Graco 307893A GM3500 SPRAYER Owner's Manual

INSTRUCTIONS-PARTS LIST
This manual contalns IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAINFOR REFERENCE
ORACO
307-893
GM3500 SPRAYER
3000psi (210 bar) MAXIMUM WORKINGPRESSURE
Model 231-078
Complete Sprayer,
with Stainless Steel DisplacementPump
1
GRACO INC. P.O. BOX 1441 MINNEAPOLIS. MN 55440-1444
COPYRIGHT 1988, GRACO INC.
Rev. A
TABLE OF CONTENTS
Introduction ...............................
2
Warnings
Setup ....................................
6
7
Fueling ...................................
Startup ...................................
8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . I . . . . .
10
Flushing Guidelines.......................
11
Troubleshooting Guide ....................
13
Repair
Pressure Control .......................
15
Pressure Control Calibration. . . . . . . . . . . . . . 17
Bearing Housing and Connecting Rod
. . . . . . . 18
Drive Housing..........................
20
Pinion, Clutch, Field, Clamp, Engine
Pinion Housing Removal. . . . . . . . . . . . . . 21
.
.
Repairing the Pinion. . . . . . . . . . . . . . . . . . 22
Clutch .............................
24
Engine .............................
25
Field and Wiring Harness
. . . . . . . . . . . . . .26
Clamp .............................
27
Clutch Housing ......................
27
Reassembly ........................
28
Parts Lists and Drawings
Complete Sprayer, 231-078 . . . . . . . . . . . . . . . 30
Pinion Assembly ........................
33
Pressure Control Assembly. . . . . . . . . . . . . . . .34
Accessories ..............................
35
Dlmensions ...............................
35
TechnicalData ............................
35
Warranty .........................
Back Cover
INTRODUCTION
GM3500 BASIC COMPONENTS (Refer to Fig3-1)
The GM3500 Sprayer functions
and operates differently
than other airless paint sprayers. Read this section to
help you become familiarwith the sprayerbeforeoperating it.
Fluid Filter
The fluid filter strains the paint help
to avoid clogsin the
hose and spray tip.
The filter includes a reusable element
and a pressure drain valve
for relieving fluid pressure.
Pressure Control
The pressure control includes an ONlOFF switch forthe
sprayer, the pressure adjusting knob,and a pressure
sensing device.The pressure control engages and
disengages the clutch to control pressure.
Hoses
The grounded, nylon spray hoses have spring guards on
bothends.The50foot(15.2m)hosehasa1/4,in.ID.The
3 foot (0.9 m), 3/16 in.ID whip hose allows flexiblegun
movement. The nylon hose material acts as
pulsation
a
dampener to absorb pressure fluctuations.
Engine
The engineis a 3.5 horsepower, four stroke gasoline engine. Its function is to drive the displacement pump to
supply paint. An adjustable throttle allows you to adjust
engine speed for large
or small orifice spray tips. When
the oillevel is too low, the engine shuts
off automatically.
If you try to start the engine without
refillingthe oil, a light
illuminates to alert you to the problem
and protect the engine from damage.
Spray Gun& RAC IV DripLess Tip Guard
Graco high pressure spray guns have a trigger safety
which prevents accidental triggering
when the safety is
engaged. See Fig 2-1. The Contractor gun provided
with this sprayer also has a filterfinal
forpaint straining.
The Graco SwitchTipTU uses high pressure fluid to remove clogs from the spray
tip without removing it from the
gun. The Revers+A-Clean@ IV DripLessTM tip guard
is a
safety feature which reduces the risk
of fluid injection.
Clutch
The clutch is engaged by the electric power generated by
the gasoline engine.The power
is controlled by the pressure switch.
Trigger safety
shown engaged
Drive Assembly
The permanently-greased drive assembly transfers
power from the gas engine
to the displacement pump.
.
.
Displacement Pump
The positive displacement,volume-balanced pump provides equalfluid delivery on both the up and down pump
strokes. Thepump has awet-cup which, when filled with
Graco ThroatSeal Liquid, helpsprevent damage to the
throat packingsand piston rod.
2
307-893
Fig 2-1
Fig 3-1
307-893
3
SAFETY WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS
Read and understandall instruction manuals before operating equipment.
FLUID.lNJECTlON HAZARD
General Safety
Safety Latch
This equipment generates very high fluid pressure. Spray 6omWheneveryoustopspraying,evenforamoment,alwayssetthe
the gun, leaks or ruptured components can inject fluid throughgun safety latch
in the closed or "safe" position. making the gun
yourskin and into your body and causeextremely serious bodilyinoperative. Failureto set the safety latch can result in accideninjury, including the need for amputation. fluid
Also,injected or
tal triggering of the gun.
splashed into the eyes
or on the skin can cause serious damage.
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
NEVER point the spray gun at anyone or at any part of the body.
NEVER put hand or fingers over the spray tip. NEVER try to injection when thetip is not installed. Check diffuser operation
regularly. Follow thePressure Relief Procedure.
below, then
"blow b a c k paint; this is NOT an air spray system.
remove the spray tip. Aim the gun into
a metal pail, holding the
ALWAYS have the tip guardin place on the spray gun when gunfirmlytothe pail. Using the lowest
possiblepressure,trigger
spraying.
the gun. If the fluid emittedis not diffused into an irregular
stream, replace thediffuser immediately.
below.before
ALWAYS follow thePressure Relief Procedure.
cleaning or removing the spraytip or servicing any system
Tip Guard
equipment.
ALWAYS have thetip guard in place on the spray gun while
NEVER try to stop or deflect leaks with your hand or body.
to the fluid injection hazard
spraying. The tip guard alerts you
Be sure equipment safety devices are operating properly beforeand helps reduce, but does
not prevent, the risk of accidentally
each use.
or any part of your body close
to the spray
placing your fingers
tip.
