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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GMax 5900 Convertible
Airless Paint Sprayers
309411E
–For Portable Airless Spraying of Architectural Coatings and Paints –
5.5 HORSEPOWER, GASOLINE POWERED
3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure
Model Series Description
233709 A Sprayer, gas powered
233710 A Sprayer, gas powered, with RAC X tip,
gun and hose
233711 A Sprayer, gas powered, with electric
mo
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Table of Contents Component Identification and Function . . . . . . . . . . . . 5 Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Basic Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Repair Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Bearing H
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WARNING SKIN INJECTION HAZARD Spray from the spray tip, hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause can also cause serious injury. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi- cal treatment! Do not point the spray tip at anyone or any part of the body. Do not put hand or fingers ov
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WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury. Ground the equipment and the object being sprayed. Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being sprayed. Extinguish all the open flames or pilot lights in the spray area. Electrically disconnect all the equipment in the spray area. Keep the spray are
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Component Identification and Function Pump On/Off Switch Pressure Control Engine On/Off Switch Engine Controls Prime/Drain Valve ti1852a Motor On/Off Switch Spray Gun Trigger Lock Reference your Spray Gun Manual ti1854a 309411 5
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Maintenance CAUTION WARNING For detailed engine maintenance and specifications, INJECTION HAZARD refer to separate engine manual, supplied. System pressure must be manually relieved to prevent system from starting DAILY: Check engine oil level and fill as necessary. or spraying accidentally. Fluid under high Manual 309410. pressure can be injected through skin and cause serious injury. To reduce risk of injury from injec- DAILY: Check that V-belt (60) is centered on pulleys tion, splashing fluid
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Troubleshooting Relieve pressure; page 6. PROBLEM CAUSE SOLUTION E=XX is displayed Fault condition exists Determine fault correction from table, page 14. Engine won’t start Engine switch is OFF Turn engine switch on. Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual. Engine oil level low Try to start engine. Replenish oil, if necessary. Honda Engines Owner’s Manual. Spark plug cable disconnected or Connect spark plug cable or replace spark plug. spark plug damaged Oil seepage in
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PROBLEM CAUSE SOLUTION Pump output low Strainer (31) clogged Clean. Piston ball (25) not seating Service piston ball check. Manual 309277. Piston packings worn or damaged Replace packings. Manual 309277. Displacement pump o-ring (227) is damaged Replace o-ring. Manual 309277. Intake valve ball not seating properly Clean and service. Manual 309277. Engine speed is too low Increase throttle setting. See Manual 309410. V–belt slipping Tighten V–belt with tension bar (101). Adjust bracket until it t
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Bearing Housing and Connecting Rod Removal 2. Assemble connecting rod (40) and bearing housing (60). 1. Relieve pressure; page 6. 3. Clean mating surfaces of bearing and drive hous- ings (60, 3). 2. Stop sprayer at bottom of stroke to get crank (E) in 4. Align connecting rod (C) with crank (E) and drive lowest position. To lower crank manually, remove housing locating pins (3b) with bearing housing spark plug and carefully rotate crank by pulling (60) holes. Push bearing housing onto drive hous
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Drive Housing Removal 3. Install four screws (47) and lockwashers (37) to pinion housing (4) and drive housing (3). 1. Relieve pressure; page 6. 4. Install two screws (31) and lockwashers (37) to drive housing (3). 2. Disconnect reed switch (A). 3. Fig. 3. Remove bearing housing. Do Removal of 5. Fig. 3. Install bearing housing. Do 1. through 6. of Bearing Housing and Connecting Rod proce- Bearing Housing and Connecting Rod proce- dure on page 9. dure on page 9. 4. Remove two screws (31) and lo
