Graco GMax 3900 Instruction Manual
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Graco GMax 3900 Instruction Manual

Airless paint sprayers 3300 psi (227 bar, 22.7 mpa ) maximum working pressure
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INSTRUCTIONS
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
GMax 3900, 5900, 5900HD, 7900
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa ) Maximum Working Pressure
Table of Manuals
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump
. . . . . . . . . . . . . . . . . . . . . .
Spray Gun
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve Kit
. . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
308867
308798
307614
308644
308919
308961
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
309XXX
First choice when
quality counts.
Model 232621
Rev. A

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  • Page 1 ......308961 Model 232621 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1999, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 2 Lunettes de protection Gafas de seguridad pendant le fonctionnement opere o transporte ou le transport GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 3 WARNING ADVERTÊNCIA Poderá ocorrer incêndio e explosão quando for pulverizado ou injetado Fire and explosion can occur when spraying or flushing flammable líquido inflamável numa área onde houver má circulação de ar; vapores fluid in an area where air circulation is poor and flammable vapors inflamáveis poderão incendiar-se a partir de uma chama ou fagulhas a can be ignited by an open flame or sparks.
  • Page 4 CONTROLS / CONTROLES / COMMANDES / CONTROLES On/Off Switch Engine Controls On/Off Switch Aan/Uit Schakelaar Interruptor de ligar e desligar Controles do motor Interrupteur Marche/Arrêt Interrupteur marche/arrêt Commandes de moteur Ein-Aus-Schalter Interruptor de encendido/apagado Controles del motor Drain Valve Pressure Control / Controle da pressão / Válvula de drenagem Système de contrôle de la pression / Vidange...
  • Page 5 PRESSURE RELIEF / ALÍVIO DE PRESSÃO / DÉCHARGE DE PRESSION / ALIVIO DE LA PRESIÓN 1 5 Follow 1–5 when you stop spraying. Siga os passos de 1–5 quando parar de pulverizar. Suivre les étapes 1 à 5 lorsqu’on arrête de pulvériser.

  • Page 6: Start Engine

    Flush / Descarga / Vidange / Enjuague 12 19 Start Engine Partida do motor WASTE RESÍDUOS Démarrage À JETER DESECHO FLUSH FLUSH DESCARGA Partida del motor DESCARGA VIDANGE VIDANGE ENJUAGUE ENJUAGUE 20 SEC. 1 MIN. 10 SEC. FLUSH FLUSH WASTE DESCARGA DESCARGA RESÍDUOS...
  • Page 7 CLEAR CLOG / DESOBSTRUÇÃO / DÉCRASSEMENT / DESTAPAR WARNING ADVERTÊNCIA MISE EN GARDE ADVERTENCIA CHANGE PAINT / TROCA DE TINTA / CHANGEMENT DE PEINTURE / CAMBIAR PINTURA Flush Prime Descarga Preparação Pressure Relief Vidange Amorçage Alívio de pressão Décharge de pression Alivio de la presión Enguaje Cebado...
  • Page 8 FLUSH FLUSH DESCARGA SPOELEN VIDANGE RINÇAGE ENJUAGUE SPÜLUNG 20 SEC. Mineral Spirits lcool mineral WASTE Essence minérale RESÍDUOS Alcohol mineral À JETER DESECHO Pressure Relief Alívio de pressão Mineral Spirits Décharge de pression Thinner Alivio de la presión White spirit Lösungsbenzin...
  • Page 9 Graco distributor 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.

  • Page 10: Table Of Contents

    ......GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1999, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 11: Warning Symbol

    Warnings and Cautions Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the instructions.

  • Page 12: Component Identification And Function

    Component Identification and Function 202 Main hose 203 Whip end hose 204 Contractor gun with RAC IV DripLess tip guard and 517 size SwitchTip Model 232611 8696A Fig. 1 Pressure Control Switch ON/OFF, enables/disables clutch function and pressure control Pressure Adjusting Knob Controls fluid outlet pressure Air Cleaner* Filters air entering the carburetor...
  • Page 13 Maintenance CAUTION WARNING For detailed engine maintenance and specifications, INJECTION HAZARD refer to separate Honda Engines Owner’s Manual, The system pressure must be manually supplied. relieved to prevent the system from starting or spraying accidentally. Fluid DAILY: Check engine oil level and fill as necessary. under high pressure can be injected through the skin and cause serious injury.

