Graco GMAX II 5900 Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
311046H
Repair
GMAX™II 5900 Convertible
TexSpray™5900 HD
Airless Sprayers
- For Portable Airless Spraying of Architectural Coatings and Paints -
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Model Series Description
248691 A Standard
248692 A Premium, with RAC®X tip, gun and hose
248693 A Standard, with electric motor kit
248694 A 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 RAC X tip, gun and hose
and Lo-Boy suction set kit
255630 A TexSpray 5900HD convertible with texture
gun and hose
255631 A Same as 255630 with electric motor kit
255954 A Same as 255630 except with electric
motor kit that is ETL approved to CSA and
UL standards
245096 A KIT, electric motor, CSA
245095 A KIT, electric motor, Non-CSA
Related Manuals
310892 311861
308491 309469
310894 309640
ti11417a

Manual Conventions
2311046H
Contents
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bearing Housing & Connecting Rod . . . . . . . . . . . 8
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pinion Housing/Rotor/Shaft/Clutch/Pulley. . . . . . 10
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Standard Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pinion and Drive Housing . . . . . . . . . . . . . . . . . . . 21
Pressure Control and Filter . . . . . . . . . . . . . . . . . . 22
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Additional helpful information.

Warning
311046H 3
Warning
The following are general warnings related to the setup, use, maintenance and repair of this equipment. Additional,
more specific, warnings may be found throughout the text of this manual, where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.Do not fill fuel tank while engine is running or hot; shut off
engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable
and can ignite or explode if spilled on hot surface.
• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m)
away from explosive vapors.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering 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 anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

Warning
4311046H
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
SUCTION HAZARD
Never place 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 or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
RECOIL HAZARD
Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.
WARNING

Maintenance
311046H 5
Maintenance
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pump switch to OFF and turn pressure control knob
fully counterclockwise.
4. Unlock trigger safety. Hold metal part of gun firmly to side
of grounded metal pail, and trigger gun to relieve
pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until ready
to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loosen
tip guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose.
DAILY: Check engine oil level and fill as necessary.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper operation.
DAILY: Check and fill the gas tank.
DAILY: 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
replace, if necessary.
Replacement elements can be purchased from your
local HONDA dealer.
WEEKLY: Check level of TSL in displacement pump
packing nut. Fill nut, if necessary. Keep TSL in nut to
help prevent fluid buildup on piston rod and premature
wear of packings and pump corrosion.
AFTER EACH 100 HOURS OF OPERATION:
Change engine oil. Reference Honda Engines Owner's
Manual for correct oil viscosity.
SPARK PLUG: Use only BPR6ES (NGK) or W20EPR-U
(NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in.
(0.7 to 0.8 mm). Use spark plug wrench when installing
and removing plug.
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4
CAUTION
For detailed engine maintenance and specifications,
refer to separate Honda Engines Owner's Manual,
supplied.

Troubleshooting
6311046H
Troubleshooting
Problem Cause Solution
E=XX is displayed Fault condition exists Determine fault correction from table, page 14
Engine will not start Engine switch is OFF Turn engine switch ON
Engine is out of gasoline Refill gas tank. Honda Engines Owner's Man-
ual.
Engine oil level is low Try to start engine. Replenish oil, if necessary.
Honda Engines Owner's Manual.
Spark plug is disconnected of damaged Connect spark plug cable or replace spark plug
Cold engine Use choke
Fuel shutoff lever is OFF Move lever to ON position
Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times.
Clean or replace spark plug. Start engine.
Keep sprayer upright to avoid oil seepage
False tripping of WatchDog system.
EMPTY is displayed. Pump does not
run.
Operating conditions out of WatchDog
parameters
Pump output is low, page 7.
Turn pressure down. Contact Graco Technical
Assistance to adjust WatchDog parameters.
Operate without WatchDog active; Manual
310892.
Engine operates, 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
Repair pump. Manual 310894.
Connecting rod is worn or damaged Replace connecting rod. Page 8.
Drive housing is worn or damaged Replace drive housing. Page 9.
Electrical power is not energizing clutch
field
Check wiring connections. Page 12.
Reference pressure control repair. Page
14 .
Reference wiring diagram. Page 23.
With pump switch ON and pressure turned to MAXI-
MUM, use a test light to check for power between clutch
test points on control board.
Remove clutch wires from control board and
measure resistance across clutch coil. At 70° F,
the resistance must be between 1.2 +0.2Ω; if
not, replace pinion housing.
Have pressure control checked by authorized Graco
dealer
Clutch is worn, damaged, or incorrectly
positioned
Adjust or replace clutch. Page 10.
pinion housing is worn or damaged Repair or replace pinion housing. Page10.

