Repair GMAX™ II 5900 Convertible TexSpray™ 5900 HD Airless Sprayers 311046H - For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Manual Conventions Contents WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bearing Housing & Connecting Rod . . . . . . . . . . . 8 Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pinion Housing/Rotor/Shaft/Clutch/Pulley .
Warning Warning The following are general warnings related to the setup, use, maintenance and repair of this equipment. Additional, more specific, warnings may be found throughout the text 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.
Warning WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • 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. • Check equipment daily. Repair or replace worn or damaged parts immediately.
Maintenance Maintenance Pressure Relief Procedure DAILY: Check pressure drain valve for proper operation. DAILY: Check and fill the gas tank. WARNING Read Skin Injection Hazard, page 3; Burn Hazard, page 4 1. 2. 3. 4. 5. 6. Lock gun trigger safety. Turn engine ON/OFF switch to OFF. Move pump switch to OFF and turn pressure control knob fully counterclockwise. Unlock trigger safety. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure.
Troubleshooting Troubleshooting Problem E=XX is displayed Engine will not start False tripping of WatchDog system. EMPTY is displayed. Pump does not run. Engine operates, but displacement pump does not operate Cause Solution Fault condition exists Engine switch is OFF Engine is out of gasoline Determine fault correction from table, page 14 Turn engine switch ON Refill gas tank. Honda Engines Owner's Manual. Engine oil level is low Try to start engine. Replenish oil, if necessary.
Troubleshooting Problem Pump output is low Cause Solution Strainer (82) is clogged Clean strainer. Piston ball (206) is not seating Service piston ball. Manual 310894. Piston packings are worn or damaged Replace packings. Manual 310894. O-ring (227) in pump is worn or damaged Replace o-ring. Manual 310894. Intake valve ball is not seating properly Clean intake valve. Manual 310894. Intake valve ball is packed with material Clean intake valve. Manual 310894.
Bearing Housing and Connecting Rod Bearing Housing and Connecting Rod Removal WARNING Read Skin Injection Hazard, page 3; Burn Hazard, page 4 1. Relieve pressure; page 5. 2. FIG. 1. Remove four screws (45) and front cover (44) 3. Remove pump. Refer to Displacement Pump, Removal, page 14. 4. Remove four screws (41) and washers (42) from bearing housing (40). 5. Pull connecting rod (43) and lightly tap lower rear of bearing housing with plastic mallet to loosen from drive housing (33).
Drive Housing Drive Housing Removal CAUTION DO NOT use drive housing screws (18) to align or seat bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear. WARNING 8. Install screws (18) in drive housing. Torque evenly to note 3 value in Fig. 1. 9. Install pump. Refer to Displacement Pump, Installation, page14. Read Skin Injection Hazard, page 3; Burn Hazard, page 4 1. Relieve pressure; page 5. 2. Remove bearing housing.
Pinion Housing/Rotor/Shaft/Clutch/Pulley PinionHousing/Rotor/Shaft/Clutch/Pulley Removal 1. If pinion housing (29) is not removed from clutch housing (19), do 2. through 5. Otherwise, do 2 and then start at 6. 5. FIG. 6. Place pinion housing (29) on bench with rotor side up. 6. Remove four screws (28) and lock washers (24). Install two screws in threaded holes (E) in rotor. Alternately tighten screws until rotor comes off. WARNING 28 24 Read Skin Injection Hazard, page 3; Burn Hazard, page 4 2.
Pinion Housing/Rotor/Shaft/Clutch/Pulley Installation 1. FIG. 10. Install drive shaft assembly (19c). Install retaining ring (19b) 2. FIG. 8. Lay two stacks of two dimes on smooth bench surface. 3. Lay armature (25) on two stacks of dimes. 4. Press center of hub (26) down to bench surface. 25 26 0.12+01 in (3.0+.25 mm) 6. Install three screws (35) through cart frame (1) and into clutch housing (19). 7. Apply Loctite® to screw (20).
