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INSTRUCTIONS-REPAIR 308868
Rev. L
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INSTRUCTIONS
GMax 3900, 5900, 5900HD
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
GMax 3900
Model Series Description
232610 A Hi-Boy
232611 A Hi-Boy with RAC 5 tip, gun and hose
232612 A Lo-Boy
232613 A Lo-Boy with RAC 5 tip, gun and hose
233005 A Hi-Boy with gauge kit
GMax 5900
Model Series Descripti
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Table of Contents Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . 15 Parts Component Identification and Function . . . . . . . . . . . . 3 GMax 3900 & GMax 5900 Hi-Boy Sprayers . . . . . 16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pinion Assembly . . . . . . . . . . . . . . . . .
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Component Identification and Function V D C 202Main hose 203Whip end hose 204Contractor gun with RAC 5 DripLess tip guard and 517 size SwitchTip J H E G R K F P S A B U W Model 232611 T 202 M N 204 X 203 L 8696B Fig. 1 A Pressure Control Switch ON/OFF, enables/disables clutch function and pressure control B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner* Filters air entering the carburetor D Fuel Tank* Uses 86 octane unleaded gasoline E Muffler* Reduces noise of internal c
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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 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 switch is OFF Turn engine switch ON Engine won’t start Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual. Engine
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PROBLEM CAUSE SOLUTION Pump output is low Strainer (31) is clogged Clean strainer. Sprayer 232627 strainer is for use in paint only. Piston ball (25) is not seating Service piston ball. Manual 308798. Piston packings are 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 is not seating properly Clean intake valve. Manual 308798. Intake valve ball is packed with material Clean intake valve. Manual
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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 4. 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 replacement gear cluster) to gear cluster (18) and 1. Relieve pressure; page 4. 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. 4. Remove bearing housing. Do 1. through 8. 2. Place bronze colored washer (20g) on shaft pro- of Bearing Housing and Connecting Rod proce- truding from large shaft of drive housing (20). d
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Pinion Assembly/Rotor/Field/Shaft/Clutch Removal If pinion assembly (19) is not removed from clutch 6. Fig. 8. Remove retaining ring (19e). housing (5), do 1. through 4. Otherwise, start at 5. 7. Tap pinion shaft (19d) out with plastic mallet. 1. Relieve pressure; page 4. 19e 2. Disconnect field cable (X) from pressure control. 19d X Fig. 8 8. Fig.9. Use an impact wrench or wedge something Bottom View between armature (4a) and clutch housing to hold 8699A Fig. 5 engine shaft during removal
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Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 10. Lay two stacks of two dimes on smooth 6. Fig. 8. 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. 7. Place pinion assembly on bench with rotor side up. 4a 0.12 ±.01 in. (3.0 ±.25 mm) 9. Apply locktite to screws. Install four screws (16) and lockwashers (1
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Clutch Housing Removal 1. Fig. 12. Remove four capscrews (75) 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. 12. Push on clutch housing (5). 75 2. Install four capscrews (75) and lockwashers (77) and secure clutch housing (5) to engine. Torque to D 200 in-lb (22.6 Nm). 15 3. Install capscrew (15) from beneath mounting Fig. 12 plate (D)
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On/Off Switch Removal Installation 1. Install new ON/OFF switch (309) so tabs of switch 1. snap into place on inside of pressure control Relieve pressure; page 4. housing. 2. Fig. 15. Remove five screws (307) and 2. Connect two wires (A) to ON/OFF switch. cover (322). 3. Install pressure control cover (322) with five 3. Disconnect two wires (A) from ON/OFF screws (307). switch (309). 4. Press in on two retaining tabs on each side of ON/OFF switch (309) and remove switch. 313 310 309 A 315 31
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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 4. 2. Fig. 15. Remove five screws (307) and 1. Fig. 15. Install green ground wire and control cover (322). board (302) with five screws (303). 3. Fig. 22. Disconnect at control board (302): 2. Fig. 22. Connect to control board (302): Four clutch leads: two violet and two black. Lead (D) from potentiometer. Two re
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Pressure Control Control Board Diagnostics 1. Fig. 15. 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 1. Flush pump. 5. Fig. 17. Use screwdriver: push retaining spring up and push out pin (29). 29 2. Relieve pressure; page 4. 3. Fig. 16. Cycle pump with piston rod (222) in its lowest position. Fig. 17 4. Fig. 16. Remove suction tube (30) and hose (33). 6. Fig. 18. Loosen locknut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump. 222 33 30 Fig. 16 Fig. 18 Repair See manual 308798 for pump repair instructions. Installation 2. Fig. 17. Push
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Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 232610, 232620 and 232627 Label 87 5 78 DETAIL A See page 18 for the parts. Ref 11 See manual 308798 for the parts. See page 22 for the parts. 40 Used on GMax 5900, 5900HD 45 Used on GMax 3900 37 93 and 94 used on GMax 5900HD 8699A 38 Used on GMax 3900, 5900 39 Bottom View 6 9 19 61 (Ref) (Ref) Ref 35 20h 20g 20 17 72 81 91 17 22 3 4b 12 13 2 91 23 18 21 56 1 92 11 55 68 10 26 17 29 5 36 7 33 8 34 67 14
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Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 232610, 232620 and 232627* Ref Ref No. Part No. Description Qty No. Part No. Description Qty 1 ENGINE 31 STRAINER 108879 GMax 3900 1 181072 GMax 3900 1 114530 GMax 5900, 5900HD 1 189920 GMax 5900, 5900HD 1 2 113084 RIVET, blind 2 32 CLIP, spring 3 192014 PLATE, indicator 1 194194 GMax 3900, 5900 1 4 CLUTCH ASSEMBLY, 194525 GMax 5900HD 1 includes 4a, 4b, 16, 17, 80 33 240795 HOSE, coupled 1 241109 GMax 3900 1 34 NUT, retaining 241113
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Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 241108 for Ref No. 20: Drive Housing Assembly 241007 for GMax 3900; Pinion Housing Assembly 241112 for GMax 3900; Drive Housing Assembly 241011 for GMax 5900 GMax 5900 Ref Ref No. Part No. Description Qty No. Part No. Description Qty 19 PINION HOUSING 1 20 DRIVE HOUSING 1 19b 105489 PIN 2 20g* WASHER 19d* PINION SHAFT 107089 GMax 3900 1 241110 GMax 3900 1 194173 GMax 5900, 5900HD 1 241114 GMax 5900, 590
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Notes
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Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayers Models 232612 and 232622 87 78 5 Label DETAIL A Ref 11 See page 18 for the parts. See manual 308798 for the parts. 40 See page 22 for the parts. 45 Used on GMax 5900, only 37 Used on GMax 3900, only 8699A 38 39 Bottom View 9 61 (Ref) (Ref) 6 Ref 35 19 20h 20g 20 72 17 81 17 91 3 22 4b 12 2 13 23 1 56 91 6 21 11 18 92 10 17 55 26 70 5 29 7 36 8 DETAIL A 33 34 17 14 62 49 16 30a 35 28 4a 30b 47 30e 30f 73 71 77 80 17