Medical Alert-Airless Sarav
Wounds
- r ~ - ,
If any fluid appears to enetrate your skin, getEMERGENCY
Trigger Guard
MEDICAL CARE AT8NCE. DO NOT TREAT ASA SIMPLE
Always have the trigger guard
in place on the gun whenspray.
CUT. Tell the doctor exactly what fluid was injected.
ing to reduce the riskof accidentally triggering the gunif it is
Note to Physician: Injectionin the skin is atraumaticinjury.
It
dropped or bumped.
isimportanttotreattheinjurysurgicallyassoonaspossible.
Do not delay treatment
to research toxicity. Toxicity is a conSpray Tip Safety
cern with some exotic coatings injected directlyinto the
ti s If
Use extreme caution when cleaning or changing spray
blood stream. Consultation with aplastic surgeon or rethe spraytip clogs while spraying, engage
thegun safety fkch
constructive hand surgeon may be
advisable.
immediately. ALWAYS follow the
Pressure Relief Procedure
Spray Gun Safety Devices
and then remove the spray
tip to cleanit.
Be sure all gun safety devices are operating properly before
of the gun; this can NEVER wipeoff build-up around the spraytip until pressure is
each use.Do not remove or modify any part
cause a malfunctionand result in serious bodily injury.
fully relieved and the gun safety latch is engaged.
~~
~~~
~~
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
fluidinjection, splashingfluid or solventin the e es oron the skin, orinjury from moving parts or electric
shod, always follow this procedure wheneveryou shut ofl the sprayer, when checking or
servicing any partof the spray system, when installing. cleaning or changing spray tips, and whenever you stop spraying.
1. Engage the gun safety latch.
2. Turn the engine ON/OFF switch
to OFF.
3. Flip the pressure control switchOFF.
to
1
4
307-893
2
4. Disengage the gun safety latch. Hold a metal part of the
gunfirmlytothesideofagroundedmetalpai1,andtrigger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container ready
to catch the drainage. Leave the valve open
until you are
ready to spray again.
7. Disconnect the sparkplug cable
lfyoo suspect that the sprayorhose
tip
iscorn lefel clogged,
fullyrelieveda~er
f o ~ o ~the
i"~
or thatpressure has not been
steps above.VERY SLOWLY loosen the tipguard retaining
nut or hose end coupling and relieve pressure gradually, then
loosen completely. Now clearthe tip or hose.
MOVING PARTS HAZARD
HOSE SAFETY
High pressure fluidin the hoses can be very dangerous.
If the
of wear,
hose developsa leak, split or rupture due to any kind
it can
damage or misuse,the high pressure spray emitted from
cause a fluid injection injury or other serious bodily injury or
property damage..
ALL FLUID HOSES MUST HAVE SPRING GUARDS ON
BOTH ENDS! The spring guards help protect the hose from
kinks or bends at or closeto the coupling which can result
in
EQUIPMENT MISUSE HAZARD
hose rupture.
General Safety
TIGHTEN all fluid connections securely
before each use. High
pressure fluid can dislodge a loose coupling or high
allowpresAny misuse of the spray equipment or accessories, such as
overpressurizing. modifying parts, using incompatible chemi- sure spray to be emitted from the coupling.
cals and fluids, or using worn
or damaged parts, can cause
NEVER usea damaged hose. Before each use, check the enthem to ruoture and result
in fluid iniection. solashinoin the eves
tire hoseforcuts, leaks, abrasion, bulging cover, or damageor
or on the skin, or other serious bodily
inju&,'orfire. Explosioi or
movement of thehose couplings.If any of these conditionsexproperty damage.
ist, replace the hose immediately. DO NOTtotry
recouple high
pressure hose or mend
it with tape or any other device. A reNEVER alter or modify any partof this equipment: doingso
paired hose cannot contain the high pressure fluid.
could causeit to malfunction.
HANDLE AND ROUTE HOSES CAREFULLY.
Do not pullon
CHECK all spray equipment regularly and repairor replace
hoses to move equipment. Keep hoses clearof moving parts
worn or damaged parts immediately.
and hot surfaces of the pump and gas engine. Do not use fluids
the inner tube and
Always wear protective eyewear, gloves, clothing and respira- or solvents which are not compatible with
coverofthe hose. DO NOTexpose Graco hose to temperatures
tor as recommended by the
fluid and solvent manufacturer.
above 180' F (82'' C) or below-40° F (40' C).
System Pressure
Hose
Grounding Continuity
This sprayer can develop 3000 psi (210 bar) MAXIMUM
WORKING PRESSURE. Be sure that all spray equipment and Proper hose grounding continuity is essential to maintaining a
grounded spray system. Check the electrical resistance
of your
DO NOT
accessories used are rated
to withstand this pressure.
If your hose does not have a
exceed the maximum working pressure of any component or fluid hoses at least once a week.
tag on it which specifies the maximum electrical resistance,
accessory usedin the system.
contact the hose supplier or,manufacturer for the maximum reFluid and Solvent Compatibility
sistance limits. Use a resistance meter
in the appropriate range
for your hose to check the resistance.
lfthe resistance exceeds
BE SUREthat all fluids and solvents used are chemically comthe recommended limits, replace it immediately. An unpatiblewith the wetted parts shownin iheTECHNlCAL DATA
on page 35. Always read the fluid and solvent manufacturer's grounded or poorly grounded hose can make your system hazardous. Also read FIREOR EXPLOSION HAZARD.
literature before using them
in this sprayer.
Moving parts can pinch or amputate your fingers
or other body
parts. KEEPCLEAR of moving parts when starting or operating
the sprayer. Follow the
Pressure Relief Procedure
on page4
beforecheckingorservicing any partofthesprayer. toprevent
it
from starting accidentally.
