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.
Table of Contents Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair Bearing Housing & Connecting Rod . . . . . . . . . . . . . 8 Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pinion Assembly/Rotor/Field/Shaft/Clutch . . . . . . . 10 Clamp . . . . . . . . . . . . . . . . . . . . .
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 medical attention. Do not point the spray tip at anyone or any part of the body.
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.
Maintenance CAUTION WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury.
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.
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.
Bearing Housing and Connecting Rod NOTE: The item numbers referenced are for the Hi-Boy models. The Lo-Boy models may have different item numbers. Use the Hi-Boy item number and part to find the corresponding Lo-Boy part and item number. Removal 1. Relieve pressure; page 5. 2. Fig. 2. Remove screws (14) and front cover (23). 3. For Hi-Boy models; remove spring clip (32) and drain hose (54). Unscrew suction tube (30) from pump, hold wrench on pump intake valve (A) to keep pump from loosening.
Drive Housing Installation Removal 1. 1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (18) and 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. Relieve pressure; page 5. 2. Fig. 3. Remove bearing housing. Do 1. through 8. of Bearing Housing and Connecting Rod procedure on page 8. 2.
Pinion Assembly/Rotor/Field/Shaft/Clutch Removal 72 17 If pinion assembly (19) is not removed from clutch housing (5), do 1. through 4. Otherwise, start at 5. 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). Fig. 6 A X Fig. 4 Bottom View 8699A 4. Fig. 5. Remove five screws (10) and lockwashers (17) and pinion assembly (19). 10 17 19 10 Fig. 5 17 8700A 5. Fig. 6.
7. Fig. 7. Remove retaining ring (19e). 8. Tap pinion shaft (19d) out with plastic mallet. 9. Fig.8. Use an impact wrench or wedge something between armature (4a) and clutch housing to hold engine shaft during removal. 19e 10. Remove four screws (16) and lockwashers (17). 19d 11. Remove armature (4a). 4a 17 16 8703B Fig. 7 8704A Fig.
Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 6. Fig. 7. Tap pinion shaft (A) in with plastic mallet. 1. Fig. 9. Lay two stacks of two dimes on smooth bench surface. 7. Install retaining ring (Z) with beveled side facing field (Y). 2. Lay armature (4a) on two stacks of dimes. 3. Press center of clutch down on bench surface. 4a 8. Fig. 6. Place pinion assembly on bench with rotor side up. 0.12 ±.01 in. (3.0 ±.25 mm) Fig. 9 dimes 8705A 9. Apply Loctite to screws.
Clutch Housing Removal 1. Fig. 11. Remove four capscrews (73) and lockwashers (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 200 in-lb (22.6 N m). D 15 Fig. 11 3. Install capscrew (15) from beneath mounting plate (D).
On/Off Switch Installation Removal 1. 1. Install new ON/OFF switch (47) so tabs of switch snap into place on inside of pressure control housing. Relieve pressure; page 5. 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 display connector wings (A) on PC board. 4.
Pressure Control Control Board Removal 1. Relieve pressure; page 5. 2. Fig. 14. Remove four screws (28) and display/cover (153). Pull display connector wings open on PC board and pull display connector out. 3. Fig. 21. Disconnect at control board (10): Installation When installing replacement control board, follow instructions with control board to set model type. 1. Fig. 14. Install control board (10) and jam nut (Z). Install connector (Y) at backside of pressure control. Lead (D) from potentiometer.
Pressure Control Repair Digital Display Messages Relieve pressure before repair; page 5. No display does not mean that sprayer is not pressurized. DISPLAY No Display psi bar MPa SPRAYER OPERATION INDICATION ACTION Sprayer may be pressurized. Loss of power or display not connected Check power source. Relieve pressure before repair or disassembly. Verify display is connected. Sprayer may be pressurized. Pressure less than 200 psi (14 bar, 1.
Displacement Pump Removal 1. Flush pump. 2. 5. Fig. 16. Use screwdriver: push retaining spring up and push out pin (29). 29 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). Fig. 16 7675B 6. Fig. 17. Loosen locknut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump. 222 33 30 7672C Fig. 15 7673B Fig. 17 Repair See manual 309277 for pump repair instructions.
Parts Drawing – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 233701, 233706 and 233716 133 DETAIL A Ref 11 45 40 37 38 39 1 Label 2 See page 20 for the parts. 3 See manual 309277 for the parts. 4 See page 24 for the parts.
Parts List – GMax 3900, 5900, 5900HD Hi-Boy Sprayers Models 233701, 233706 and 233716* Ref No. Part No.
Parts List & Drawing – Pinion Assembly Ref No. 19 and 20 Ref No. 19: Pinion Housing Assembly 245398 for GMax 3900; Pinion Housing Assembly 245399 for GMax 5900, 5900HD Ref No. 20: Drive Housing Assembly 245442 for GMax 3900; Drive Housing Assembly 245443 for GMax 5900, 5900HD Ref No. Ref No. Part No.
Notes 309409 21
Parts Drawing – GMax 3900 and GMax 5900 Lo-Boy Sprayers Models 233700 and 233705 DETAIL A Ref 11 45 40 37 133 1 Label 2 See page 20 for the parts. 3 4 See manual 309277 for the parts. See page 24 for the parts.
Parts List – GMax 3900 and GMax 5900 Lo-Boy Sprayers Models 233700 and 233705 Ref No. Part No.
Parts Drawing – Sprayer GMax 3900, 5900 and 5900HD Sprayers Models 233700 through 233703 Models 233706 through 233708; 233716 and 233717 100a 47 Ref 100b 100c 143 50 Ref 19 144 150 55 153 144 ti7660a 151 10a 100d 147 22 100e 28 10 143 100f 149 100g 133 15 142 100h 62 Ref 152 78 100q 100r 100s 85 100k 100j 100p 100n 100m 48 45 85 8716A 24 309409
Parts List – Sprayer Models 233700 through 233703; 233705 through 233707; 233716 and 233717 REF REF NO. PART NO.
Parts List/Drawing – Sprayers with RAC X Tip, Gun & Hose Models 233702, 233703, 233707, 233708, 233717 GMax 3900, 5900, 5900HD Airless Paint Sprayers Includes items 201 to 204 Ref No. Part No. Description 201 233701 GM3900 Hi-Boy Sprayer 1 See parts list on page 18 GM5900 Hi-Boy Sprayer 1 See parts list on page 18 GM5900HD Hi-Boy Sprayer 1 See parts list on page 18 GM3900 Lo-Boy Sprayer 1 See parts list on page 23 GM5900 Lo-Boy Sprayer 1 See parts list on page 23 HOSE, grounded, nylon; 1/4 in.
Technical Data Honda GX120 Engine Power Rating @ 3700 rpm ANSI . . . . . . . . . . . . . . . . . . . . . . . 4.0 Horsepower DIN 6270B/DIN 6271 NA . . . . . . . . . . . . . . . . . . . . . . 2.1 Kw – 2.8 Ps NB . . . . . . . . . . . . . . . . . . . . . . 2.6 Kw – 3.6 Ps Honda GX160 Engine Power Rating @ 3700 rpm ANSI . . . . . . . . . . . . . . . . . . . . . . . 5.5 Horsepower DIN 6270B/DIN 6271 NA . . . . . . . . . . . . . . . . . . . . . . 2.9 Kw – 4.0 Ps NB . . . . . . . . . . . . . . . . . . . . . . 3.
Graco Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
