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INSTRUCTIONS-REPAIR
309409E
Important Safety Instructions
Read all warnings and instructions in this
manual. Save These instructions.
GMax 3900, 5900, 5900HD
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 3900
Model Series Description
233701 A Hi-Boy
233703 A Hi-Boy with RAC X tip, gun and hose
233700 A Lo-Boy
233702 A Lo-Boy with RAC X tip, gun and hose
GMax 5900
Model Series Description
233706 A Hi-Boy
233708 A Hi-Boy with RAC X tip, gun and hose
233705 A
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Table of Contents Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . 17 Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GMax 3900 & GMax 5900 Hi-Boy Sprayers . . . . . 18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Bearing Housing & Connecting Rod
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WARNING 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 medi- cal attention. Do not point the spray tip at anyone or any part of the body. Do not put hand or fingers over the
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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. See Electrical Grounding on page . 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 t
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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 under high pressure can be injected through the DAILY: Check engine oil level and fill as necessary. skin and cause serious injury. To reduce the risk of DAILY: Check hose for wear and damage. an injury from injection, splashing fl
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Troubleshooting Relieve pressure; page 5. 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 is low Try to start engine. Replenish oil, if necessary. Honda Engines Owner’s Manual. Spark plug cable is disconnected or damaged Connect spark plug cable or replace spark plug Cold engine Use choke
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PROBLEM CAUSE SOLUTION Pump output is low Strainer (31) is clogged Clean strainer. Sprayer 233716 strainer is for use in paint only. Piston ball (206) is not seating Service piston ball. Manual 309277. Piston packings are worn or damaged Replace packings. Manual 309277. O-ring (227) in pump is worn or damaged Replace o-ring. Manual 309277. Intake valve ball is not seating properly Clean intake valve. Manual 309277. Intake valve ball is packed with material Clean intake valve. Manual 309277. Do n
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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 may have different (21). item numbers. Use the Hi-Boy item number and part to find the corresponding Lo-Boy part and item number. 3. Clean mating surfaces of bearing and drive hous- ings. Removal 1. 4. Align connecting rod with crank (B) and carefully Relieve pressure; page 5. align locating pins (F) in drive housing (20) with holes
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Drive Housing Removal Installation 1. Liberally apply bearing grease (supplied with 1. replacement gear cluster) to gear cluster (18) and Relieve pressure; page 5. 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. 2. Fig. 3. Remove bearing housing. Do 1. through 8. of Bearing Housing and Connecting Rod proce- 2. Place bronze colored washer (20g) on shaft pro- dure on page 8. truding from large shaft of drive
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Pinion Assembly/Rotor/Field/Shaft/Clutch Removal 72 If pinion assembly (19) is not removed from clutch housing (5), do 1. through 4. Otherwise, start at 5. 17 E 1. Relieve pressure; page 5. 2. Remove drive housing; page 9. 3. Disconnect field cable (X) from pressure control, and gallon counter sensor at (A). 8701B Fig. 6 A Bottom View X 8699A Fig. 4 4. Fig. 5. Remove five screws (10) and lockwashers (17) and pinion assembly (19). 10 17 19 10 17 8700A Fig. 5 5. Fig. 6. Place pinion assembly (19)
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7. Fig. 7. Remove retaining ring (19e). 9. Fig.8. Use an impact wrench or wedge something between armature (4a) and clutch housing to hold 8. Tap pinion shaft (19d) out with plastic mallet. engine shaft during removal. 19e 10. Remove four screws (16) and lockwashers (17). 11. Remove armature (4a). 19d 4a 17 16 8703B 8704A Fig. 8 Fig. 7 309409 11
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Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 9. Lay two stacks of two dimes on smooth 6. Fig. 7. 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). 3. Press center of clutch down on bench surface. 8. Fig. 6. Place pinion assembly on bench with rotor side up. 4a 0.12 ±.01 in. (3.0 ±.25 mm) 9. Apply Loctite to screws. Install four screws (16) and lockwashers (17
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Clutch Housing Removal 1. Fig. 11. Remove four capscrews (73) and lock- washers (77) which hold clutch housing (5) to engine. 5 7 2. Remove screw (15) from under mounting plate (D). 3. Remove engine key (7). 4. Pull off clutch housing (5). Installation 77 1. Fig. 11. Push on clutch housing (5). 73 2. Install four capscrews (73) and lockwashers (77) and secure clutch housing (5) to engine. Torque to D 200 in-lb (22.6 Nm). 15 8708A 3. Install capscrew (15) from beneath mounting Fig. 11 plate (D).