FIRE'OR EXPLOSION HAZARD
of
Static electricityis created by the flow offluid through the pump 2. Fluidhoses: use only grounded hoses with a maximum
500feet(l50m)combinedhoselen thtoensuregrounding
and hose. If every partof the spray equipment is not properly
continuity. See Hose Grounding ontlnuity.
grounded, sparking may occur, and the system may become
hazardous. Sparking may also occur when plugging
in or un3. Spraygun:obtain grounding through connectionto a propplugging a power supply cord or using a gasoline engine.
erly grounded fluid hose and sprayer.
Sparks can ignite fumes from solvents and the fluid being
sprayed, dust particles and other flammable substances,
4. Object being sprayed: according to local code.
whether you are spraying indoors oroutdoors, and can cause 5,
a Fluidsupp~yconta;ner:
to localcode.
fire orexplosionand serious bodily injury and property damage.
6. All solvent pails used when flushing, according to local
If you experience any static sparking or even a slight shock
code. Use only metal pails, which are conductive. Do not
while using this equipment, STOP SPRAYING IMMEDIplace thepail on a non-conductive surface, such
as paper
ATELY. Check the entire system for proper grounding.
Do not
or cardboard, which interrupts the grounding continuity.
use the system again
until the problem has been identified and 7, To
conti.;iru
when
orrelieving
corrected.
pressure, always hold a metal
part of the gun firmly to the
Grounding
side of a grounded metal pail, then trigger the gun.
To reducethe risk of static sparking, ground the sprayer and all Flushing safety
other spray equipment used or located in the spray area.
CHEcKyour localelectricalcodefordetailedgroundinginStluCReduce the risk of fluid injection W r y , static sparking, or
tions for your area and type of equipment, BE SURE to ground
splashing by following
theflushlng procedure givenon Page 10
of this manual.FollowthePressure Relief Procedureon
page
all of this spray equipment:
4, and remove the spray
tip before flushing. Hold
ametal part of
8
1. Sprayer: connect a ground wire and clamp (supplied) to a the gun firmlyto the sideof a grounded metalpail and usethe
true earth ground. lowest possible fluid pressure during flushing.
GASOLINE ENGINE HAZARD
NEVER fill the fuel tank whilethe engine is running or hot. fuel
NEVER operate the engine
in a closed building unless the enDiDed outside. The exhaust contalns carbon
spilled on a hot surface can ionite and cause a fire. cline exhaust is
307-893
5
SETUP
1 . Connect Hoseand Gun. Refer to Fig 6-1.
PRESSURE CONTROL
ONlOFF SWITCH
a. Remove the plastic
cap plug from the filter outlet
50 ft.(15.2 m) main fluid
nipple and screw the
hose onto the nipple.
b. Connect the whip end hose between thefluid
hose and thegun inlet connection.
c. Don't use threadsealant; and don't install the
spray tip yet!
WARNING
If you are supplying your
own hoses and spray
gun,
be sure the hoses are electrically conductive. That
the gun has a tip guard that
andeach part is ratedfor
is
at least 3000psi(210 bar) Working Pressure. This
to reduce the riskof serious bodily injury caused by
static sparking, fluid injection over-pressurization
or
and rupture of the hoseor gun.
~~
~
~~
~
SECONDARY H
OUTLET 1/4 NP
~
2. Two Gun Hookup. Refer to Fig 6-1. Remove the
cap from the secondary hose outlet
and attach an accessory hose andgun to the114 npsm(m) nipple.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance
and component Clamage, follow these precautions:
1. Always use nylon spray hose at least 50 ft.
(15.2 m) long.
2. Never useawire braid hose asit is too rigid to act
as a pulsation dampener.
3. Never install any shutoff device between the
fil6-1.
ter and the main hose. See Fig
4. Always use the main filter outlet for one opgun
eration. Neverplug this outlet.
3. Fill PackingNuwet-Cup. Refer to Fig
6-1. Fill the
packing nuffwet-cup 1/3 full with Graco Throat Seal
Liquid (TSL), supplied.
4. Check the engineoil level. Refer to the Honda engine manual, supplied. This is a summary
of the information: Remove one of the oil fill plugs; theoil
should be almost overflowing. SeeFig 7-1. Add oil
as necessary.
Recommended lubricatiqn oil. Use a high quality detergent oil, SAE1OW-40, classified "FOR SERVICE
SE or SF", for regular useand for the breaking-in of
a new engine.
"
6
307-893
WHIP END HOSE
Fig 6-1
SETUP
5. Be sure your system is properly grounded before operating it.
Read and follow the warning section, FIRE OR EXPLOSION HAZARD, on
page 5.
6 . Fillthe gas tank.
See theFUELINGsection, below.
7. Flushthe pump to remove the lightweight
oil which
was left in to protect pump parts after factory testing.
a. Before using water-base paint, flush with
mineral spirits followed by soapy water, and
then a clean water flush.
b. Before usingoil-base paint, flush with mineral
spirits only.
c. See FLUSHING GUIDELINESon page 11 for
the flushing procedure.
8. Prepare the paintaccording to the manufacturer's
recommendations.
a. Remove anyskin that may have formed.
b. Stir the paint to mix pigments.
\
c. Strain the paint through a fine nylon mesh
bag (available at most paint dealers) to
remove particles that could clog the filteror
spray tip. This is probably the most important
step toward trouble-free spray painting.
9. Keep the sprayer uprlght and level
during opera-
/
MUFFLER
//
Fig 7-1
tion and whenever isit being moved.
FUELING
-
WARNING
Gasoline is extremely flammableand explosive under certain conditions.
Always shutoff the engine before refueling.
Refuel in a well-ventilated area.
Do not smoke or allow flames or sparks
in the area
where the engineis refueled or where the gasoline
is stored.
Do not overfill the tank. Make sure the cap
filleris
securely closed after refueling.
Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel can ignite. If any fuel is spilled,
make sure the area is dry before starting the
engine.
1. Fuel specifications.Use automotive gasolinewith
a pump octane number (
or 86 or higher
or a research octane numberof 91 or higher. Unleaded fuel minimizes combustion chamber
deposits.