  • Page 14: Troubleshooting

    0.2Ω (GMax 5900); if not, replace pinion housing. Check control board fuse. If blown, replace with equivalent automotive fuse. Have pressure control checked by authorized Graco dealer. Clutch is worn, damaged, or incorrectly Replace clutch. Page 9. positioned Pinion assembly is worn or damaged...
  • Page 15 PROBLEM CAUSE SOLUTION Pump output is low Strainer (31) is clogged Clean strainer Piston ball (25) is not seating Service piston ball. Manual 308798. Piston packings are worn or damaged Replace packings. Manual 308798. O-ring (227) in displacement pump is worn or Replace o-ring.

  • Page 16: Bearing Housing And Connecting Rod

    Bearing Housing and Connecting Rod NOTE: The item numbers referenced are for the 2. Assemble connecting rod (22) and bearing housing Hi-Boy models. The Lo-Boy models models may have (21). different item numbers. Use the Hi-Boy item number and part to find the corresponding Lo-Boy part and 3.

  • Page 17: Gmax 3900 And

    Drive Housing Removal Installation 1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (18) and Relieve pressure; page 4. to areas called out by note 3. Use full 0.62 pint (0.29 liter) of grease for GMax 3900 and 0.68 pint (0.32 liter) of grease for GMax 5900.
  • Page 18 Pinion Assembly/Rotor/Field/Shaft/Clutch Removal If pinion assembly (19) is not removed from clutch 6. Fig. 8. Remove retaining ring (Z). housing (5), do 1. through 4. Otherwise, start at 5. 7. Tap pinion shaft (A) out with plastic mallet. Relieve pressure; page 4. 2.
  • Page 19 Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 10. Lay two stacks of two dimes on smooth 6. Fig. 8. Tap pinion shaft (A) in with plastic mallet. bench surface. 7. Install retaining ring (Z) with beveled side facing 2. Lay armature (4a) on two stacks of dimes. field (Y).

  • Page 20: Clutch Housing

    Clutch Housing Removal 1. Fig. 12. Remove four capscrews (75) and lock- washers (77) which hold clutch housing (5) to engine. 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull off clutch housing (5). Installation 1.

  • Page 21: Model

    On/Off Switch Removal Installation 1. Install new ON/OFF switch (309) so tabs of switch snap into place on inside of pressure control Relieve pressure; page 4. housing. 2. Fig. 15. Remove five screws (307) and 2. Connect two wires (A) to ON/OFF switch. cover (322).

  • Page 22: Operation

    Pressure Control Transducer 5. Remove pressure control transducer (318z) and packing o-ring (318aa) from filter housing (318a). Relieve pressure; page 4. 1. Fig. 15. Install packing o-ring (318aa) and pres- sure control transducer (318z) in filter 2. Fig. 15. Remove five screws (307) and housing (318a).