Troubleshooting
311046H 7
Problem Cause Solution
Pump output is low Strainer (82) is clogged Clean strainer.
Piston ball (206) is not seating Service piston ball. Manual 310894.
Piston packings are worn or damaged Replace packings. Manual 310894.
O-ring (227) in pump is worn or damaged Replace o-ring. Manual 310894.
Intake valve ball is not seating properly Clean intake valve. Manual 310894.
Intake valve ball is packed with material Clean intake valve. Manual 310894.
Engine speed is too low
Increase throttle setting. Manual 310892.
V-belt slipping Tighten V-belt with tension bar (132). Adjust
bracket until it takes 15 lb of force to lock tension
bar down
Clutch is worn or damaged Adjust or replace clutch. Page 10.
Pressure setting is too low Increase pressure. Manual 310892.
Fluid filter (56), tip filter or tip is clogged or
dirty
Clean filter. Manual 310892 or 309639.
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce
overall length of hose. Use of more than
100 ft of 1/4 in. hose significantly reduces
performance of sprayer. Use 3/8 in. hose
for optimum performance (50 ft minimum).
Excessive paint leakage into throat
packing nut
Throat packing nut is loose Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leak-
age.
Throat packings are worn or damaged Replace 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 prime Air in pump or hose
Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well.
Reassemble valve.
Pump packings are worn
Replace pump packings. Manual 310894.
Paint is too thick Thin the paint according to the supplier's
recommendations
Engine speed is too high Decrease throttle setting before priming
pump. Manual 310892.
Clutch squeaks each time clutch
engages
Clutch surfaces are not matched to each other
when new and may cause noise
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
High engine speed at no load Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load
Worn engine governor Replace or service engine governor
Gallon counter not working Bad sensor, broken or disconnected wire.
Displaced or missing magnet.
Check connections. Replace sensor or
wire. Reposition or replace magnet.
No display, sprayer operates Display damaged or has bad connection Check connections. Replace display.

Bearing Housing and Connecting Rod
8311046H
Bearing Housing and Connecting Rod
Removal
1. Relieve pressure; page 5.
2. FIG. 1. Remove four screws (45) and front cover (44)
3. Remove pump. Refer to Displacement Pump, Removal,
page 14.
4. Remove four screws (41) and washers (42) from bearing
housing (40).
5. Pull connecting rod (43) and lightly tap lower rear of
bearing housing with plastic mallet to loosen from drive
housing (33). Pull bearing housing and connecting rod
assembly off drive housing.
6. Inspect crank (B) and connecting rod (43) for excessive
wear and replace parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (C) in bearing
housing (40) with high-quality motor oil. Liberally pack top
roller bearing (E), lower bearing (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. Install screws (41) and washers (42) in bearing housing.
Torque evenly to note 3 value in Fig. 1.
6. Install pump. Refer to Displacement Pump, Installation,
page 14.
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4
CAUTION
DO NOT use bearing housing screws (41) to align or
seat bearing housing with drive housing. Align these
parts with locating pins, to avoid premature bearing
wear.
FIG. 1
3
2
1Oil
Pack with bearing grease 114819
Torque to 25 ft-lb (34 N.m)
F
B
38
E
D
43
1
2
3
C
2
44
45
41
42
40
A
88
33
87
68
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Drive Housing
311046H 9
Drive Housing
Removal
1. Relieve pressure; page 5.
2. Remove bearing housing. Refer to Bearing Housing and
Connecting Rod, Removal, page 8.
3. Premium sprayers: Remove two screws (108) and gallon
counter sensor (39).
4. Remove six screws (38).
5. Lightly tap around drive housing (33) to loosen drive
housing. Pull drive housing straight off pinion housing. Be
prepared to support combination gear (32) which may
also come out.
Installation
1. FIG. 2 . Apply all grease supplied with replacement gear
cluster to gear cluster (32) and to areas called out by note 3.
2. FIG. 3. Ensure thrust washers are on combination gear
(32) as shown.
3. Clean mating surfaces of pinion and drive housings.
4. Align gears and push new drive housing straight onto
pinion housing (29) and locating 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
Gallon counter sensor is connected to control board in pres-
sure control. Pulling on the sensor wires could cause damage.
CAUTION
Thrust washers may stick to grease inside of drive housing.
Do not lose or misplace.
CAUTION
DO NOT use drive housing screws (18) to align or seat
bearing housing with drive housing. Align these parts
with locating pins, to avoid premature bearing wear.
FIG. 2
B
29
3
B
33
38
30
ti5740a
239
22
32
31
33b
33a
3
30
3
2
1
Gallon counter sensor
Pack with grease 114819
Torque to 25 ft-lb (34 N.m)
1
32
1
2
30
31
30,30a1
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1
2
Steel
Copper