2. Gasolines containing alcohol (gasohol).Do not
use gasohol containing methanolif it contains no
cosolvents and corrosion inhibitors
for methanol. If it
does contain such additives,
still do not use ifitit contains more than5% methanol.
Do not use gasohol containing more than 10%
ethanol.
Be sure the gasohol has octane ratings
at least as
high as stated in
Fuel specifications.
NOTE: The' Honda engine warranty does not cover
damage resulting from the use
of gasolines containing alcohol.See theHONOA engine manual
for more information.
3. General. Do not use oil and gasoline mixtures or
contaminated gasoline. Avoid getting dirt, dust
or
water in the fuel tank.
4. Tank capacity. 0.66
gallons (2.5 liter). Always leave
at least1/2 in. at the top
of the tank for expansion.
5. Shut off the engine before refueling.
6. After refueling, tighten the fuel tank cap flrmly.
~~
307-893
7
NOTE: Refer toFig 9-1 as you start the sprayer.
Use this procedure each time you start
the sprayer to
help ensure the sprayer
is ready to operate and
that you
start it safely.
NOTE: When starting a sprayer
that IS NOT primed, remove the spraytip.
1. Check the gas tank.Open the fuel shutoff valve.
2. Check the engineoil level.
NOTE: The engine stops automatically is
if low
it on oil.
If
you try to startit again without adding more
oil, a
red lighton the rear ofthe engine'lights as you
pull the starter rope.
3. If a secondary hose and gun
is not installed,be
sure the cap is securely plugging the nipple.
!
13. Open the choke.In cold weather youmay have to
leave the choke closed
for 10 to 30 seconds before
opening it to keep the engine running. Otherwise,
open the choke as soon
as the engine starts.
14. Disengage the gun safety latch.
15. To start the pump,open thefilter's pressure drain
valve. Turn the pressure control switch
to O N and
slowly increase the pressure
setting until the pump
starts to cycle slowly. Cycle the pump slowly
until
fluid is flowing smoothly from the pressure drain
valve, indicatingthat the pumpis fully primed. Close
the pressure drain valve. Holding a metal
part of the
gun firmly against
and aimed into a grounded metal
container, squeeze the trigger until
fluid is flowing
smoothly from the gun. Release the trigger
and engage the gun safety latch.
gun.the separate
tip
4. Place the suction tube into the paint container. 16. Install the spray tip in the See
manual, 307-848.
5. Flip the pressure control switch to OFF.
6. Open the fuel shutoff lever
by pushing itin the direction of the arrow.
7. Be sure the spark plug cableis firmly pushed
onto the'plug.
I'
To reduce the risk
of serious bodily injury from from
fluid injection, NEVER operate the spray gun with
the tip guard removed.
IcA
Never attempt to start the engine unless
fluid pressure is relieved and the pressure control ON/OFF
switch is OFF. Trying tostat? the engine underload
will damage therecoil system.
17. Adjust the engine speed and pump pressure.
First set the throttle lever
to the maximumRPM setting (fullyleft). Trigger thegun onto a test paper to
check the spray pattern
and atomization. Adjust the
pressure adjustingknob until you get a good pattern.
Then slowly lower the throttle setting as far as you
can without changing the spray pattern.
8. Set the pressure adjusting knob
all the way counterclockwise to the lowest pressure setting.
9. Pull the throttle lever away from the fuel totank
maximum position (fully left).
10. If the engineis cold, completely close the gray engine choke lever,located beneath the air cleaner.
If the engineis warm, you may need to close the
choke only halfway or not atall.
11. Turn the engine switch to ON.
12. Grasp the starter rope.
Holding the frame with
one
hand, pull the rope rapidly and firmly. Continue holding the rope as you let it return.
Pull and return the
rope until the engine starts.
WARNING
Letting the ropereturn too fast may cause serious
It could also
bodily injuryif the rope hits someone.
jam the ropein the recoil assembly.
~
8
307-893
CAUTION
Always use the lowest possible pressure throttle
and
setting to increase the life
of the sprayer. Higher settings cause excessive clutchcycling as well as tip
and pumpwear.
CAUTION
Close the fuel valve whenever you are transporting
the sprayer to prevent fuel from flooding the
engine.
Keep the sprayer upright
and level when operating
it and when transporting it. This prevents crankcase oil from leaking into the combustion chamber
which makes startuD vervdifficult.
Fig 9-1-
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9
MAINTENANCE
-WARNING
I
To reduce the riskof serious bodily injury, including
fluid injection or splashing
in the eyes or on the skin,
or injury from moving parts, always followPresthe
sure Relief Procedure Warning
on page11 before
checking, adjusting, cleaning and shutting down the
sDraver. Disconnect the SDark DIua.
DAILY: Checkthe engine oil level andfill as necessary.
DAILY: Check andfill the gas tank.
AFTER THE
FIRST 20 HOURS OF OPERATION: Drain theoil and refill with clean oil.
CAUTION
For detailed engine maintenance and specifications, refer to the separate engine manual, supplied.
WEEKLY: Check the level of the
TSL in the displacement pump packing nut. Fillif itnecessary. KeepingTSL
in the nut helps lubricate the packings.
AFTER EACH100 HOURS OF OPERATION: Change
WEEKLY: Remove the cover ofthe air filter and clean the Oil.
the element. Replace the element
if necessary. Ifoperating in an unusually dusty environment, check the filter
SPARK PLUG: Use only a (NGK)BPGES or BPR6ES
daily and replaceif necessary.
plug. Gap the plug to
0.025-0.030 in. (0.7-0.8mm). Be
Replacement elements can be purchased from your
losure to use a spark plug wrench when installing and retal Honda dealer. moving the plug.