Pressure Control Pressure Control On/Off Switch Removal Installation WARNING 1. Install new ON/OFF switch (169f) so tabs of switch snap into place on inside of cover. 2. Connect ON/OFF switch connector to control board. 3. Swing up cover (169a) and secure with two screws (71). Read Skin Injection Hazard, page 3; Burn Hazard, page 4 1. FIG. 10. Remove two screws (71) and swing down cover (169a). 2. Disconnect ON/OFF switch (169f) connector from control board. 3.
Pressure Control Control Board Removal 4. WARNING Installation Read Skin Injection Hazard, page 3; Burn Hazard, page 4 1. 2. 3. • Display connector • Engine, ground and clutch wires Remove four screws (169c) and control board (169b). FIG. 10. Remove two screws (71) and swing down cover (169a) Remove strain relief bushings (123a and 123b).
Pressure Control Digital Display Messages • • WARNING Digital messages are not available on all sprayers Blinking LED total count equals digital error code i.e., two blinks is the same as E=02 Relieve pressure before repair, page 5. DISPLAY* No Display SPRAYER OPERATION INDICATION ACTION Sprayer may be pressurized Loss of power or display not connected Check power source. Relieve pressure before repair or disassembly. Verify display is connected.
Displacement Pump Displacement Pump Removal 1. Flush pump. 2. FIG. 19. Stop pump with piston rod in its lowest position. 6. Raise latch lock. Push latch open. WARNING Read Skin Injection Hazard, page 3; Burn Hazard, page 4 3. Do Pressure Relief, page 5. 4. Separate drain hose from sprayer. FIG. 13 7. FIG. 14. Ratchet open pump door. a. Ratchet pump door forward. FIG. 11 5. Disconnect material hose from pump. FIG. 14 b. c. d. Twist latch u-bolt out of pump door recess.
Displacement Pump e. f. Twist latch u-bolt back from pump door outer edge Place u-bolt on pump door protrusion Installation 1. FIG. 20. Adjust piston rod with pin holder to pull out piston rod. Tap piston rod on hard surface to push in piston rod. 2. Push pump collar flush with bearing housing ledge to be able to close pump door. ti6325a FIG. 16 8. Ratchet pump door forward. FIG. 20 FIG. 17 9. 3. Open pump door. FIG. 21. Slide pump into connecting rod. Push pump pin until it is fully retained.
Displacement Pump 5. FIG. 22. Rotate pump to align with material hose. Connect material hose and hand tighten to 70 in-lb 7. FIG. 24. Attach drain hose to sprayer. FIG. 24 8. FIG. 22 6. FIG. 25. Fill pump with Graco TSL until fluid flows onto top of seal. FIG. 23. Tighten latch and rotate latch lock into locked position. FIG. 25 FIG.
Parts Parts Standard Sprayer - Parts Drawing 3EE EXPLODED VIEW ON PAGE ,ABEL $%4!), ! 3EE %NGINE $ETAIL ON PAGE 2EF 3EE PARTS ON PAGE 3EE PARTS ON PAGE 3EE PARTS ON PAGE 2EF A 2EF B 2EF $%4!), !
Parts Standard Sprayer - Parts List Ref Part Description 1 2 3 4 5 6 7 8 9 10 11 12 14 18 19 20 22 23* 287423 156306 119509 15E891 191084 183350 108068 108795 112827 245245 237686 112798 276974 183401 287519 121727 114528 108803 24* 26* 27* 28* 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 105510 193510 FRAME, cart WASHER, flat WHEEL, pneumatic CLIP, retaining SLEEVE, cart WASHER PIN, spring straight SCREW, mach, pnh BUTTON, snap HANDLE, cart WIRE, ground assembly w/ clamp SCREW, thread form
Parts Engine Detail 140 141 15 115 139 138 (Ref) 135 135 18 136 137 126 17 144 61 142 Ref 20 125 129 127 143 130 16 131 124 17 ti5750a 128 17 Engine Detail - Parts List Ref Part Description 15 16 17 18 20 61 115 124 125 126 127 128 114530 114653 110996 183401 121727 112717 194126 245272 116139 198689 112406 198997 ENGINE, gas, 5.