  • Page 23: Displacement Pump

    1. Fig. 19. Pull piston rod out 1.5 in. Screw in pump until holes in bearing cross link and piston rod Fig. 20 align. Fig. 21. Fill packing nut with Graco TSL until fluid flows onto the top of seal. 1.5 in. Fig. 21...
  • Page 24 Parts Drawing – GMax 3900 and GMax 5900 Hi-Boy Sprayers Models 232610 and 232620 Label DETAIL A Ref 11 See page 17 for the parts. See manual 308798 for the parts. See page 21 for the parts. Used on GMax 5900, Model 232620 Used on GMax 3900, Model 232610 8699A Bottom View...
  • Page 25 Parts List – GMax 3900 and GMax 5900 Hi-Boy Sprayers Models 232610 and 232620 Part No. Description Part No. Description ENGINE STRAINER 108879 GMax 3900, Model 232610 181072 GMax 3900, Model, 232610 114530 GMax 5900, Model 232620 189920 GMax 5900, Model, 232620 113084 RIVET, blind 194194...
  • Page 26 Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241108 for Ref No. 20: Drive Housing Assembly 241007 for GMax 3900; Pinion Housing Assembly 241112 for GMax 3900; Drive Housing Assembly 241011 for GMax 5900 GMax 5900 Part No.
  • Page 27 Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayers Models 232612 and 232622 Label DETAIL A Ref 11 See page 17 for the parts. See manual 308798 for the parts. See page 21 for the parts. Used on GMax 5900, Model 232622 only Used on GMax 3900, Model 232612 only 8699A Bottom View...
  • Page 28 Parts List – GMax 3900 and GMax 5900 Lo–Boy Sprayers Models 232612 and 232622 Part No. Description Part No. Description ENGINE 30ac 194306 ..HOSE, fluid 108879 GMax 3900, Model 232612 30ad 101818 ..CLAMP, hose 114530 GMax 5900, Model 232622 30ae 170957 ..TUBE, suction 113084...

  • Page 29: Spray Gun

    GMax 5900 240248 your sprayer. The drawing shows the best place- ment of these labels for good visibility. Order the labels from your Graco distributor. Apply other language here French 185956...
  • Page 30 Parts Drawing – Sprayer GMax 3900 and 5900 Sprayers Models 232610 through 232613 and 232619 Models 232620 through 232623 and 232629 318f 318e 318d 318b 318c 318z 318aa 318a 318g 318h 318m 318n 318l 318j 318k 8716A...
  • Page 31 Parts List – Sprayer Models 232610 through 232613 and 232619; 232620 through 232623 and 232629 NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 193653 PLATE, control 318e 171941 SPRING, compression 241093 BOARD, PC 318f 192706 BOWL, filter 111839 SCREW, mch pan, 6–32 x 1/2 in. 318g 193710* SEAL, valve 240776...

  • Page 32: Technical Data

    ......22 in. (55.9 cm) Graco Phone Number TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you: 1–800–690–2894 Toll Free...