10 307-893
FLUSHING GUIDELINES
I
WARNING
Pressure Relief Procedure
4. Disengage thegun safety latch.Hold a metal part of
Toreduce the riskof serious bodily injury, including
Ruid
the gun firmly to the side of a grounded metal pail,
and trigger the gun to relieve pressure,
injection, splashing fluid
or solvent in the eyes or on the
skin, or injury from moving parts or electric shock,
allatch.
ways follow this procedure whenever you shut
off the 5. Engage the gun
6.
Open
the
pressure
drain
valve, having a container
sprayer, when checkingor servicing any pari of the
ready to catch the drainage. Leave the valve open
spray system, when installing, cleaning or changing
until you are ready to spray again.
spray tips,and whenever you stop spraying. .
1. Engage the gun safety latch.
7. Disconnect the spark plug cable
2. Turn the engine ON/OFF switchOFF.
to
If you suspect that the spray tip
or hose is completely
clogged, or that pressure has not beenfully relieved af3. Flip the pressure control switchOFF.
to
ter fobwing the stepsabove, VERY SLOWLY loosen
the tip guard retaining nut
or hose end coupling and relieve pressuregradually, then loosen completely. Now
clear thetip or hose.
1
When to Flush
2
-
CAUTION
1. New Sprayer.Your new GM3500'Sprayer was
factory tested in lightweight oil which was left in toproNEVER leave water in the sprayer if there is the
tect pump parts.
slightest chance it could freeze. Push the water out
with mineral spirits.Water left to freezein the presBefore using water-base paint, flush with mineral
sure control tube prevents the sprayer
from being
spirits followed by soapy water, and then a clean
started and causes serious damage to the pressure
water flush.
control.
Before using oil-basepaint, flush with mineral spirits
only.
2. Changing Colors.Flush with a compatible solvent 6. Startup after storage.
such as mineral spirits or water.
Before using water-base paint, flush out mineral
3. Changing from water-base to oil-base paint.
spirits withsoapy water andthen aclean water flush.
Flush withwarm, soapy water, then mineral spirits.
* When usingoil-base paint, flush out the
mineralspir4. Changing from oil-base to water-base paint.
its with the paint tobe sprayed and the sprayeris
Flush with mineral spirits, followed by warm, soapy
ready to use.
water, then a clean water flush.
Continued onpage 12.
5. Storage.
Water-base paint: flush with water, then mineral
spirits and leave the pump, hose and gun filled with
mineral spirits. Shut off the sprayer, remove the
spark plug cable, and open the pressure drain valve
to relieve pressure and leave it open.
Oil4asepaint:flush with mineral spirits. Shut
off the
sprayer, remove the spark plug cable, and open the
pressure drain valve to relieve pressure
and leave it.
open.
FLUSHING GUIDELINES
How to Flush
1. Follow thePressure Relief Procedure Warningon
page 11.
6. Disengage the gun safety latch. Point the spray gun
into a metal waste container
and with a metalpart of
the gun firmly touching the metal container, squeeze
the gun trigger. SeeFig 12-2. This procedurehelps
2. Remove the filter bowl and screen; see manual
reduce the risk
of static sparking and splashing. Start
307-273, supplied. Clean the screen separately and
the
sprayer,
trigger
the gun and slowly the
turnpresinstall the bowl without the screen
to flush it. See Fig
sure
adjusting
knob
clockwise
just
until
the
pump
12-1.
starts. Keep the gun triggered until clean solvent
comes from the nozzle. Release the trigger and engage the gun safety latch.
7. Check all fluid connections for leaks.
If anyJeak, first
follow thePressure Relief Procedure Warningon
page 11. Now tighten the connections, startthe
sprayer, and recheck the connections for leaks.
FILTER
BOWL
8.
Remove the suction tube from the pail. Disengage
the gun safety and trigger the gun to force solvent
from the hose.Do not let thepump run dry for more
than 30 seconds to avoid damaging the
pump packings! Then follow thePressure Relief Procedure
Warning on page 11.
9.
Leave the pressure drain valve open until
you are
ready to use the sprayer again. Unscrew the filter
bowl and reinstall the clean screen. Reinstall the
bowl, hand tight only.
SCREEN
'
FILTER
SUPPORT
IO. If you flushed with mineral spirits and are goingto
PRESSURE
DRAIN VALVE
use a water-base paint, flush with soapy water
followed by a clean water flush. Then followPresthe
sure Rellef Procedure Warning
on page 11.
Fig 12-1
3. Close the filter's pressure drain valve.
4. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal pail. Put the suction
tube
inthe
pail.
5. Remove the spraytip from the gun.
-1
To reduce the risk of static sparking and splashing,
always remove the spray tip form the gun,hold
and
a metal part of the gun firmly to the
side aimed
of and
into a grounded metalpail when flushing.
12 307-893
METAL TO META
CONTACT WHEN
FLUSHING
Fig 1
I
WARNING
Pressure Relief Procedure
To reduce the risk
of serious bodily injury, including
fluid
5. Engage the gun safety latch.
injection, splashingin the eyesor on the skin, or injury
from moving
always
follow
this
when- 6. Open thefluid pressure drainvalve and leaveit
you shut off the sprayer, checking, adjust
or clean the open until
you start the sprayer again.
system, or change spray tips.
7. Disconnect the spark
plug cable.
1. Engage the gun safety latch.
lfyoususpect that the hose or tip is completelyclogged
2. Turn the engine ON/OFF switch
to OFF.
or that pressure is not fully relieved affer following the
stepsabove, VERY SLOWLYloosen a hose end fitting
or the tip guard retaining nut and relieve pressure
gradually. Now clear thetip or hose.
3. Flip the pressure control switch OFF.
to
4. Disengagethe gun safety latch. Holding metal
a part
of the gun firmly to the side
agrounded
of
metal pail,
trigger the gun.
Check everythingin the guide before disassembling the sprayer.
JROBLEM
fnginekprayer won't start
CAUSE
Engine switch notON
Engine oil level low
I
I
SOLUTION
Turn on.
Try starting engine.If light on rear of
engine glows, replenish oil..
