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INSTRUCTIONS-PARTS LIST 308864
Rev. F
This manual contains important
warnings and information.
First choice when
READ AND KEEP FOR REFERENCE.
quality counts.
INSTRUCTIONS
5.5 HORSEPOWER, GASOLINE POWERED
GMAX 5900 Convertible
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model Series Description
232624 A Sprayer, gas powered
232625 A Sprayer, gas powered, with RAC 5 tip,
gun and hose
232626 A Sprayer, gas powered, with electric mo-
tor kit
232629 A Same as 232626
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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. WARNING Fire and explosion can occur when spraying or flushing flammable fluid in an area where air circulation is poor and flammable vapors can be ignited by an open flame or sparks. To help prevent a
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Component Identification and Function 202Main hose 203Whip end hose 204Contractor gun with RAC 5 C DripLess tip guard and 517 size SwitchTip V H J R D S E G F K P X T A U B 203 Y M 202 L 204 N Model 232624 W Fig. 1 A Pressure Control Switch ON/OFF, enables/disables clutch function B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner* Filters air entering carburetor D Fuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline E Muffler* Reduces noise of internal comb
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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 308863. 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 WARNING INJECTION HAZARD To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from moving parts, always follow Pressure Relief Procedure Warning, page 4, before checking, adjust- ing, cleaning or shutting down sprayer. Check everything in chart before disassembling sprayer. PROBLEM CAUSE SOLUTION 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. Engin
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PROBLEM CAUSE SOLUTION Pump output low Strainer (31) clogged Clean. Piston ball (25) not seating Service piston ball check. Manual 308798. Piston packings worn or damaged Replace packings. Manual 308798. O-ring (227) in displacement pump is worn or Replace o-ring. Manual 308798. damaged Intake valve ball not seating properly Clean and service. Manual 308798. Engine speed is too low Increase throttle setting. See Manual 308863. V–belt slipping Tighten V–belt with clamp (101). Adjust clamp until i
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Bearing Housing and Connecting Rod Removal 3. Clean mating surfaces of bearing and drive hous- ings (17, 12). 1. Relieve pressure; page 4. 4. Align connecting rod (14) with crank (E) and drive housing locating pins (12b) with bearing housing (17) holes. Push bearing housing onto drive hous- 2. Stop sprayer at bottom of stroke to get crank (E) in ing or tap into place with plastic mallet. lowest position.To lower crank manually, remove spark plug and carefully rotate crank by pulling starter rop
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Drive Housing 2. Place bronze colored washer (12g) on shaft pro- 1. truding from large shaft of drive housing (12). Relieve pressure; page 4. Note: If replacing a washer with pin holes with a washer without pin holes, remove guide pins from housing. Place silver colored washer (12h) on pin- ion housing. Assemble washers (15) and (16) onto Removal gear (7). Align gears and push new drive housing 2. Fig. 4. Remove bearing housing. Do Removal of straight onto pinion housing and locating pins (A). B
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley Removal 39 If pinion assembly (8) is not removed from clutch 6 housing (3), do 1. through 4. Otherwise, do 1 and then E start at 5. 1. Relieve pressure; page 4. 2. Disconnect field cable (X) from pressure control. Fig. 7 6. Fig. 8. Remove retaining ring (Z). X 7. Tap pinion shaft (A) out with plastic mallet. Z A Bottom View Fig. 5 3. Fig. 6. Remove five screws (5) and lockwashers (6) and pinion assembly (8). Fig. 8 5 6 8. Fig. 10. Remo
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Pinion Assembly/Rotor/Shaft/Clutch/Pulley Installation 11. Install five screws (5) and lockwashers (6). 1. Fig. 10. Install jack shaft assembly (3c). Install retaining ring (3b). 12. Fig. 8. Tap pinion shaft (A) in with plastic mallet. 2. Fig. 9. Lay two stacks of two dimes on smooth 13. Install retaining ring (Z). bench surface. 3. Lay armature (4a) on two stacks of dimes. 14. Fig. 7. Place pinion assembly on bench with rotor side up. 4. Press center of clutch down on bench surface. 15. Apply l
