 3400 and 3900 2 612 010 in 66 34 25 mm GMAX 5900 and 7900 A Torque to 125 10 in lb 14 1 1 Nem A Chamfer this side 33 Technical Data Technical Data 3400 Models Engine Honda GX120 Engine 12 mesh 1523 micron 12 mesh 1523 micron Inlet Paint Strainer stainless steel screen reusable stainless steel screen reusable Outlet Paint Filter 60 mesh 250 micron 60 mesh 250 micron stainless steel screen reusable stainless steel screen reusa
22. 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 e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids contain ing such solvents e 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 e 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 e Read MSDSs to know the specific hazards of the fluids you are using e 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 operati
23. le Models 5900 9 Pressure Relief Procedure 10 GOUGING scott O cu y Aid O 10 SCLUD a A i dd GE 11 Convertible Models Only 12 Starp co acne aw SEER ooo ert ba eens Sk 13 Switch Tip Guard Assembly 14 SBV Te wate dude ed eee aw 14 Clearing Tip Clog8 15 WatchDog Protection System ProContractor and Ironman units only 15 Hose Reel ProContractor units only 16 Digital Tracking System ProContractor and Ironman units 17 GR Nc Ed NOA EDN dd DAD 18 Cleanub ee a ees o by warn de an o GR 19 Maintenance ees 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 HASTA Ce uf O sz O O O KENNETH RFC 33 Clamp Removal 33 Clamp Installation 33 Technical Data i524 i y ia RD Wb Go 34 Graco Standard Warranty
24. llow flushing fluid to circulate until flushing fluid appears clear lt WN 8 Turn prime valve forward to SPRAY position Trigger gun into flushing pail to purge fluid from hose d Set engine switch to ON l TO ti5262a ti14845a C 44847a 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 ti22731a 10 Turn prime valve down DRAIN position ti14842a 11 Remove filters from gun and sprayer if installed Clean and inspect Install filters SY ti15018a 20 12 If flushing with water flush again with mineral spirits or Pump Armor to leave a protective coating to pre vent freezing or corrosion 13 Wipe sprayer hose and gun with a rag soaked in water or mineral spirits ti2776a 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 guar
25. ogged 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 Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections 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 ommendations see operation manual Clutch squeaks each time clutch Clutch surfaces are not matched to Clutch surfaces need to wear into each other engages each other when new and may cause Noise will dissipate after a day of run time noise High engine speed at no load Misadjusted throttle setting Reset throttle to 3300 engine rpm at no load Replace or service engine governor Gallon counter not working Bad sensor broken or disconnected Check connections Replace sensor or wire wire Displaced or missing magnet Reposition or replace magnet No display sprayer operates Display damaged or has bad connec Check connections Replace display tion 332919C 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 Pump problem See the proper fluid pump manual for the sprayer fo
26. on To avoid severe burns e 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 e Protective eyewear and hearing protection e 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 reproduc tive harm Wash hands after handling 4 332919C Component Identification Component Identification Standard Models 3400 3900 5900 5900HD 7900 7900HD D Pressure Conr 332919C Pump Engine Controls K Drain Hose Easy Out Pump Filter mje ooo Component Identification ProContractor Models 3900 5900 7900 5900HD 7900HD CIL 7 UD Pump B SnatConrol 30
27. ore repair pressurized not connected or disassembly Verify display is connected Sprayer may be Pressure less than Increase pressure as needed osese eevee eevee eoooe pressurized 200 psi 14 bar 1 4 MPa EF er lm Sprayer is pressurized Normal operation Spray Ted Saee Fund Feee Power is applied Pressure varies with tip size and pressure control setting 2 Check fluid path for clogs such as clogged filter pe nm is running 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 eeooo Sprayer stops Engine Exceeded pressure limit N iid i Sprayer stops Engine Pressure transducer faulty 1 Check transducer connection gn Gu g 4 eeg is running bad connection or broken 2 Disconnect and reconnect transducer plug to Le 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 eres Sprayer stops Engine High clutch current 1 Check wiring connections gore seez Is running 2 Measure 1 2 0 2 O GMAX II 3900 1 7 0 2 O GMAX II 5900 7900 amp TexSpray 7900HD across clutch field at 70 F 3 Replace clutch field assembl
28. plied engine oil funnel when draining oil OIL FUNNEL ti23054a Troubleshooting Troubleshooting 7 Problem Cause Solution Fault condition exists Determine fault correction from table page 31 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 Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion cham Remove spark plug Pull starter 3 to 4 times ber Clean or replace spark plug Start engine Keep sprayer upright to avoid oil seepage False tripping of WatchDog system Operating conditions out of WatchDog _ Turn pressure down Contact Graco Technical EMPTY is displayed Pump does not parameters Assistance to adjust WatchDog parameters run Operate without WatchDog active see Opera Pump output is low page 23 tion manual Engine operates but displacement Error code displayed See Digital Display Messages page 31 pump does not operate Pump switch is OFF Turn pump switch ON Increase pressure due to dried paint Electrical power is not energizing clutch See Parts manual E XX is displayed Engine will not start See Digital Display Messages page 31 With pump switch