Spark plug cable disconnected or Connect cable on top of engine or respark plug bad
place spark plug.
Out of gas
Replenish
Return pressure control to authorized
Graco dealer for rep-:?
Water frozenin pressure control.
-
,
3ngine won'tpull over.
Oil seepageinto combustion
chamber.
Remove spark plug. Pull engine over
3 or 4 times. Clean and replace plug.
Try to start. Keep sprayer upright to
avoid seepage.
?as engine operatesbut
jisplacement pump doesn't
)perate
Pressure control switch turned
OFF
Turn on.
Pressure setting too low
Increase pressure.
Displacement pump outlet filter dirty Clean filter.
or clogged
Tip ortip filter clogged Clean
Displacement pumprod seized by dry
paint
Connecting rod wornor damaged
I
tip or tip filter.
Service pump. See307-806.
Replace. See page18.
Driie housing wornor damaged
Replace. Seepage 20.
Electrical power not energizing
field
Check wiring connections.See page
15.
With pressure control switch ON and
pressure turned toMAXIMUM, use a
test light to check continuity across
black and wire wires from pressure
control.
Have pressure control checked by
authorized Graco dealer.
Clutch wornor damaged
Service. See page24.
Pinion assembly worn
or damaged
Service. See page21.
'
Continued on page 14
307-893 13
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
SOLUTION
~~~
Displacement . pump outpu
low on upstroke
Displacement pump outpu
low on downstroke or bot1
strokes
~
Pump inlet screen clogged
Clean.
Piston ball check not seating
Service piston ball check.
Piston packings worn or damaged
Replace packings,
Displacement pump sleeve gasket
worn or damaged
Replace.
Pump inlet screen clogged
Clean.
Piston packings worn or damaged
Replace packings.
Intake valve ball check not seating
properly
Clean and service.
Engine RPM too low
Increase throttle setting. See Startup,
Step 17, page 8.
Clutch worn or damaged
Paint leaks into wetcup
Low fluid delivery
Loose wet-cup
Tighten just enough to stop leakage.
Throat packings worn or damaged
Replace packings. See 307-793.
Displacement rod worn or
damaged
Replace. See 307-793.
Pump inlet screen clogged
Clean.
Pressure setting too low
Increase pressure. See Startup, Step
17, page8.
Engine RPMtoo low
Dirty outlet filter, tip filter or tip
Spitting from gun
Increase throttle setting. See Startup,
Step 17, page 8.
Clean.
Large pressure dropin hose
Use larger diameter hose.
Air in fluid pump or hose
Check for loose connectionsat intake
and tiohten. Then mime the ix.mD.
,
.
See STaiup, page8:
Tip partially clogged
Fluid supply is low or empty
14 307-893
Replace. See page24.
Clear,
Refill and reprime the pump. See
Startup, page 8. Check fluid supply
often to Drevent running dry.
REPAIR
Pressure Control Replacement
WARNING
To reduce the riskof serious bodily injury, including
fluid injection or splashing in the eyes
or on the skin,
or injury from moving parts, always followPresthe
on page 13 before
sure.Relief Procedure Warning
checking, adjusting, cleaning
and shutting down the
sprayer. Disconnect the spark
plug cable.
1. Disconnect both hoses at the pressure control (63),
holding the elbows firmly.
See theCAUTION below.
Take noteof the original location
of each hoseto be
sure you reassemble them correctly at the end of this
procedure. See Fig15-1,
CAUTION
DO NOTallow the elbow(314) to turn when removing or connecting the hoses. Turning the elbows can
2. Working under the engine mounting plate
of the cart,
disconnect thered, black and white wires. Then remove the three nuts (61)
and lockwashers (9)from
the capscrews(62) which hold the pressure control
bracket (67) to the cart. Remove the pressure control. See Fig15-2.
3. Remove the pressure control cover and screws
(76,64) andthe four screws(65) holding bracket(67)
to thepressure control. See Fig15-1.
(see page 17)
Fig 15-1
4. Remove the wire clamp
(32) from the pressure control wires. See Fig 15-2.
procedure continued on newt page
VIEW FROM UNDER ENGINE MOUNTINGPLATE
Fig 15-2
307-893
15
~
REPAIR
5. Disconnect the wires from the rectifier(307).Remove the screw (311),nut (306)and lockwasher
(305).See Fig16-1,
6. Unscrew the connector (313)from the box, pulling
the wiresout with it.
9. Reassemble in the reverse order.
Be Sureto reinstall
the wire clamp (32)on the new pressure control
wires. Fasten both clamps to the cart with the
same screws, lockwashers
and nuts (62,9,61)
which
hold the bracket(67)to the cart. See Fig
15-2.
8. Removethescrew(310)andiockwashers(305)from
the ground wire (308).
dure on the next page before regular operation
of the
sprayer.
7. Holding thehex of the adapters(A) at the control box
with a wrench, remove the elbows
(314).
10. Perform thePressure Control Calibration proce-
31 1,305,306
RED
RECTIFIER (307) CONNECTIONS
Fig 16-1
16 307-893
REPAIR
Pressure Control Calibration(See Fig 17-1)
WARNING
L
USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE
to reduce the risk
of a fluid
injection injuryor other serious bodily injury which can result from component rupture, electric shock, fire, explosio
or moving parts.
This procedure sets the sprayer to 182-210 bar
MAXIMUM WORKING PRESSURE.
This procedure must be performed whenever the
pressure control assembly
is removed and reinstalled
or replaced to be sure the sprayeris properly calibrated.
NEVER attempt to increase the fluid outlet pressure
by performing these calibrationsin any other way.
NEVER EXCEED 210 bar MAXIMUM WORKING
PRESSURE. Normal. operation of the sprayer at
higher pressurescould result in component rupture,
fire or explosion.
ALWAYS use anew 15.2 m sprayhose rated for at
least 210 bar MAXIMUM WORKING PRESSURE
A used, under-rated
when performing this procedure.
hose could develop a high pressure or
leakrupture.