Parts Pinion and Drive Housing - Parts Drawing and List Ref No. 29: Pinion Housing 287465 Ref No. 33: Drive Housing 287700 Ref Part Description 29 29a 29b 29c 29d 287476 241114 112770 105489 114683 PINION HOUSING & COIL PINION SHAFT RETAINING RING, large PIN O-RING Ref 33 33a 33b Qty 1 1 1 2 1 Part Description HOUSING, drive 194173 WASHER 116192 WASHER Qty 1 1 1 * Premium models and TexSpray 5900HD convertible.
Parts Pressure Control and Filter - Parts Drawing A #ONTROL 0REMIUM 4EX3PRAY ($ #ONVERTIBLE #OMPLETE 0ART .UMBER R B C P C M G N 0REMIUM MODELS K F D E A J D H #ONTROL 3TANDARD #OMPLETE 0ART .UMBER A A 3TANDARD 0REMIUM -ODELS -ODELS 4EX3PRAY ($ #ONVERTIBLE 0ART .
Parts Pressure Control and Filter - Parts List REF PART DESCRIPTION 53* 54* 55* 56* 57* 58* 59* 60* 64 65 15C765 117285 15C766 243984 15C780 15C972 224807 224806 15E925 164672 162485 66* 67* 71 72* 73* 74* 91★ 91a★ 92★ 96* 122 123 241732 111457 116585 15E284 15E022 111699 287293 115524 244346 104813 248314 15D541 CAP, filter O-RING TUBE, diffusion FILTER, fluid HANDLE PIN, grooved BASE, valve VALVE, drain GASKET, transducer ADAPTER ADAPTER, nipple (TexSpray 5900HD Convertible) TRANSDUCER, pressure c
Parts Clutch Housing - Parts Drawing and List Ref Part 19 287519 HOUSING, clutch Includes 19b, 19c, 19e, 19j & 19k 114962 RING, retaining, internal 287422 SHAFT, drive, input 15E887 HOUSING, clutch 115078 O-RING 115079 O-RING 15E894 STOP, armature 108803* SCREW, hex, socket head 19b 19c 19e 19j 19k 21 23 Description Ref Part Description 24 105510* WASHER, lock, spring (hi-collar) 25 * ARMATURE, clutch, 5 in. 26 193510* HUB, armature 27 * ROTOR, clutch, 5 in.
Parts Premium Sprayers - Parts Drawing and List Models 248692, 248696, 248889, 248890, 255630, 255631, 255954 Includes items 201 to 204 Ref 40: Bearing Housing 181 40 182 204 52 196 197 50 51 150 180 45 ti6429a 202 Ref 201 202 204 205 Part Description Qty 248691 Hi-Boy Sprayers 1 See parts, page 18 248695 Lo-Boy Sprayers 1 See parts, page 18 Includes Lo-Boy Suction Set Kit, See parts, page 26 240794 HOSE, grounded, nylon; 1/4 in.
Parts Lo-Boy Suction Set - Parts Drawing and List Models 248695, 248697, 248890 Ref 401 402 403 404 405 406 407 408 409 410 Part 287631 287537 287536 189920 241920 15D000 15C980 15C981 118505 117559 115099 Description Qty KIT, repair, tube suction HOSE, suction, GMAX II 3900/5900 1 HOSE, drain, GMAX II 3900/5900 1 STRAINER, 1-11 1/2 npsm 1 DEFLECTOR, threaded 1 CLIP, drain line 1 NUT, jam 1 WASHER, suction, swivel 1 RING, retaining, external 1 O-RING 2 WASHER, garden hose 1 TI A
Technical Data Technical Data Power Honda GX160 Engine (ANSI Power Rating @ 3600 rpm) 5.5 Horsepower (4.1 kW) Electric Motor 2.0 HP (1.5 kW) Maximum working pressure 3300 psi (227 bar, 22.7 MPa) Noise Level Sound power 100 dBa per ISO 3744 Sound pressure 86 dBa measured at 3.1 feet (1 m) Cycles/gallon (liter) 93 (25) Maximum delivery Gas Engine 1.6 gpm (6.0 liter/min) Electric Motor 1.1 gpm (4.2 liter/min) Maximum tip size Gas Engine 1 gun with 0.043 in. tip 2 gun with 0.029 in.
Graco Standard Warranty 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.