29. r further trouble With a pressure gauge plumbed into the paint hose start the engine Turn pump switch ON Does sprayer exceed maximum pressure shooting procedures YES Disconnect clutch wires from control board see Mechanical problem in the clutch pinion as diagram page 29 Does the pump stop run sembly clutch may be close to the rotor ning YES Make sure clutch wires are plugged in see dia Check for a short from the two clutch wires gram page 29 Do the clutch test points read to the frame If shorted repair or replace 10 18 DC volts faulty wire YES Unplug transducer from control board NO Replace the control board YES Bad transducer Replace and test with a new one 94 332919C 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 WatchDog continuously enabled Flashing Red light on continuously with potentiometer OFF after a replacement board is installed Go to step 4 Is 1 3 Ohms reading pres ent Mechanical problem Repair or replace clutch pinion assembly 332919C Control board commanding engine to run See error code section for further troubleshooting Model not selected Go to step 3 Is 10 12 VDC present
30. se 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 noz zle 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
31. ten leaky fittings Repeat l 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 J ti13024a 4 Screw assembly onto gun Tighten ti2710a Spray ti5797a 10 Trigger gun again into flushing fluid pail until mate 1 Spray test pattern Increase pressure to eliminate rial appears heavy edges Use smaller tip size if pressure adjust ment can not eliminate heavy edges 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 stop ping ti13243a ti13025a 14 332919C WatchDog Protection System ProContractor and Ironman units only Clearing Tip Clogs 1 Release trigger engage trigger lock Rotate Switch Tip Disengage trigger lock Trigger gun to clear clog 2 Engage trigger lock Return Switch Tip to original position Disengage trigger lock and continue spray ing STAIN NS 332919C 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 yitiy re OF mi ti22711a Turn WatchDog switch OFF Add ma
32. terial 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 15 Hose Reel ProContractor units only Hose Reel ProContractor units only 3 Pull reel handle down and turn clockwise to reel in To avoid injury keep your head clear of hose reel while winding up hose 1 Make sure hose is routed through hose guide es ti22745a NOTE The hose reel can be locked into two posi tions Usage A and Storage B ti22744a 16 332919C 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 ti22713a 1 Turn pressure to lowest setting Trigger gun to relieve pressure Turn prime valve down to DRAIN position ti22714a ti13243a 2 Turn power ON Pressure display appears Dashes will not appear unless pressure is less than 200 psi 14 bar 1 4 MPa ti22715a Change Display Units Press and hold DTS button for 5 seconds to change pressure units psi bar MPa to desired units Selec tion 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 ti22716
33. trol board y White to Barrel K a E i N ZA AN Black to Tips White l _ Engine Control Board A te Sg i White L Black E ti14924a STEP 3 Plug in cord and turn switch ON Turn meter to DC volts STEP 4 Check the engine ther mal sensor meter should read continuity Note engine should be cooled down Turn meter to continuity test Engine Control Board Yellow 28 332919C Troubleshooting Convertible Electric Motor Runs No AC Output to Sprayer Control Board Troubleshooting Procedure see following page for actual steps See step 1 See step 2 Is there over 10 20 Is there continuity Repair or replace the power cord AC volts YES YES See step 3 Repair or replace see the sprayer ae Is there continuity the power cord control board trou bleshooting in this manual Repair or replace wire splice s on the power cord wires See step 4 Is there over 100 AC volts YES See step 5 Is there over NO Replace transformer 10 20 AC volts YES Replace cord jack 332919C 29 Troubleshooting Convertible Electric Motor Runs No AC Output to Sprayer Control Board Steps DP STEP 1 020AC Plug in cord and turn 2000 switch ON Connect Y wires to transformer k and power cord Turn xD A meter to AC volts ti14925a STEP 2 Check
34. ts 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 e MINNEAPOLIS MN 55440 1441 USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised July 2014
35. ured at 3 1 ft 96 dBa measured at 1m 332919C 35 Technical Data 5900 Models Honda GX160 Engine ANSI Power Rating 3600 rpm Sprayer 5 5 Horsepower 1 kW Maximum Working Pressure 3300 psi 228 bar 22 8 MPa Maximum Delivery Rating 1 6 gom 6 06 Ipm i 8 mesh 2589 micron 8 mesh 2589 micron Inlet Paint Strainer i stainless steel screen reusable stainless steel screen reusable Outlet Paint Filter 60 mesh 250 micron 60 mesh 250 micron stainless steel screen reusable stainless steel screen reusable Pump Inlet Size 1 5 16 12 UN 2A 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 174 npsm from fluid fiter 378 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 Maximum Tip Size Weight GMAX 5900 ProContractor 5m SSCS GMAX 5900 ProContractor 38 0 in 96 5 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 GMAX 5900 Lo Boy GMAX 5900 ProContractor GMAX 5900 Convertible Standard GMAX 5900 IronMan TexSpray 5900HD ProContractor TexSpray 5900HD Standard Width 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
36. y Sprayer stops Engine Loss of paint to pump or 1 Check for empty paint condition clogged inlet is running severe pressure loss strainer failed pump or severe leak 2 Reduce pressure and turn pump switch OFF and ON to restart pump with constant green LED 3 WatchDog function can be deactivated by turning WatchDog switch OFF grese geoes ceses Sprayer stops Engine Pressure greater than 1 Open prime valve and gun seee seese 2 IS running 2000 psi 138 bar 14 MPa 2 Verify no flow obstructions or clogged filter RE a while in Flush Timer Mode Error codes also appear on control board as a blinking red After a fault follow these steps to restart sprayer LED LED is an alternate to digital messages 1 Correct fault condition 1 Remove two screws 71 and swing down cover 130 2 lum sprayer OFF 2 Start engine Blink count is the same as error code E 0X 3 Turn sprayer ON 332919C 31 Pinion Assembly Clutch Armature Clamp Pinion Assembly Clutch Armature Clamp Pinion Assembly Clutch Armature Removal Pinion Assembly If pinion assembly 29 is not removed from clutch hous ing 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 an
Download Pdf Manuals
Related Search