Improper calibration can cause the sprayer
to overpressurize and result in component rupture, or
fireexin the pressure controlasplosion. It may also prevent the sprayer from obtainingAVOID touching the wire
sembly when the control box cover
is removed, to rethe maximum working pressure, resulting in poor
duce the riskof electric shock.
sprayer performance.
Service Tools Needed:
NEW 15.2 m, 231 bar flexible, nylon airless spray
hose, PartNo. 21C-541
New 0.023 size spray tip.
0-350 bar fluid-filled pressure gauge, Part No.
102-81 4
20 liter pail and water
Mineral spirits
1. Follow the Pressure Relief Procedure Warning
on
5.
page 13.
2. Installthe new 15.2 m spray hose to
sprayeroutthe
let. On the other end of the hose, install the gun and
new ,023 size tip. Install the fluid-filled pressure
gauge in the top
port (6- See fig 15-1) of the fluid
filter. Remove the pressure control cover.
3. With the gun safety latch engaged, start the engine
(only). Using 318”
a ignitionwrench, turn the pressure
adjustment nut (E) clockwise two full turns. See Fig
17-1. With the pressure control
knob (D) turned to
ON.
the minimum setting, turn the sprayer switch
THE DISPLACEMENT PUMP SHOULD NOT CYCLE
Then note the pressure to which the gauge bedrops
fore the pressure starts to rise again.
IffhepressuredropstobeIow18Zbar,turnthedifferentia1 wheel (A) clockwise to bring the pressure to
182 bar.
If the pressure stops dropping before 182 bar, turn
the differential wheel (A)
counterclockwiseto decrease the pressure.
on
Follow thePressure Relief Procedure Warning
page 13. Install the pressure control cover. Flush the
water out with mineral spirits, relieve pressure again,
aand thenremove all the test equipment.
I f if does cycle, shut the sprayer switch OFF, disengage the gun safety latch, trigger thegun into a
grounded waste container
until pressure is relieved,
and engage the latch again. Turn the (E)
nuta little
further clockwise. Turn the sprayer
on again to be
sure THE PUMP DOES NOT CYCLE.
4. Increase the throttle setting and then the pressure
control setting to the maximum while triggering the
gun. Keep the gun triggered while observing the
pressure at which the pump stalls, which should
be
approximately 210 bar.
NOTE: When the gun trigger
is released, it is normalfor
the stall pressure to be 217to 238 bar, during
this
procedure.
/f the pressure is not 210 bar, turn the adjusting nut
(E) clockwise to reduce pressure and counterFig 17-1
clockwise to increase pressure to obtain exactly
210 bar pressure.
A\
/D
307-893 17
Bearing Housing & Connecting Rod
REPAIR
WARNING
To reduce the risk
of serious bodily injury, including
fluid injection, splashingfluid in the eyes or on the
skin, or injury from moving parts, always follow the
Pressure Relief Procedure
Warnins on page 13
before repairing any part of the sprayer. Disconnect
the soarkDlua cable.
NOTE: Steps 1to 13 refer to Fig 18-1.
1. Remove the front cover
and screws (23’68).
2. Unscrew the suction tube (30) from the pump, hold(B)to keep the
ing a wrench on the pump intake valve
pump from loosening.
3. Disconnect the pump outlet hose (59) from thedisplacement pump outlet nipple
(87).
4. Use a screwdriverto push aside the retaining spring
(26) at the topof the pump. Push the pin out
(25)the
rear.
5. Loosen the jamnut (27) withan adjustable wrench.
Unscrew and remove the displacement pump.
6.
Use a hex
key wrench to remove the four screws (73)
and lockwashers (74)from the bearing housing.
7. While pulling the connectingrod (22) with one hand,
lightly tap the lower rear
of the bearing housing (21)
with a plastic mallet to loosen
it from the drive housing (20). Pull the bearing housing and the connecting
rod assembly (22)off the drive housing.
8. Inspect the crank
(A) for excessive wear and replace
parts as needed.
9. Evenly lubricate the
inside of the bronze bearing
(F)
in !he bearing housing(21.) and the insideof the connecting rod link (D)with high quality motor oil. Liberally pack the roller bearing
(E) in the connectingrod
assembly (22) with bearing
grease.
10. Assemble the connecting
rod (22) and bearing housing (21).
CAUTION
11. Clean the mating surfaces
of the bearing and drive
housings.
12. Align the connecting
rod with the crank
(A) and carefully align the locating
pins (C) in the drive housing
(21).Push
(20) with the holes
in the bearing housing
the bearing housing onto the drive housing
or tap it
into place with a plastic mallet.
18 307-893
13. Install the screws (73)and lockwashers (74) on the
bearing housingand tighten evenly to
125-145 in-lb
(14-16 Nm).
NOTE: Refer to Fig19-1 for Step 14.
REPAIR
14. Screw the displacement
pump about 3/4 of the way
into the bearing housing
(21). Hold thepin (25) up to
the pinhole in the connectingrod assembly (22) and
continue screwing in the pump until the pin slides
off the pump until the top
easily into the hole. Back
threads of the pump cylinder are flush with theofface
the bearing housing
and the outletnipple (87) is facing back. Push the retaining spring (26) into the
groove all the way around the connecting rod.
Tighten the locknut(27) very tight- about.65 to 75
ft-lb (90to 100 N.m) -with a 2-1/4 in. open end
wrench and a light hammer.
WARNING
To reduce the risk of pin
the(25) being projected into
the air and resulting
in serious bodily injury, including
injury to the eyes, or property damage, including
damage to the pump connecting rod or bearing
housing:
Be sure the retaining spring (26) is firmly in the
(25)
groove all the way around, to prevent the pin
from working loose due to vibration.
If the pin works loose,or itother parts could break
off
due to the force of the pump action. These parts
could be projected through the air.
