Graco GMAX II 5900, Repair Manual

Page 1: ... Same as 248693 except with ETL approval to CSA and UL standards 248695 A Standard with Lo Boy suction set kit 248696 A Premium same as 248890 except with ETL approval to CSA and UL standards 248697 A Standard with Lo Boy suction set kit and electric motor kit 248889 A Premium same as 248692 except with electric motor kit 248890 A Premium with Lo Boy suction set kit 255630 A TexSpray 5900HD conver...

Page 2: ... 24 Premium Sprayer 25 Lo Boy Suction Set 26 Technical Data 27 Graco Standard Warranty 28 Manual Conventions Note WARNING WARNING a potentially hazardous situation which if not avoided could result in death or serious injury Warnings in the instructions usually include a symbol indicating the hazard Read the general Warnings section for additional safety information Hazard Symbol CAUTION CAUTION a...

Page 3: ...ering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at any...

Page 4: ...e hands near the pump fluid inlet when pump is operating or pressurized Powerful suction could cause serious injury CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon mon oxide can cause death Do not operate in an enclosed area TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes ...

Page 5: ...Y 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 Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscosity WEEKLY Remove engine air filter cover and clean ele ment Replace element if necessary If operating in an unusually dusty environment check filter daily and repla...

Page 6: ...but displacement pump does not operate Error code displayed Reference Pressure Control repair page 14 Pump switch is OFF Turn pump switch ON Pressure setting too low Turn pressure adjusting knob clockwise to increase pressure Fluid filter 29 is dirty Clean filter Page 22 Tip or tip filter is clogged Clean tip or tip filter Manual 309639 Displacement pump piston rod is stuck due to dried paint Repa...

Page 7: ... packings Manual 310894 Displacement rod is worn or damaged Replace rod Manual 310894 Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Rep rime pump Manual 310892 Tip is partially clogged Clear tip Manual 309639 Fluid supply is low or empty Refill fluid supply Prime pump Manual 310892 Check fluid supply often to prevent running pump dry Pump is difficult to pr...

Page 8: ...ring D inside connecting rod 43 with bearing grease 2 Assemble connecting rod 43 to bearing housing 40 Rotate connecting rod to lowest position 3 Clean mating surfaces of bearing and drive housings 4 Align connecting rod with crank B and carefully align locating pins in drive housing 33 with holes in bearing housing 40 Push bearing housing onto drive housing or tap into place with plastic mallet 5...

Page 9: ...ating pins B 5 Install six screws 38 6 Install gallon counter sensor 39 with two screws 108 7 Install bearing housing Refer to Bearing Housing and Connecting Rod Installation page 8 8 Install screws 18 in drive housing Torque evenly to note 3 value in Fig 1 9 Install pump Refer to Displacement Pump Installation page14 FIG 3 WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 CAUTION Gallo...

Page 10: ...oles E in rotor Alternately tighten screws until rotor comes off FIG 6 7 FIG 7 Remove retaining ring 29e 8 Turn pinion housing over and tap pinion shaft 29d out with plastic mallet FIG 7 9 FIG 9 Remove belt guide bracket 146 belt guard 148 and Vee belt 147 10 Hold pulley 62 and remove four screws 23 and washers 24 from hub 26 Remove armature 25 and spacer 19f 11 Engine Detail page 18 Remove screw ...

Page 11: ...62 and install four screws 23 and washers 24 in hub 26 Torque to 125 in lb 14 Nm 9 Install belt guard 146 belt guide bracket 148 and Vee belt 147 10 FIG 7 Tap pinion shaft 19c in with plastic mallet 11 Install retaining ring 19b 12 FIG 6 Place pinion housing on bench with rotor side up 13 Apply locktite to screws Install four screws 28 and lockwashers 24 Alternately torque screws to 125 in lb unti...

Page 12: ...retaining tabs on each side of ON OFF switch 169f and remove switch from cover Installation 1 Install new ON OFF switch 169f so tabs of switch snap 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 FIG 10 WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 54 54 F A B J TI A R 4 54 5 4 2 C D M E G H D C A F...

Page 13: ...Remove pressure control transducer 66 and o ring 67 from filter housing 72 Installation 1 FIG 10 Install o ring 67 and pressure control transducer 66 in filter housing 72 Torque to 35 45 ft lb 2 Install transducer connector and rubber grommet in control housing 3 Connect transducer 66 lead to control board 169b 4 Swing up cover 169a and secure with two screws 71 Pressure Adjust Potentiometer Remov...

Page 14: ...sducer if fluid path is not clogged and proper hose is used Sprayer stops Engine is running Pressure transducer faulty bad connection or broken wire 1 Check transducer connection 2 Disconnect and reconnect transducer plug to ensure good connection with control board socket 3 Open prime valve Replace sprayer transducer with known good transducer and run sprayer Replace transducer if sprayer runs or...

Page 15: ...prayer FIG 11 5 Disconnect material hose from pump FIG 12 6 Raise latch lock Push latch open FIG 13 7 FIG 14 Ratchet open pump door a Ratchet pump door forward FIG 14 b Twist latch u bolt out of pump door recess c Place u bolt on pump door outer edge d If pump door is stuck do steps e f and 8 otherwise go to step 9 FIG 15 WARNING Read Skin Injection Hazard page 3 Burn Hazard page 4 ...

Page 16: ...IG 19 Installation 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 FIG 20 3 FIG 21 Slide pump into connecting rod Push pump pin until it is fully retained Note Pin will snap into position FIG 21 4 FIG 22 Close pump door and rotate latch into posit...

