Graco GMAX 3400 Instruction Manual

332919C
Operation
GMAX™3400, GMAX™II 3900/5900/7900, and
TexSpray 5900HD/7900HD Airless Sprayers
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 ✓
GMAX II 3900
Model: Standard ProContractor Lo-Boy RentalPro
360G
16W865 ✓
16W866 ✓
16W867 ✓
16W984 ✓
GMAX II 5900
Model: Standard ProContractor Lo-Boy Ironman Convertible
16W869 ✓
16W870 ✓
16W871 ✓
16W881 ✓
16W873 ✓
GMAX II 7900
Model: Standard ProContractor Lo-Boy Ironman Roof Rig
16W883 ✓
16W884 ✓
16W885 ✓
16W887 ✓
16W987 ✓
TexSpray 5900HD
Model: Standard ProContractor
16W889 ✓
16W882 ✓
TexSpray 7900HD
Model: Standard ProContractor Ironman
16W890 ✓
16W888 ✓
16X949 ✓
ti23055a
EN
Related Manuals:
Parts 332921

Table of Contents
2332919C
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
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

Warning
332919C 3
Warning
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
•Use equipment only in well ventilated area.
•Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can
ignite or explode if spilled on hot surface.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths
(potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic
or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until you iden-
tify and correct the problem.
•Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection
occurs, get immediate surgical treatment.
•Do not aim the gun at, or spray any person or animal.
•Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part
of the body.
•Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
•Use Graco nozzle tips.
•Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying, fol-
low the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the 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. 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.

Warning
4332919C
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment
manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material,
request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety
hazards.
•Make sure all equipment is rated and approved for the environment in which you are using it.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction
and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids contain-
ing such solvents.
•Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for com-
patibility.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can
cause death.
•Do not operate in an enclosed area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
•Read MSDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:
•Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause
cancer, birth defects or other reproductive harm.
This product contains a chemical known to the State of California to cause cancer, birth defects or other reproduc-
tive harm. Wash hands after handling.
WARNING

Component Identification
332919C 5
Component Identification
Standard Models (3400, 3900, 5900, 5900HD, 7900, 7900HD)
OFF
ON
ON
OFF
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A
B
C
D
E
F
G
H
J
L
K
M
A Engine ON/OFF Switch
B Grounding Clamp
C Pump On/Off Switch
D Pressure Control
E Prime Valve
F Gun Trigger Lock
GStrainer
HPump
J Engine Controls
K Drain Hose
L Easy Out Pump Filter
MHose

Component Identification
6332919C
ProContractor Models (3900, 5900, 7900, 5900HD, 7900HD)
OFF
ON
ON
OFF
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A
B
C
D
E
F
G
HJ
K
P
R
N
M
L
S
T
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A Grounding Coil
B Smart Control 3.0 Display
C Pump ON/OFF Switch
DWatchDogTM Switch
E Pressure Control
F Prime Valve
G Gun Trigger Lock
HStrainer
J Drain hose
KPump
L Toolbox
M Rod Pull Feature
N Engine Controls
PProConnectTM II Pump Clamp
R Filter
S Engine ON/OFF Switch
T Hose Reel

Component Identification
332919C 7
Ironman Models (5900, 7900, 7900HD)
OFF
ON
ON
OFF
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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
DWatchDogTM Switch
E Pressure Control
F Prime Valve
G Gun Trigger Lock
H Heavy Duty Strainer
J Drain Hose
K MaxLife Pump
L Rod Pull Feature
M Engine Controls
NProConnectTM II Pump Clamp
P Easy Out Pump Filter
R Engine ON/OFF Switch
SHose

Component Identification
8332919C
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 Valve
F Gun Trigger Lock
GHose
HPump
J Drain Hose
K Rod Pull Feature
LStrainer
M Engine Controls
NProConnectTM II Pump Clamp
O Easy Out Pump Filter

Component Identification
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 Valve
F Gun Trigger Lock
GHose
HStrainer
JPump
K Engine Controls
L Drain Hose
M Easy Out Pump Filter
NPowerPack

Pressure Relief Procedure
10 332919C
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
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 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.
Grounding
To ground sprayer: Attach sprayer grounding clamp to
earth ground.
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 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.
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.
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Setup
332919C 11
Setup
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.
3. Engage gun trigger lock.
4. When spraying texture, remove inlet strainer and fil-
ter bowl screen when spraying materials.
5. Fill throat packing nut with TSL to prevent prema-
ture packing wear. Do this each time you spray.
6. Check engine oil level. Add SAE 10W-30 (summer)
or 5W-20 (winter), if necessary.
7. Fill fuel tank.
8. Attach sprayer grounding clamp to earth ground.
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Setup
12 332919C
Convertible Models Only:
Change Engine to Motor
1. Disconnect engine power cord.
2. Release tension bar.
3. Remove engine; tilt and slide back.
4. Install motor; drop in and push forward.
5. Look through side vent holes and ensure drive belt
is in motor pulley.
6. Secure motor with tension bar.
7. Plug in pressure control power cord.
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Startup
332919C 13
Startup
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.
2. Turn prime valve down to DRAIN position. Turn
pressure control counterclockwise to lowest pres-
sure.
3. Set pump switch OFF.
4. Start Engine
a. Move fuel valve to open.
b. Move choke to closed.
c. Set throttle to fast.
d. Set engine switch to ON.
5. Pull rope to start engine.
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
position.
7. Disengage spray gun trigger lock.
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Startup
14 332919C
8. Hold gun against grounded metal flushing pail. Trig-
ger gun and increase fluid pressure slowly until
pump runs smoothly.
Inspect fittings for leaks. Do not stop leaks with your
hand or a rag! If leaks occur, turn sprayer OFF
immediately. Perform Pressure Relief Procedure
steps 1-3, page 10. Tighten leaky fittings. Repeat
Startup procedure steps 1 - 5. If no leaks, continue
to trigger gun until system is thoroughly flushed.
Proceed to step 6.
9. Place siphon tube in material pail.
10. Trigger gun again into flushing fluid pail until mate-
rial appears.
Switch Tip™Guard Assembly
1. Perform Pressure Relief Procedure, page 10.
2. Engage gun trigger lock. Insert Switch Tip. Insert
seat and OneSeal™.
3. Insert Switch Tip.
4. Screw assembly onto gun. Tighten.
Spray
1. Spray test pattern. Increase pressure to eliminate
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.
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CA
B
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WatchDog™Protection System (ProContractor and Ironman units only)
332919C 15
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.
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.
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.
To avoid injury, never point gun at your hand or into a
rag!
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Hose Reel (ProContractor units only)
16 332919C
Hose Reel
(ProContractor units only)
1. Make sure hose is routed through hose 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 (A) and Storage (B).
To avoid injury, keep your head clear of hose reel
while winding up hose.
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(A) (B)
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Digital Tracking System (ProContractor and Ironman units)
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 units or reset data.
1. Turn pressure to lowest setting. Trigger gun to
relieve pressure. Turn prime valve down to DRAIN
position.
2. Turn power ON. Pressure display appears. Dashes
will not appear unless pressure is less than 200 psi
(14 bar, 1,4 MPa).
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.
Job Gallons
1. Short press DTS button to move to Job Gallons (or
liters x 10).
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.
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OFF
ON
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FT
M
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Digital Tracking System (ProContractor and Ironman units)
18 332919C
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.
3. The sprayer model briefly displays (e.g. 5900),
SERIAL NUMBER scrolls past and then serial num-
ber (e.g. 00001) displays.
4. Short press DTS button and MOTOR ON scrolls
past and then total motor run hours are displayed.
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.
6. Press and hold DTS button to clear error code to
zero.
7. Short press DTS button. W-DOG scrolls past then
OFF displays if watchdog switch is OFF. ON dis-
plays if Watchdog switch is ON.
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%.
9. Short press to move to SOFTWARE REV.
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Cleanup
332919C 19
Cleanup
1. Perform Pressure Relief Procedure (page 10),
steps 1 - 4. Remove siphon tube set from paint and
place in flushing fluid. Remove tip guard from gun.
NOTE: Use water for water-base paint, mineral spir-
its for oil-base paint, or other solvents recom-
mended by manufacturer.
2. Start Engine
a. Move fuel valve to open.
b. Move choke to closed.
c. Set throttle to fast.
d. Set engine switch to ON.
3. Pull rope to start engine.
4. Turn pump switch ON. Turn prime valve forward to
SPRAY position.
5. Increase pressure to 1/2. Hold gun against paint
pail. Disengage trigger lock. Trigger gun until flush-
ing fluid appears.
6. Move gun to waste pail, hold gun against pail, trig-
ger gun to thoroughly flush system. Release trigger
and engage trigger lock.
7. Turn prime valve down to DRAIN position and allow
flushing fluid to circulate until flushing fluid appears
clear.
8. Turn prime valve forward to SPRAY position. Trigger
gun into flushing pail to purge fluid from hose.
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OFF
ON
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Cleanup
20 332919C
9. Raise siphon tube above flushing fluid and run
sprayer for 15 to 30 seconds to drain fluid. Turn
pump switch and engine OFF
10. Turn prime valve down DRAIN position.
11. Remove filters from gun and sprayer, if installed.
Clean and inspect. Install filters.
12. If flushing with water, flush again with mineral spirits,
or Pump Armor, to leave a protective coating to pre-
vent freezing or corrosion.
13. Wipe sprayer, hose and gun with a rag soaked in
water or mineral spirits.
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