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley Removal 6. Remove four screws (16) and lockwashers (37). Install two screws in threaded holes (E) in rotor. 1. If pinion assembly (4) is not removed from clutch Alternately tighten screws until rotor comes off. housing (169), do 2. through 5. Otherwise, do 2. and then start at 6. 16 37 2. Relieve pressure; page 6. E 3. Disconnect field cable (X) from pressure control and reed switch (A). Fig. 6 7. Fig. 7. Remove retaining ring (169b). 8. Tap pinion
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley Installation 8. Hold pulley (53) and install four screws (88) and washers (37) in hub (94). Torque to 125 in-lb 1. Fig. 9. Install jack shaft assembly (169c). Install (14 Nm). retaining ring (169b). 9. Install belt guard (117), belt guide bracket (171) 2. Fig. 8. Lay two stacks of two dimes on smooth and vee belt (103). bench surface. 10. Fig. 7. Tap pinion shaft (169c) in with plastic 3. Lay armature (86) on two stacks of dimes. mallet. 4. Press hub
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On/Off Switch Removal Installation 1. Install new ON/OFF switch (51) so tabs of switch 1. Relieve pressure; page 6. snap into place on inside of pressure control housing. 2. Fig. 10. Remove four screws (11) and display/cover (12). 2. Connect ON/OFF switch connector (B) to PC board. 3. Pull display connector wings (A) open on PC board and pull display connector out. 3. Push display connector into PC board close dis- play connector wings (A) on PC board. 4. Disconnect ON/OFF switch connector (B)
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Pressure Control Control Board Removal Installation When installing replacement control board, follow 1. instructions with control board to set model type. Relieve pressure; page 6. 1. Fig. 10. Install control board (147) and jam nut 2. Fig. 10. Remove four screws (11) and (147a). Install connector (Ref 4) at backside of display/cover (12). Pull display connector wings pressure control. open on PC board and pull display connector out. 3. Fig. 17. Disconnect at control board (147): 2. Install g
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Pressure Control Repair Digital Display Messages Relieve pressure before repair; page 6. No display does not mean that sprayer is not pressurized. DISPLAY SPRAYER INDICATION ACTION OPERATION No Display Sprayer may be pressurized. Loss of power or display Check power source. Relieve not connected pressure before repair or dis- assembly. Verify display is connected. Sprayer may be pressurized. Pressure less than Increase pressure as needed 200 psi (14 bar, 1.4 MPa) Sprayer is pressurized. Power is
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Displacement Pump Removal 58 1. Flush pump. 2. Relieve pressure; page 6. 3. Fig. 11. Cycle pump with piston rod (222) in its Fig. 12 lowest position. 4. Fig. 11. Remove suction tube (73) and hose (167). 6. Fig. 13. Loosen jam nut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump. 222 167 73 Fig. 11 5. Fig. 12. Use screwdriver: push retaining spring up Fig. 13 and push out pin (58). Repair See manual 309277 for pump repair instructions. Installation 2. Fig. 12. Pu
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Notes 309411 17
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Parts – Basic Sprayer 1 See exploded view on page 21 Model 233709, Series A DETAIL A 2 See parts in manual 309277 101 166 53 103 171 5 Ref 3 See Engine Detail on page 20 117 4 See parts on page 22 175 189 5 See parts on page 24 47 37 123 Label 6 97 169 5 99 35 188 16 102 34 37 1 4 120 82 3h 3g 36 6 61 64 3 124 40 31 87 37 60 19 39 5 20 5 63 38 72 54 6 62 6 137 1 3 6 106 DETAIL A 59 58 141 151 21 121 57 105 167 107 95 48 2 23 32 115 128 102 73 74 Ref 127 71 100 49 70 140 142 139 162 110 179 18 4
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Parts – Basic Sprayer Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 3 245443 HOUSING, drive (5900) 1 76 206994 FLUID, TSL 8 oz bottle 1 4 245399 HOUSING, pinion (5900) 1 81 195119 LABEL, warning 1 parts, page 21 82 195098 LABEL, instruction (English) 1 5 245245 HANDLE, cart 1 87 114271 STRAP, retaining 1 6 116806 SWITCH, reed 1 88 108803 SCREW, hex, socket head 4 10 196670 LABEL, crtl box cover, Ultra 1 95 162485 NIPPLE, adapter 1 16 101682 SCREW, cap, sch 4 97 183350 W
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Engine Detail 118 111 L 93 J 124 P 41 112 N M 92 42 C 170 166 32 Ref 101 146 125 101 53 156 108 165 52 C ti1846a 84 C Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 41 183401 KEY, parallel 1 125 198693 HANDLE, slide, engine 2 42 198689 BRACKET, belt guard (motor) 2 146 116139 GRIP, handle 2 52 245272 BASE, mounting 1 156 198695 BRACKET, torsion bar 1 53 198688 PULLEY, engine 1 165 111800 SCREW, cap, hex hd, flange 2 84 194925 BRACKET, tension 1 166 112717 WASHER 2 92 1944