Pinion Housing/Rotor/Shaft/Clutch/Pulley
10 311046H
PinionHousing/Rotor/Shaft/Clutch/Pulley
Removal
1. If pinion housing (29) is not removed from clutch housing
(19), do 2. through 5. Otherwise, do 2 and then start at 6.
2. Do Pressure Relief Procedure, page 5.
3. FIG. 4. Disconnect clutch cable connectors.
a. Remove two screws (71) and swing down cover (130a).
b. Remove strain relief (171).
c. Disconnect clutch cable connectors (X).
FIG. 4
4. FIG. 5 . Remove four screws (36), lock washers (37) and
pinion housing (29).
FIG. 5
5. FIG. 6. Place pinion housing (29) on bench with rotor side
up.
6. Remove four screws (28) and lock washers (24). Install
two screws in threaded holes (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 (20) and washer
(61) from engine drive shaft. Remove pulley (62) and
motor shaft sleeve (144). Remove pulley and key (18).
12. Fig. 9. Remove three screws (35) from beneath cart
frame (1).
13. Lift off clutch housing (19e).
14. Remove retaining ring (19b). Pull drive shaft assembly
(19c) out.
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4
X
Bottom View
ti6293a
CLUTCH (+)
CLUTCH (-)
29
36
37
36
37
ti5742a
E
28
24
ti5743a
ti5987b
E
29e
29d
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Pinion Housing/Rotor/Shaft/Clutch/Pulley
311046H 11
Installation
1. FIG. 10. Install drive shaft assembly (19c). Install retaining
ring (19b)
2. FIG. 8. Lay two stacks of two dimes on smooth bench
surface.
3. Lay armature (25) on two stacks of dimes.
4. Press center of hub (26) down to bench surface.
FIG. 8
5. FIG. 9. Place spacer (19f) and armature (26, 25) on drive
shaft assembly (19c).
6. Install three screws (35) through cart frame (1) and into
clutch housing (19).
7. Apply Loctite®to screw (20). Install screw, washer (61),
key (18) and pulley (62) in end of drive shaft assembly
(19c). End of driveshaft (19c) must be 0.090 in. below
flush with end of bushing.
8. Hold pulley (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
until rotor is secure.
14. Push pinion housing (29) assembly onto clutch housing
(19e). Tap lightly on front of bearing housing (40) with a
plastic mallet to push drive housing and pinion housing
assembly onto clutch housing.
15. Install pinion housing with five screws (36) and lockwashers
(37).
16.
FIG. 4 . Connect clutch cable connectors (X) to board.
17. Page 9. Do Drive Housing, Installation.
FIG. 9
0.12+01 in (3.0+.25mm)
2526
dimes
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Pressure Control
12 311046H
Pressure Control
On/Off Switch
Removal
1. FIG. 10. Remove two screws (71) and swing down
cover (169a).
2. Disconnect ON/OFF switch (169f) connector from control
board.
3. Press in on two 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
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Pressure Control
311046H 13
Control Board
Removal
1. FIG. 10. Remove two screws (71) and swing down
cover (169a)
2. Remove strain relief bushings (123a and 123b).
3. Disconnect at control board (169b):
• Lead from potentiometer (169d)
• Lead from transducer (66)
• Lead from WatchDog switch (169g)
• Lead from ON/OFF switch (169f)
• Lead from gallon counter sensor (pump stroke)
• Display connector
• Engine, ground and clutch wires
4. Remove four screws (169c) and control board (169b).
Installation
1. FIG. 10 . Install control board (169b) with four screws (169c).
2. Connect engine wires to control board (169b).
3. Install control box (169a) with four screws (71).
4. Connect at control board (169b):
• Ground and clutch wires
• Display connector
• Lead from gallon counter sensor (pump stroke)
• Lead from ON/OFF switch (169f)
• Lead from WatchDog switch (169g)
• Lead from transducer (66)
• Lead from potentiometer (169d)
5. Install new strain relief bushings (123a and 123b).
6. Swing up cover (169a) and secure with two screws (71).
Pressure Control Transducer
Removal
1. FIG. 10. Remove two screws (71) and swing down
cover (169a)
2. Disconnect transducer (66) lead from control board
(169b).
3. Pull transducer connector through rubber grommet (113).
4. 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
Removal
1. Fig. 13.Remove two screws (71) and swing down
cover (169a)
2. Disconnect potentiometer (169d) lead from control board
(169b).
3. Loosen set screws on potentiometer knob (169h) and remove
knob, shaft nut, lock washer and potentiometer (169d).
4. Remove shaft spacer (169e) from potentiometer.
Installation
1. Install shaft spacer (169e) on potentiometer (169d).
2. FIG. 10. Install potentiometer, shaft nut, lock washer and
potentiometer knob (169h).
a.Turn potentiometer shaft clockwise to internal stop.
Assemble potentiometer knob (169h) to strike pin on
cover (169a).
b.After adjustment of step a., tighten both set screws in
knob 1/4 to 3/8 turn after contact with shaft.
3. Connect potentiometer lead to control board (169b).
4. Swing up cover (169a) and secure with two screws (71).
Digital Display Messages
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4
WARNING
Read Skin Injection Hazard, page 3; Burn Hazard, page 4