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On/Off Switch Removal Installation 1. Install new ON/OFF switch (47) so tabs of switch 1. Relieve pressure; page 5. snap into place on inside of pressure control housing. 2. Fig. 14. Remove four screws (28) and display/cover (153). 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 5. 1. Fig. 14. Install control board (10) and jam nut (Z). 2. Fig. 14. Remove four screws (28) and Install connector (Y) at backside of pressure display/cover (153). Pull display connector wings control. open on PC board and pull display connector out. 3. Fig. 21. Disconnect at control board (10): 2. Install green grou
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Pressure Control Repair Digital Display Messages Relieve pressure before repair; page 5. 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 1. Flush pump. 5. Fig. 16. Use screwdriver: push retaining spring up and push out pin (29). 29 2. Relieve pressure; page 5. 3. Fig. 15. Cycle pump with piston rod (222) in its lowest position. 4. Fig. 15. Remove suction tube (30) and hose (33). 7675B Fig. 16 6. Fig. 17. Loosen locknut by hitting firmly with a 222 20 oz (maximum) hammer. Unscrew pump. 33 30 7672C Fig. 15 7673B Fig. 17 Repair See manual 309277 for pump repair instructions. Installation 2. Fig. 16. Push p
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Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 233701, 233706 and 233716 133 15 1 Label DETAIL A Ref 11 2 See page 20 for the parts. 53 45 3 See manual 309277 for the parts. 4 40 See page 24 for the parts. 87 5 Used on GMax 5900, 5900HD 71 37 61 Used on GMax 3900 6 38 7 Used on GMax 3900, 5900 39 6 Bottom View 9 78 Ref 35 2 19 2 20h 3 2 20g 1 2 2 20 72 1 91 89 11 56 17 17 1 4b 81 10 22 23 91 17 18 6 70 5 92 7 1 55 49 8 18 20m 2 36 1 17 DETAIL A 2 20k 14 16 35 26 4a 21 12 68 47
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Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 233701, 233706 and 233716* Ref No. Part No. Description Qty Ref No.Part No. Description Qty 1 ENGINE 31 STRAINER 108879 GMax 3900 1 181072 GMax 3900, 5900 1 114530 GMax 5900, 5900HD 1 189920 GMax 5900HD 1 2 113084 RIVET, blind 2 32 197124 CLIP, spring 1 3 192014 PLATE, indicator 1 33 198847 HOSE, coupled 1 4 CLUTCH ASSEMBLY, 34 NUT, retaining includes 4a, 4b, 16, 17, 72, 80 192723 GMax 3900 1 241109 GMax 3900 1 193031 GMax 5900, 5900HD
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Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 245398 for Ref No. 20: Drive Housing Assembly 245442 for GMax 3900; Pinion Housing Assembly 245399 for GMax 3900; Drive Housing Assembly 245443 for GMax 5900, 5900HD GMax 5900, 5900HD Ref Ref No. Part No. Description Qty No. Part No. Description Qty 19 PINION HOUSING 1 20 DRIVE HOUSING 1 19a KIT, repair, coil 20g WASHER 107089 GMax 3900 1 245268 GMax 3900 1 245267 GMax 5900, 5900HD 1 194173 GMax 5900, 5