  • Page 33: Graco Warranty

    Graco distributor 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.
  • Page 34 Used in the GMax and GMx 7900 Sprayers Model 240–800, Series A Used in the GMax 5900HD and Mark V Sprayers GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1997, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 35 This equipment is for professional use only. Read all instruction manuals, tags, and labels before operating the equipment. Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor. Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
  • Page 36 Pump Repair Kit which could result in pump rupture and cause serious bodily injury. If the sleeve cannot be removed easily, return the sleeve and cylinder to Pump Repair Kit your Graco distributor for removal. 239–923 239–928 240–291 240–248 240–917 240–916...
  • Page 37 Service Repair When Pump Is Off The Sprayer Disassembling the pump Fig. 25. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal. Fig. 23. Remove packing nut (202) and throat adjust- ment spacer (228). Fig. Fig.
  • Page 38 Service Fig. 30. Remove throat packings and glands from cyl- WARNING inder. Discard throat packings and glands. COMPONENT RUPTURE HAZARD Do not clean or wipe the piston valve threads. Cleaning the piston valve threads could destroy the special sealing Used on 240–291 patch and cause the piston valve to come loose 240–800...
  • Page 39 Service Fig. 32. Install ball (206) in piston rod. If Loctite is ap- Fig. 34. Soak all leather packings in SAE 30W oil for 1 plied to piston valve threads, ensure that none gets on hour minimum prior to assembly. Place male gland ball.
  • Page 40 Service Fig. 36. Grease piston packings and sleeve top edge. Fig. 38. Grease top inch or two of piston rod that will go through the cylinder throat packings. Fig. 38 Fig. 39. Grease o-ring (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylinder.
  • Page 41 Service Fig. 40. Reassemble intake valve with new o-ring Fig. 42. Torque seal and packing nut (202) down onto (227), seat (212) and ball (214). Seat may be flipped throat nut spacer (228) to 100 10 in-lb. over and used on other side. Clean seat thoroughly. Remove throat nut spacer (228) when pump packings begin to leak after much use.
  • Page 42 Notes...
  • Page 43 Service Repair When Pump Is On The Sprayer Fig. 2. Use screwdriver to push retaining spring up and WARNING push pin out. INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 3.
  • Page 44 Service Fig. 4. Remove piston rod and sleeve. Fig. 7. Invert piston rod and insert into cylinder to force out throat packings. Fig. 4 Fig. 4. Invert piston rod and sleeve and pound on hard surface until piston rod comes out of sleeve. Fig.
  • Page 45 Service Fig. 9. Remove piston valve from piston rod with a Fig. 11. Soak all leather packings in SAE 30W oil for 1 wrench. hour minimum prior to assembly. Stack male gland (204). Alternately stack UHMWPE (203) and leather (223) packings (note orientation). Install female gland (224).
  • Page 46 Service Fig. 13. Soak all leather packings in SAE 30W oil for 1 Fig. 15. Grease piston packings and sleeve top edge. hour minimum prior to assembly. Stack male gland (219) on piston rod. Alternately stack UHMWPE (208) and leather (218) packings (note orientation) on piston rod.
  • Page 47 Service Fig. 18. Grease o-ring (221) and place on sleeve. Slide Fig. 20. Push in pin. sleeve/piston rod assembly into bottom of cylinder. Re- place o-ring (207) if desired. Note: O-ring (207) is not required for safe pump opera- tion. Fig.
  • Page 48 Service Cross Sectional Reference Pump 240–291 & 240–917 V-Max UHWMPE, blue Leather Pump 240–291 & 240–917 V-Max UHWMPE, blue Leather Fig 23 Technical Data PTFE Maximum working pressure ..... . . Wetted parts .
  • Page 49 Parts – Pump 239–923 Model 239–923, Series A 201* Carbon Steel Displacement Pump 221* Part No. Description Qty. 201* 179–810 SEAL, throat 193–046 NUT, packing 224* 203* 192–692 V-PACKING, throat, V-Max UHMWPE, blue 204* 178–942 GLAND, male, throat 240–522 CYLINDER, pump *223 206* 105–444...
  • Page 50 Parts – Pump 240–291 Model 240–291, Series A 201* Carbon Steel Displacement Pump 221* Part No. Description Qty. 201* 183–171 PLUG 193–032 NUT, packing 203* 193–124 V-PACKING 224* V-Max UHMWPE, blue 204* 183–176 GLAND, packing, male, throat *203 240–520 CYLINDER, pump 206* 101–947 BALL, sst, 0.3750 in.
  • Page 51 Parts – Pump 240–917 Model 240–917, Series A 221* Carbon Steel Displacement Pump Part No. Description Qty. 201* 201* 112–590 PLUG 189–589 NUT, packing 203* 193–722 V-PACKING V-Max UHMWPE, blue 240–920 CYLINDER, pump 219* 206* 107–203 BALL, sst, 0.3750 in. 224* 207* 107–306...
  • Page 52 Parts – Pump 240–800 Model 240–800, Series A 201* Carbon Steel Displacement Pump 221* Part No. Description Qty. 201* 183–171 PLUG 224* 193–032 NUT, packing 203* 193–124 V-PACKING V-Max UHMWPE, blue *203 204* 183–176 GLAND, packing, male, throat 241–334 CYLINDER, pump 219* 223* 206*...

  • Page 53: Graco Standard Warranty

    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 sub- stitution of non–Graco component parts.

  • Page 54: Spray Tip

    SwitchTip , and 2 finger trigger. Four finger trigger is optional; see parts list. Models 220–955, 820–165 Patents Pending Model 217–593 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 http://www.graco.com COPYRIGHT 1983, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 55 ....Graco Phone Numbers ......
  • Page 56 WARNING WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex- tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin is a serious injury.
  • Page 57 Do not use hoses to pull equipment. Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex- pose Graco hoses to temperatures above 82 C (180 F) or below –40 C (–40 F). Do not lift pressurized equipment.

  • Page 58: Installation/Operation

    Additional cards are available skin and cause serious injury. To reduce the risk of at no charge from Graco Inc. an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure...