Pressure Control
14 311046H
Digital Display Messages
* Error codes also appear on control board as a blinking
red LED. LED is an alternate to digital messages.
1. Remove two screws (71) and swing down cover (130).
2. Start engine. Blink count is the same as error code(E=0X).
After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
WARNING
Relieve pressure before repair, page 5.
DISPLAY* SPRAYER OPERATION INDICATION ACTION
No Display 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, 1.4 MPa)
Increase pressure as needed
Sprayer is pressurized. Power is applied.
(Pressure varies with tip size and
pressure control setting.)
Normal operation Spray
Sprayer stops. Engine is running. Exceeded pressure limit 1. Check fluid path for clogs, such as
clogged filter.
2. Open prime valve and gun if running
AutoClean.
3. Use Graco paint hose, 1/4 in. x 50 ft
minimum. Smaller hose or metal braid
hose may result in pressure spikes.
4. Replace transducer 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 control
board if sprayer does not run.
Sprayer stops. Engine is running. High clutch current 1. Check wiring connections.
2.
Measure: 1.2 +0.2 Ω (GMAX II 3900);
1.7 +0.2Ω(GMAX II 5900/ 7900)
across clutch field at 70°F.
3. Replace clutch field assembly.
Sprayer stops. Engine is running. Loss of paint to pump or severe
pressure loss
1. Check for empty paint condition, clogged
inlet strainer, failed pump or severe leak.
2. Reduce pressure and turn pump
switch OFF and ON to restart pump.
3.
Watch dog function can be deactivated
by turning WatchDog switch OFF.
Sprayer stops. Engine is running. Pressure greater than
2000 psi (138 bar, 14 MPa) while
in Flush Timer Mode
1. Open prime valve and gun.
2. Verify no flow obstructions or clogged
filter.
ti6314a
psi
bar
MPa
ti6315a
ti6316a
ti6317a
ti6318a
(with constant
green LED)
ti6320a
• Digital messages are not available on all sprayers
• Blinking LED total count equals digital error code
i.e., two blinks is the same as E=02

Displacement Pump
311046H 15
Displacement Pump
Removal
1. Flush pump.
2. FIG. 19
. Stop pump with piston rod in its lowest position.
3. Do Pressure Relief, page 5.
4. Separate drain hose from sprayer.
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

Displacement Pump
16 311046H
e. Twist latch u-bolt back from pump door outer edge
f. Place u-bolt on pump door protrusion
FIG. 16
8. Ratchet pump door forward.
FIG. 17
9. Open pump door.
FIG. 18
10. FIG. 19. Pull out pump pin and place in pin holder
FIG. 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 position.
Do not tighten latch.
ti6325a
ti6378a

Displacement Pump
311046H 17
5. FIG. 22. Rotate pump to align with 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

Parts
18 311046H
Parts
Standard Sprayer - Parts Drawing
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TexSprayer 5900HD
Convertible Only