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On/Off Switch Removal Installation 1. Relieve pressure; page 4. 1. Install new ON/OFF switch (309) so tabs of switch snap into place on inside of pressure control housing. 2. Fig. 11. Remove five screws (307) and cover (322). 2. Connect two wires (A) to ON/OFF switch. 3. Disconnect two wires (A) from ON/OFF switch (309). 4. Press in on two retaining tabs on each side of 3. Install pressure control cover (322) with five ON/OFF switch (309) and remove. screws (307). 313 310 309 A 315 319 318a
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Pressure Control Control Board Removal Two red leads (A) to ON/OFF switch (80). 4. Remove five screws (303), green ground wire and 1. Relieve pressure; page 4. circuit board (302). Installation 1. Fig. 11. Install control board (302) and green 2. Fig. 11. Remove five screws (307) and ground wire with five screws (303). cover (322). 2. Connect to control board (302): 3. Fig. 18. Disconnect at control board (302): Two red leads (A) to ON/OFF switch (309). Lead (E) to transducer. Four clut
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Pressure Control Control Board Diagnostics 1. Fig. 11. Remove five screws (307) and 3. Turn ON/OFF switch ON. cover (322). 4. Observe LED operation and reference following 2. Start sprayer. table: LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times Sprayer shuts down and LED contin- Run away pressure. 1. Check pressure transducer con- repeatedly Pressure greater than ues to blink two times repeatedly nection at control board 4500 psi (310 bar, 31 2. Replace pressure transducer MPa). 3. R
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Displacement Pump Removal 19 1. Flush pump. 2. Relieve pressure; page 4. 3. Fig. 12. Cycle pump with piston rod (222) in its Fig. 13 lowest position. 4. Fig. 12. Remove suction tube (107) and hose (47). 6. Fig. 14. Loosen jam nut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump. 222 47 107 Fig. 12 5. Fig. 13. Use screwdriver: push retaining spring up Fig. 14 and push out pin (19). Repair See manual 308798 for pump repair instructions. Installation 2. Fig. 13. Pu
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Notes 308864
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Parts – Basic Sprayer Model 232624, Series A 1 See exploded view on page 18 DETAIL A 74 79 68 112b 2 See parts in manual 308798 71 76 Ref 3 See Engine Detail on page 17 75 112a 1 4 See parts on page 19 5 See parts on page 21 81 65 5 6 Label 64 6 3 5 63 72 9 62 10 1 8 83 12h 2112 12g 7 16 79 131 10 90 41 3 132 39 6 14 4 45 76 44 13 17 11 15 6 1 12 57 18 40 19 43 55 47 20 59 117 27 56 61 21 2 108 62 52 105 106 49 50 107 51 104 101 103 122 102 48 8(Ref) 82 86 42 4 42(Ref) 46 47(Ref) 60 88 58 109 2
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Parts – Basic Sprayer Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 1 183401 KEY, parallel 1 101 241935 LATCH, adjustable 1 2 193548 PULLEY 1 102 110885 SCREW, mach, pnhd, thrd forming 2 3 241306 CLUTCH HOUSING ASSY 1 103 108947 NUT, square 2 4 193553 ROTOR, clutch, 5 in. 1 104 187147 STRAINER 1 5 100644 CAPSCREW, sckt hd,, 1/4–20 x 3/4 in. 4 105 241718 .DEFLECTOR 1 6 105510 LOCKWASHER, spring, 1/4 in. 11 106 194194 CLIP, spring 1 7 241440 GEAR, combination 1 107 193097 T
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Parts List & Drawing – Pinion Assembly Ref No. 8 and 12 Ref No. 8: Pinion Housing Assembly 241112 Ref No. 12: Drive Housing Assembly 241011 Ref Ref No. Part No. Description Qty No. Part No. Description Qty 8 PINION HOUSING 1 12 HOUSING, drive 1 8b 105489 PIN 2 12g* 194173 WASHER 1 8d* 193358 PINION SHAFT 1 12h* 194172 WASHER 1 8e* 112770 RETAINING RING, large 1 *Must be ordered separately *Must be ordered separately 8d 8b 8e 9 (Ref.) 10 (Ref.) 8 12h 12g 15 (Ref) 12 10 (Ref.) 9 (Ref.) 7(Ref.) 16
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Parts Drawing – Sprayer Ref No. 42 Pressure Control Assembly 307 301 318f 314 313 304 305 310 309 318a 312 308 319 304 302 318d 303 318b 320 315 318c 318z 306 311 318aa 323 310 318a 305 322 318g 307 318h 318m 318n 318l 318j 318k 8716A 308864
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Parts List – Sprayer Models 232624 REF REF NO. PART NO. DESCRIPTION QTY NO. PART NO. DESCRIPTION QTY 301193653 PLATE, control 1 318f 192706 BOWL, filter 1 302 241093 BOARD, PC 1 318g193710* SEAL, valve 1 303 111839 SCREW, mch pan, 6–32 x 1/2 in. 5 318h193709* SEAT, valve 1 304240776 HARNESS, wiring. 1 318j194102* HANDLE, valve 1 305 193497 GASKET, control 2 318k 114688* NUT, cap, hex hd 1 306 193652 HOUSING, control box 1 318l 114708* SPRING, compression 1 307 114631 SCREW, mch, pan hd 10 318m
