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Graco Inc. 245096 manual

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Table of contents for the manual

  • Page 1

    Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2005, Graco Inc. is r egistered to I. S. EN ISO 9001 311046J Repair GMAX ™ II 5900 Con ver tible T e xSpra y ™ 5900 HD Airless Spra y er s - For P ortable Airless Spra ying of Ar ch itectural Coatings and P aints - 3300 psi (22.8 MP a, 228 bar) Maximu m Working Pres sure Important Sa[...]

  • Page 2

    Manual Conventions 2 311046J Contents W ARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bea[...]

  • Page 3

    Warning 311046J 3 Wa r n i n g The f ollowing are ge neral warnings related to the se tup , us e, maint enance and repair of this equipment. Additional, more specific , warnings may be f ound throughout the te xt of this manual, where app licable . WA R N I N G FIRE AND EXPLOSION HAZARD Flammab le fumes, such as solv ent and paint fumes, in work a [...]

  • Page 4

    Warning 4 311046J EQUIPMENT MISUSE HAZARD Misuse can ca use death or serious injur y . • Do not exceed the maximum w ork in g pressure or temperature rating of the low est rated system component. See T echnical Data in all equipment man uals. • Use fluids and solv ents that are compatible with equipment wetted parts. See T echnical Dat a in all[...]

  • Page 5

    Maintenance 311046J 5 Maintenance Pressure Relief Pr ocedure 1. Lock gun trigger saf ety . 2. T urn engine ON/OFF s witch to OFF . 3. Mov e pump s witch to OFF and tur n pressure control knob fully counterclockwise. 4. Unlock trigger safety . Hold metal par t of gun fir mly to side of grounded metal pail, and tr igger gun to reliev e pressure. 5. L[...]

  • Page 6

    Troubleshooti ng 6 311046J T r oubleshooting Problem Cause Solution E=XX is displa yed F aul t condition exists Deter mine fault correction from tab le, page 14 Engine will not star t Engine switch is OFF T urn engine s witch ON Engine is out of gasoline Refill gas tank. Honda Engines Owner's Man- ual. Engine oil lev el is low T ry to star t e[...]

  • Page 7

    Troubleshooting 311046J 7 Pr oblem Cause Solution Pump output is low Strainer (82) is clogged Clean strainer . Piston ball (206) is not seating Ser vice piston ball. Manual 310894. Piston packings are worn or damaged Replace packings. Manual 310894. O-ring (227) in pump is wor n or damaged Replace o-r ing. Manual 310894. Intake v a lv e ball is not[...]

  • Page 8

    Bearing Housing and Co nnecting Rod 8 311046J Bearing Housing and Connecting Rod Remo val 1. Reliev e pressure; page 5. 2. F IG . 1. Remo ve f our screw s (45) and front cover (44) 3. Remov e pump. Ref e r to Displaceme nt Pump, Rem ov al , page 14. 4. Remov e four screws (41) and washers (42) from bearing housing (40). 5. Pull connecting rod (43 )[...]

  • Page 9

    Drive Housing 311046J 9 Drive Housing Remo val 1. Reliev e pressure; page 5. 2. Remov e beari ng housing. Refer to Bearing Housin g and Connecting Rod, Remov al , page 8. 3. Premium spra yers: Remov e two screws (108) and gallon counter sensor (39). 4. Remov e six screws ( 38). 5. Lightly tap around dr ive housing (33) to loo sen drive housing. Pul[...]

  • Page 10

    Pinion Housing/Rotor/Shaft/Clutch/Pu lley 10 311046J Pinion Housing/Rotor/Shaft/Clutc h/Pulley Re m ova l 1. If pinion housing (29) is not remov ed from clutch housin g (19), do 2. through 5. Otherwise, do 2 and then star t at 6. 2. Do Pressure Relief Procedure , page 5. 3. F IG . 4. Disconnect clutch cable connectors. a. Remov e two screws (71) an[...]

  • Page 11

    Pinion Housing/Rotor/Shaft/Clutch/Pulley 311046J 11 Installation 1. F IG . 10. Install drive shaft assemb ly (19c). Install retaining ring (1 9b) 2. F IG . 8. La y two stac ks of two dimes on smooth bench surf ace. 3. Lay armature (25) on two stacks of dimes. 4. Press center of hub (26) down to bench surface. F IG . 8 5. F IG . 9. Place spacer (19f[...]

  • Page 12

    Pressure Control 12 311046J Pressure Contr ol On/Off Switch Re m ova l 1. F IG . 10. Remov e two screws (71) and swing down cov er (169a). 2. Disconnect ON/OFF s witch (1 69f) connector from control board. 3. Press in on two retaining tabs on each side of ON/OFF s witch (169f) and remov e s witch from cov er . Installation 1. Install ne w ON/OFF s [...]

  • Page 13

    Pressure Control 311046J 13 Contr ol Board Re m ova l 1. F IG . 10. Remov e two screws (71) and swing down cov er (169a) 2. Remov e strain relief bushings (123a and 123b). 3. Disconnect at control board (169b): • Lead from potentiometer (169d) • Lead from transducer (66) • Lead from W atchDog switch (169g) • Lead from ON/OFF switch (169f) ?[...]

  • Page 14

    Pressure Control 14 311046J Digital Displa y Messages * Error codes also appear on control board as a blinking red LED . LED is an alternate to digital messages . 1. Remov e two scre ws (71) and swing do wn cove r (130). 2. Start engine. Blink c ount is the same as error code(E=0X). After a f ault, f ollow t hese steps to restar t spra yer: 1. Corr[...]

  • Page 15

    Displacement Pump 311046J 15 Displacement Pump R emo v al 1. Flush pump. 2. F IG . 19 . Stop pump with piston rod in its lowest position. 3. Do Pressure Relief, page 5. 4. Separate drain hose from spra yer. F IG . 11 5. Disconnect material hose from pump. F IG . 12 6. Raise latch lock. Push latch op en. F IG . 13 7. F IG . 14. Ratchet open pump doo[...]

  • Page 16

    Displacement Pump 16 311046J e. T wist latch u-bolt back from pump door ou ter edge f . Place u-bolt on pump door protrusion F IG . 16 8. Ratchet pump door f orward. F IG . 17 9. Open pump door . F IG . 18 10. F IG . 19. Pull out pump pin and place in pin holder F IG . 19 Installation 1. F IG . 20. Adjust piston rod with pin holder to pull out pist[...]

  • Page 17

    Displacement Pump 311046J 17 5. F IG . 22. Rotate pump to align with materia l hose. Connect material h ose and hand tigh ten to 70 in-lb F IG . 22 6. F IG . 23 . Tighten latch and rotate latch loc k into lock ed position. F IG . 23 7. F IG . 24. Attach drain hose to spra yer . F IG . 24 8. F IG . 25. Fill pump with Graco TSL until fl uid flows ont[...]

  • Page 18

    Parts 18 311046J Pa r t s Standard Spra yer - P ar ts Drawing $%4 !),! $%4 !),!   3EEEXPLODEDVIE WONPAGE 3EE%NGINE$ETAILONPAGE   3EEPAR TSONPAGE              3EEPAR TSONPAGE ?[...]

  • Page 19

    Parts 311046J 19 Standard Spra yer - P ar ts List Ref Part Description Qty 1 287423 FRAME, car t 1 2 156306 W ASHER, flat 2 3 119509 WHEEL, pneumatic 2 4 15E891 CLIP , retaining 2 5 191084 SLEEVE, car t 2 6 183350 W ASHER 2 7 108068 PIN, spring straight 2 8 108795 SCREW , mach, pnh 4 9 112827 BUTT ON, snap 2 10 245245 HANDLE, car t 1 11 237686 WIRE[...]