Page 17: ...material hose Connect material hose and hand tighten to 70 in lb FIG 22 6 FIG 23 Tighten latch and rotate latch lock into locked position FIG 23 7 FIG 24 Attach drain hose to sprayer FIG 24 8 FIG 25 Fill pump with Graco TSL until fluid flows onto top of seal FIG 25 ...

Page 18: ... Standard Sprayer Parts Drawing 4 4 3EE EXPLODED VIEW ON PAGE 3EE NGINE ETAIL ON PAGE 3EE PARTS ON PAGE 3EE PARTS ON PAGE 2EF 2EF ABEL 2EF 2EF 2EF 2EF TI B B 2EF A 2EF 3EE PARTS ON PAGE 2EF TexSprayer 5900HD Convertible Only ...

Page 19: ...USHING strain relief 1 67 111457 O RING 1 68 243993 HOSE coupled 1 69 241920 DEFLECTOR threaded 1 72 15E284 HOUSING filter 1 82 189920 STRAINER 1 11 1 2 npsm 1 86 15E802 FITTING pump quick disconnect 1 87 287543 HOSE coupled 1 88 15F110 PIN pump 1 89 248215 TUBE intake 1 90 118494 O RING 1 91 287162 VALVE auto clean 1 93 287253 TOOL BOX 1 94 118852 SCREW machine hex washer hd 3 98 113161 SCREW fla...

Page 20: ...17 WASHER 1 115 194126 LABEL warning 1 124 245272 BASE mounting 1 125 116139 GRIP handle 2 126 198689 BRACKET belt guard motor 1 127 112406 SCREW 3 128 198997 BRACKET tension 1 129 198693 HANDLE slide engine 2 130 198695 BRACKET torsion bar 1 131 110963 SCREW cap hex hd flange 2 135 114816 NUT hex 1 136 116149 SPACER 1 137 194414 BRACKET J box 1 138 114813 SCREW mach hex washer hd 1 139 114678 BUS...

Page 21: ... 287476 PINION HOUSING COIL 1 29a 241114 PINION SHAFT 1 29b 112770 RETAINING RING large 1 29c 105489 PIN 2 29d 114683 O RING 1 Ref Part Description Qty 33 HOUSING drive 1 33a 194173 WASHER 1 33b 116192 WASHER 1 Premium models and TexSpray 5900HD convertible 2EF 2EF 2EF 2EF 2EF C A B 2EF 2EF 2EF 2EF 2EF D 2EF B A 2EF Pinion Housing 29 includes Clutch Field ...

Page 22: ... Parts Drawing TI B 3TANDARD ODELS F A A H J B C C M G D E D K R N P A 0REMIUM ODELS F A A H J B C G D E D K R ONTROL 3TANDARD OMPLETE 0ART UMBER ONTROL 0REMIUM 4EX3PRAY ONVERTIBLE OMPLETE 0ART UMBER 0REMIUM MODELS 4EX3PRAY ONVERTIBLE 0ART UMBER ...

Page 23: ... 248314 PLUG includes 123 1 123 15D541 O RING 1 154 116756 FITTING elbow 45 degrees 1 169a 249583 BOX control premium 1 169a 249584 BOX control standard 1 169b 287516 CONTROL board 1 169c 117317 SCREW plastite pan hd 7 169d 240925 POTENTIOMETER 1 169e 198650 SPACER shaft 1 169f 116752 SWITCH rocker 1 169g 119541 SWITCH toggle 1 169h 116167 KNOB potentiometer 1 169j 195428 BOOT toggle 1 169k 15E857...

Page 24: ...ive input 1 19e 15E887 HOUSING clutch 1 19j 115078 O RING 1 19k 115079 O RING 1 21 15E894 STOP armature 1 23 108803 SCREW hex socket head 4 24 105510 WASHER lock spring hi collar 8 25 ARMATURE clutch 5 in 1 26 193510 HUB armature 1 27 ROTOR clutch 5 in 1 28 101682 SCREW cap sch 4 Included in Clutch Repair Kit 241113 Ref Part Description Qty 19c 19b 23 24 19e 25 26 24 28 27 21 19j 19k ti5754a ...

Page 25: ...I SPRAY GUN 1 Includes RAC X 517 size SwitchTip and HandTite Guard See 311861 for parts 241705 TEXTURE SPRAY GUN see 308491 for parts TexSpray 5900HD Convertible 1 205 241735 HOSE whip 1 4 in x 3 ft TexSpray 5900HD Convertible 1 ti6429a 204 202 Ref Part Description Qty 40 289274 HOUSING bearing complete 1 45 118444 SCREW mach hex wash hd 1 50 15E625 PIN housing bearing 1 51 15G890 LATCH housing be...

Page 26: ...ction 401 287537 HOSE suction GMAX II 3900 5900 1 402 287536 HOSE drain GMAX II 3900 5900 1 403 189920 STRAINER 1 11 1 2 npsm 1 404 241920 DEFLECTOR threaded 1 405 15D000 CLIP drain line 1 406 15C980 NUT jam 1 407 15C981 WASHER suction swivel 1 408 118505 RING retaining external 1 409 117559 O RING 2 410 115099 WASHER garden hose 1 TI A ...

Page 27: ...in tip 4 gun with 0 019 in tip Electric Motor 1 gun with 0 031 in tip 2 gun with 0 017 in tip Inlet paint strainer 16 mesh 1190 micron stainless steel screen reusable Outlet paint filter 60 mesh 250 micron stainless steel screen reusable Pump inlet size 1 5 16 12 UN 2A Fluid outlet size npsm from fluid filter Wetted parts zinc plated carbon steel PTFE Nylon polyurethane UHMW polyethylene fluoroela...

Page 28: ...s for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD ...