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Repair
™
GMAX II 5900 Convertible
™
TexSpray 5900 HD
Airless Sprayers
311046J
- 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.
Model Series Description
248691 A Standard
248692 A Premium
248693 A Standard, with electric motor kit
248694 A Same as 248693 except with ETL
approval to CSA and UL standards
248695 A Stan
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Manual Conventions Contents WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pinion and Drive Housing . . . . . . . . . . . . . . . . . . . 21 Repair . . . . . . . . . . .
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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
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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. � Do not alter or m
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Maintenance Maintenance DAILY: Check pressure drain valve for proper operation. Pressure Relief Procedure DAILY: Check and fill the gas tank. WARNING DAILY: Check that V-belt (147) is centered on pulley and is not inverted. Replace if worn or damaged. AFTER THE FIRST 20 HOURS OF OPERATION: Read Skin Injection Hazard, page 3; Burn Hazard, page 4 Drain engine oil and refill with clean oil. Reference 1. Lock gun trigger safety. 2. Turn engine ON/OFF switch to OFF. Honda Engines Owner's Manual for
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Troubleshooting Troubleshooting Problem Cause Solution E=XX is displayed Fault condition exists Determine fault correction from table, page 14 Engine will not start Engine switch is OFF Turn engine switch ON Engine is out of gasoline Refill gas tank. Honda Engines Owner's Man- ual. Engine oil level is low Try to start engine. Replenish oil, if necessary. Honda Engines Owner's Manual. Spark plug is disconnected of damaged Connect spark plug cable or replace spark plug Cold engine Use choke Fuel
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Troubleshooting Problem Cause Solution Pump output is low 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. Engine speed is too low Increase thro
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Bearing Housing and Connecting Rod Bearing Housing and Connecting Rod Removal CAUTION DO NOT use bearing housing screws (41) to align or WARNING seat bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear. Read Skin Injection Hazard, page 3; Burn Hazard, page 4 5. Install screws (41) and washers (42) in bearing housing. Torque evenly to note 3 value in Fig. 1. 1. Relieve pressure; page 5. 6. Install pump. Refer to Displacement Pump, Install
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Drive Housing Drive Housing Removal CAUTION DO NOT use drive housing screws (18) to align or seat WARNING bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear. 8. Install screws (18) in drive housing. Torque evenly to note Read Skin Injection Hazard, page 3; Burn Hazard, page 4 3 value in Fig. 1. 9. Install pump. Refer to Displacement Pump, Installation, 1. Relieve pressure; page 5. page14. 2. Remove bearing housing. Refer to Bearing Hous
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Pinion Housing/Rotor/Shaft/Clutch/Pulley Pinion Housing/Rotor/Shaft/Clutch/Pulley 5. FIG. 6. Place pinion housing (29) on bench with rotor side Removal up. 1. If pinion housing (29) is not removed from clutch housing 6. Remove four screws (28) and lock washers (24). Install (19), do 2. through 5. Otherwise, do 2 and then start at 6. two screws in threaded holes (E) in rotor. Alternately tighten screws until rotor comes off. WARNING 28 24 E E Read Skin Injection Hazard, page 3; Burn Hazard,
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Pinion Housing/Rotor/Shaft/Clutch/Pulley 6. Install three screws (35) through cart frame (1) and into Installation clutch housing (19). 1. FIG. 10. Install drive shaft assembly (19c). Install retaining ® 7. Apply Loctite to screw (20). Install screw, washer (61), ring (19b) key (18) and pulley (62) in end of drive shaft assembly 2. FIG. 8. Lay two stacks of two dimes on smooth bench (19c). End of driveshaft (19c) must be 0.090 in. below surface. flush with end of bushing. 3. Lay armature (
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Pressure Control Pressure Control On/Off Switch Removal Installation 1. Install new ON/OFF switch (169f) so tabs of switch snap WARNING 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. Press in on two retaining tabs
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Pressure Control Control Board � Display connector Removal � Engine, ground and clutch wires 4. Remove four screws (169c) and control board (169b). WARNING Installation 1. FIG. 10. Install control board (169b) with four screws (169c). 2. Connect engine wires to control board (169b). 3. Install control box (169a) with four screws (71). Read Skin Injection Hazard, page 3; Burn Hazard, page 4 4. Connect at control board (169b): � Ground and clutch wires 1. FIG. 10. Remove two screws (71) and swing
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Pressure Control Digital Display Messages � Digital messages are not available on all sprayers WARNING � 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* SPRAYER OPERATION INDICATION ACTION No Display Sprayer may be pressurized Loss of power or display not Check power source. Relieve pressure connected before repair or disassembly. Verify display is connected. Sprayer may be pressurized Pressure less than
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Displacement Pump Displacement Pump 6. Raise latch lock. Push latch open. Removal 1. Flush pump. 2. FIG. 19. Stop pump with piston rod in its lowest position. WARNING Read Skin Injection Hazard, page 3; Burn Hazard, page 4 3. Do Pressure Relief, page 5. FIG. 13 4. Separate drain hose from sprayer. 7. FIG. 14. Ratchet open pump door. a. Ratchet pump door forward. FIG. 11 5. Disconnect material hose from pump. FIG. 14 b. Twist latch u-bolt out of pump door recess. c. Place u-bolt on pump door out
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Displacement Pump e. Twist latch u-bolt back from pump door outer edge Installation f. Place u-bolt on pump door protrusion 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 3. FIG. 21. Slide pump into connecting rod. Push pump pin until it FIG. 17 is fully retained. Note: Pin will s
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Displacement Pump 5. FIG. 22. Rotate pump to align with material hose. Connect 7. FIG. 24. Attach drain hose to sprayer. material hose and hand tighten to 70 in-lb FIG. 24 8. FIG. 25. Fill pump with Graco TSL until fluid flows onto top of seal. FIG. 22 6. FIG. 23. Tighten latch and rotate latch lock into locked position. FIG. 25 FIG. 23 311046J 17
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Parts Parts Standard Sprayer - Parts Drawing TexSprayer 5900HD Convertible Only 18 311046J
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Parts Standard Sprayer - Parts List Ref Part Description Qty 91 287162 VALVE, auto clean 1 Ref Part Description Qty 93† 287253 TOOL BOX 1 1 287423 FRAME, cart 1 94† 118852 SCREW, machine, hex washer hd 3 2 156306 WASHER, flat 2 98 113161 SCREW, flange, hex hd 3 3 119509 WHEEL, pneumatic 2 99 15E918 BRACKET, holder, manual 1 4 15E891 CLIP, retaining 2 100 15E736 BRACKET, holder, manual 1 5 191084 SLEEVE, cart 2 101 119510 HOLDER, manual 1 6 183350 WASHER 2 102† 15E902 PLATE 1 7 108068 PIN, sprin
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Parts Engine Detail 140 141 15 115 139 135 18 138 136 (Ref) 135 137 126 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 Qty Ref Part Description Qty 129 198693 HANDLE, slide, engine 2 15 114530 ENGINE, gas, 5.5 Honda 1 130 198695 BRACKET, torsion bar 1 16 114653 SCREW, cap, flange hd 4 131 110963 SCREW, cap, hex hd, flange 2 17 110996 NUT, flng hd, hex 6 135 114816 NUT, hex 1 18 183401 KEY, parallel 1 136 116149 SPACER 1 20 1