Parts
311046H 19
Standard Sprayer - Parts List
Ref Part Description Qty
1 287423 FRAME, cart 1
2 156306 WASHER, flat 2
3 119509 WHEEL, pneumatic 2
4 15E891 CLIP, retaining 2
5 191084 SLEEVE, cart 2
6 183350 WASHER 2
7 108068 PIN, spring straight 2
8 108795 SCREW, mach, pnh 4
9 112827 BUTTON, snap 2
10 245245 HANDLE, cart 1
11 237686 WIRE, ground assembly w/ clamp 1
12 112798 SCREW, thread forming, hex hd 1
14 276974 CAP, leg 2
18 183401 KEY, parallel 1
19 287519 HOUSING, clutch 1
20 121727 SCREW, cap, hex hd 1
22 114528 SCREW, mach, phillips, pnhd 2
23* 108803 SCREW, hex, socket head
(see page 24)
4
24* 105510 WASHER, lock, spring (hi-collar) 8
26* 193510 HUB, armature (see page 24) 1
27* ROTOR, clutch, 5 in. 1
28* 101682 SCREW, cap, sch 4
29 287465 HOUSING, pinion, 5900 1
30 114672 WASHER, thrust 2
31 114699 WASHER, thrust 1
32 287460 GEAR, combination 1
33 287700 HOUSING, drive, convert 1
34 116618 MAGNET 1
35 112395 SCREW, cap, flnghd 3
36 102962 SCREW, cap sch 4
37 104008 WASHER, lock, spring 4
38 15C753 SCREW, mach, torx, hex wash hd 6
39 119562 SWITCH, reed w/connector 1
40 289274 HOUSING, bearing 1
41 114666 SCREW, cap, socket hd 4
42 106115 WASHER, lock spring (hi-collar) 4
43 287472 ROD, connecting (5900) 1
44 287511 COVER, front, 5900; includes 45 1
45 118444 SCREW, machine hex washer head 4
47 287513 PUMP, displacement (5900) 1
includes 86, 89, 90; Manual 310894
287579 PUMP, displacement (TexSpray
5900HD convertible) includes 86
1
61 112717 WASHER 1
62 198688 PULLEY, engine 1
63 114425 BUSHING, 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† 15C857 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, flange, hex hd 3
99 15E918 BRACKET, holder, manual 1
100 15E736 BRACKET, holder, manual 1
101 119510 HOLDER, manual 1
102† 15E902 PLATE 1
103† 100270 SCREW, cap, hex hd 2
104† 102040 NUT, lock, hex 3
110 LABEL, identification
15F755 Premium & TexSpray 5900HD
Convertible
1
15E854 Standard 1
114 15E979 LABEL, identification 1
15E980 LABEL, identification (TexSpray
5900HD convertible)
1
116▲15F638 LABEL, warning 1
117▲290228 LABEL, caution 1
118▲804495 LABEL, warning 1
119 195098 LABEL, instruction (English) 1
132 245688 BAR, torsion; includes 133, 134 1
133 114808 CAP, vinyl 1
134 198772 COLLAR, torsion bar 2
142 119584 CORD, power, convertible 1
145 100078 SCREW, thd forming, hex hd 6
146 198996 BRACKET, belt guide 1
147 193547 BELT, Vee, 30 1
148 198691 GUARD, belt 1
151 116038 WASHER, wave spring 2
164 15F947 SHIELD, magnetic 1
169 BOX, control (see pages 22-23)
287648 Premium 1
287649 Standard 1
172 114271 STRAP, retaining 1
173 119569 BUSHING, strain relief 1
174 119677 SPRING, retaining 1
185 15F584 LABEL, ProConnect 1
190 114687 CLIP, retainer 1
191 119790 O-RING 1
195▲195119 LABEL, warning 1
▲ Replacement Danger and Warning labels, tags, and
cards are availabel at no cost.
* Included in Clutch Repair Kit 241113
† Not used on TexSpray 5900HD Convertible
Ref Part Description Qty

Parts
20 311046H
Engine Detail
Engine Detail - Parts List
129
143
17
17
128
131 124
126
127
18
130
140
141
139
138
135137
115
15
144
12520
61
142 Ref
16
17
136
ti5750a
135
(Ref)
Ref Part Description Qty
15 114530 ENGINE, gas, 5.5 Honda 1
16 114653 SCREW, cap, flange hd 4
17 110996 NUT, flng hd, hex 6
18 183401 KEY, parallel 1
20 121727 SCREW, cap, hex hd 1
61 112717 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 BUSHING, snap 1
140 194181 BOX, junction, engine 1
141 114805 JACK, 1/4 engine 1
143 15E896 PULLEY, engine 1
144 15B314 SLEEVE, motor shaft 1
Ref Part Description Qty