  • Page 20

    Parts 20 311046J Engine Detail Engine Detail - P ar ts List 12 9 1 4 3 1 7 1 7 12 8 131 12 4 12 6 12 7 1 8 13 0 1 40 1 4 1 13 9 13 8 13 5 13 7 11 5 1 5 1 44 12 5 2 0 6 1 1 4 2 Ref 1 6 1 7 13 6 ti5750 a 13 5 (Ref) Ref Part Description Qty 15 114530 ENGINE, gas , 5.5 Honda 1 16 114653 SCREW , cap, fl ange hd 4 17 110996 NUT , flng hd, he x 6 18 18340[...]

  • Page 21

    Parts 311046J 21 Pinion and Drive Housi ng - P ar ts Drawing and List Ref No. 29: Pinio n Housing 287465 Ref No. 33: Driv e Housing 287700 Ref P art Description Qty 29 287476 PIN ION HOUSING & COIL 1 29a 241114 PINION SHAFT 1 29b 112770 RET AINING RING, large 1 29c 105489 PIN 2 29d 114683 O -RING 1 Ref P art Description Q ty 33 HOUSING, drive 1[...]

  • Page 22

    Parts 22 311046J Pressure Control and Filt er - P ar ts Drawing                     TIB 3TANDARD -ODELS  F  A A  H J ?[...]

  • Page 23

    Parts 311046J 23 Pressure Contr ol and Fi lter - P ar ts List ★ Premium & T e xSpra y 5900HD Conv er tible models only * Included in Filter Base Repair Kit 287510 REF P ART DESCRIPTION QTY 53* 15C765 CAP , filter 1 54* 117285 O-RING 1 55* 15C766 TUBE, diffusion 1 56* 243984 FIL TER, fluid 1 57* 15C780 HANDLE 1 58* 15C972 PIN, gro ov ed 1 59* [...]

  • Page 24

    Parts 24 311046J Clutch Housing - P ar t s Drawing and List Ref Part Description Qty 19 287519 HOUSING, clu tch 1 Includes 19b , 19c, 19e , 19j & 19k 19b 114962 RING, retaining, inter nal 1 19c 287422 SHAFT , dr ive , input 1 19e 15E88 7 HOUSING, clutch 1 19j 115078 O-RING 1 19k 115079 O-RI NG 1 21 15E894 ST OP , ar ma ture 1 23 108803* SCREW ,[...]

  • Page 25

    Parts 311046J 25 Premium Spray ers - P ar ts Drawing and List Ref 40: Bearing Housing Ref. Part Description Qty . 201 Hi-Bo y Spra yers 1 See par ts, page 18 Lo-Bo y Spra y ers 1 See par ts, page 18 Includes Lo-Bo y Suction Set Kit, See par ts, page 26 202 2407 94 HOSE, grounded, n ylon; 1/4 in. ID; 1 cpld 1/4 npsm(f be); 50 f oot (15 m); spring gu[...]

  • Page 26

    Parts 26 311046J Lo-Boy Suction Set - P ar ts Drawing and List Models 248695, 248697, 248890 Ref Part Description Qty 287631 KIT , re pair , tube suction 401 287537 HOSE, suction, GMAX II 3900/590 0 1 402 2875 36 HOSE, drain, GMAX II 3900/590 0 1 403 1899 20 STRAINER, 1-11 1/2 npsm 1 404 2419 20 DEFLECTO R, threaded 1 405 15D000 CLIP , dra in line [...]

  • Page 27

    Technical Data 311046J 27 Te c h n i c a l D a t a Dimensions Po w e r Honda GX160 Engine (ANSI P ower Rating @ 3600 rp m ) 5.5 Horsepower (4.1 kW) Electric Motor 2.0 HP (1.5 kW) Maximum working pr essure 3300 psi (227 bar , 22.7 MP a) Noise Le vel Sound pow er 100 dBa per ISO 3744 Sound pressure 86 dBa measured at 3. 1 feet (1 m) Cycles/gallon (li[...]

  • Page 28

    Graco Standard Warranty 28 311046J Graco Standar d W arranty Graco warrants all equipment ref erenced in th is document which is manuf actured by Graco and bearing its name to be free from de fe ct s i n material and workmanship on the date of sale to the origin al purch aser for use. With the e xception of any special, e xtended, or limited warran[...]