  • Page 59: How To Use The Gun

    Installation/Operation How to Use the Gun 7. If adjusting the pressure does not give a good spray pattern, follow the Pressure Relief Proce- 1. Connect a grounded fluid hose to the gun inlet. dure on page 5 and then try another tip size. See Fig.

  • Page 60: How To Clean The Spray Tip

    Installation/Operation How to Clean the Spray Tip 2. Remove the spray tip and blow out the obstruction by applying air to the front of the spray tip. Or, let and Clear a Spray Tip Obstruction the spray tip and gun nozzle soak to dissolve the obstruction.

  • Page 61: How To Clean The Filter

    Installation/Operation How to Check the Gun Diffuser Operation 5. Apply lithium-base grease to the threads of the fluid tube (19) and reassemble the gun. Check the diffuser operation weekly. The gun diffuser/ seat (A) breaks up spray and reduces the risk of fluid injection when the tip is not installed.
  • Page 62 Installation/Operation How to Flush the Gun Always flush the pump and the gun before the fluid WARNING being sprayed can dry in it. NOTE: If it is available, the flushing procedure To reduce the risk of serious bodily provided in your pump or sprayer manual should be Ä...

  • Page 63: Service

    Service 4. If the gun handle (6) was removed, hand tighten it into the fluid housing (26); it should fit easily. Only if necessary, loosen the setscrew (4), align the handle with the fluid housing and torque the setscrew to 80–90 in-lb (9–10 N.m). 5.
  • Page 64 Notes...

  • Page 65: Parts Drawing

    Parts Drawing Model 220–955, Series D Includes items 1 and 4 to 41 Model 235–990, Series C Includes items 1 to 39 Model 217–593, Series E Includes items 1 to 39 Included with 1 Model 820–165, Series D Includes items 1 to 39 Purchase separately...

  • Page 66: Parts List

    Parts List Model 220–955, Series D; Model 235–990, Series C; Model 217–593, Series E; Model 820–165, Series D Ref. Ref. Part No. Description Qty. Part No. Description Qty. 218–070 NEEDLE–DIFFUSER/SEAT KIT 179–721 FLUID TUBE 166–969 GASKET, 179–763 SPRING tip (used with flat tips only) 220–251 TIP GUARD 179–722...
  • Page 67 3 ft (0.9 m) whip hose for more flexible gun movement. TIP GUARDS Standard filter elements These tip guards fit all Graco airless spray guns. Choose the one that’s right for your application. One of 224–455 Two, 50 mesh filters (179–731) these tip guards is included with every Graco airless 224–456...

  • Page 68: Technical Data

    ....3600 psi (252 bar, 25.2 MPa) TO PLACE AN ORDER , contact your Graco distrib- Fluid Orifice Size ....

  • Page 69: Graco Warranty

    Graco distributor 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.
  • Page 70 INSTRUCTIONS-PARTS LIST 308–644 Rev. B This manual contains important Supercedes Rev. A warnings and information. First choice when READ AND KEEP FOR REFERENCE. quality counts. INSTRUCTIONS Reverse-A-Clean Dripless Guard 4050 psi (279 bar) Maximum Working Pressure Model 237–859, Series A WARNING WARNING ac237–859...

  • Page 71: Graco Inc. Is Registered To I.s. En Iso

    Screw the PS RAC snugly onto the gun, holding the tip guard in the desired position while tightening the nut. CAUTION Fig. GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1996, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 72 AVAILABLE TIPS Orifice Flow Rate* Fan Width** Inch (mm) Size Inch gpm (lpm) 2.0–4.0 4.0–6.0 6.0–8.0 8.0–10.0 10.0–12.0 12.0–14.0 14.0–16.0 16.0–18.0 18.0–20.0 (51–102) (102–152) (152–203) (203–254) (254–305) (305–356) (356–406) (406–457) (457–508) 0.007 .053 (.20) 221–207 221–307 0.009 .087 (.33) 221–209 221–309 221–409 221–509...
  • Page 73 Graco distributor 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 manual is also suitable for:

Gmax 5900hdGmax 5900Gmax 7900

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