15. Reinstall thefront cover and screw(23,68). Reconnect the suction tube
(30) and pump outlet hose
(59).
See Fig18-1.
Fig 19-1
307-893
19
Drive Housing
REPAIR
WARNING
To reduce the risk
of serious bodily injury, including
fluid injection, splashing fluidin the eyes or on the
skin, or injury from moving parts, always follow the
Pressure Relief Procedure Warningon page 13
before repairing any part of the sprayer. Disconnect the spark plug cable.
NOTE: Refer to Fig20-1 for this procedure.
1. Remove the front cover and screws
(23,68)
2. Disconnect the pump outlet hose (59) from disthe
(57).
placement pump nipple
3. Use a hex key wrench to remove the two screws
(I 0)
and lockwashers (11) from the bottom front of the
pinion housing (1911). Then remove the top two
screws (IO)and lockwashers (1 1).
4. Working from the front
of the drive housing, remove
the two screws(73) and lockwashers(74).
5. Lightly tap around the drive housing with a plastic
mallet to loosenit from the pinion housing.
6. While holdingthe connecting rod
(22) with one hand,
lightly tap the backof the bearing housing(21) to
loosen the drive housing. Then
pull the drive housing
straight off the pinion housing.
CAUTION
DO NOTallow the gear cluster(18) to fall when removing thedrive housing (20). It iseasily damaged
if dropped. The gear may stay engaged
in either the
drive housingor pinion housing.
DO NOT lose the thrust balls
(2Oc or 19j) located at
each endof the gear cluster, or allow them
fallto
between gears. The ball, which is heavily covered with
grease, usually stays in the shaft recesses, but
could be dislodged. If caught between gearsand
not removed, the balls will seriously damage the
drive housing.If the balls are not
in place, thebearings will wear prematurely.
7. Liberally apply bearing grease
(ZOd, supplied) to the
gear cluster(18). Check to be sure the thrustballs
(20c and 19j) arein place.
8. Placethe bronze-colored washer (2Oa) and then the
silver-colored washer (20b) on the shaft protruding
from thebig bearing of the drive housing (20). Align
the gears and push the new drive housing straight
onto the pinion housing and locating pins.
9. Starling at Step6 and working backwards, continue
to reassemble the sprayer. Or, move ahead
to the
next section in this manual if further service is
needed.
REPAIR
Pinion, Clutch, Clamp, Field and Engine
Disassembly of these parts can start from the pinion
housing, or from the clutch
if no pinion service is needed.
If starting from the pinion housing,
first follow Steps1
to 6 of Drive Housing.onpage 20, then continue below.
If starting from the clutch,
see page24.
Pinion Housing Removal
WARNING
To reduce the risk
of serious bodily injury, including
fluid injection, splashing fluidin the eyes or on the
skin, or injury from moving parts. always follow the
Pressure Relief Procedure Warning onpage 13
before repairing any part
of the sprayer. Disconnect
the sparkplug cable.
NOTE: Refer to Fig21-1 for Steps 1 to 3, except where
noted.
1. Remove the two bottom screws (IO) and lockwashers (1 1) first, and then remove the three screws
(IO) and lockwashers (11) holding the pinion housing (19n) to the clutch housing
(2).
2. Pull the pinion housing away from the clutch housing. The armature (4a)
will come withit.
3. Pull the armature (4a)off the hub (19f - see Fig
23-1) of the pinion housing.
Do not lose the thrust ball (19j). Refer to the
CAUTION on page 20 for more information.
NOTE: To disassemble the pinion,go to page 22.To
disassemble moreof the sprayer, goto page 24.
To reassemble the sprayer from this point, skip
ahead toReassembly,page 29, Step 7.
19j
Fig 21-1
307-893 21
Repairing the Pinion
REPAIR
WARNING
To reduce the risk
of serious bodily injury, including
fluid injection, splashing fluidin the eyesoron the
skin, or injury from moving parts, always follow the
Pressure Relief Procedure Warningon page13
before repairing any part of the sprayer. Disconnect
the spark plug cable.
NOTE: Refer toFig 23-1 unless otherwise instructed.
NOTE: A hydraulic press is requiredfor disassembly
and reassembly if you purchase thepinion
parts
individually. If you
do not have such a press, use
RePairKit221-043, which includestheshaft and
bearings pre-assembled and lubricated.
lfyouareusing the RepairKit,221-043,follow Steps1 to
4, below.
1. Remove the smallring (19e) from thehub and the
large ring (19k) from the bearing recess.
I f you havepurchasedpartsseparately,use the following
instructions, disassemblingonly as far as needed for the
parts being replaced.
NOTE: The old large bearing (19d)will be damaged
when removed. Havean extra one on
hand if you
need to remove it for any reason.
1. If replacing the small bearing
( I ~ c )press
,
the old one
out of the pinion housing (19n).
2. Remove the small ring (19e) from the
hub and the
large ring (19k) from the bearing recess.
3. Push on the frontof the shaft(19b) to force the bear-
ing and hub assembly out of the housing.
4. using a hydraulic press, place pieces of Steel bar
stock on the inner
race of the large bearing (19d) and
press the shaft through the
hub and bearing. See Fig
23-2.
5. Apply lubricantto the parts as shownin Fig 23-1.
6.
2. Push on the frontof the shaft(19b) to force the
bearing and hub assembly outof the housing.
0
of the pinion hous3. Press them a i l bearing (19c) out
of
ing (1 9n). Remove the new bearing from the shaft
the kit and press itinto the housing. SeeDETAILA in
Fig 23-1.
4. Install the shaft assembly (19a), pushingit to the
shoulder of the housing (19n).
6.
Install the rings (19eand 19k).
7. Skip ahead toReassembly,page 29, Step
7, or continue at the next section.
22 307-893
Press fit the following parts:
Small bearing (19c) into rear of housing
(19n). See DETAILA in Fig 23-1.
Large bearing (19d)
to shoulder of shaft (19b).
Hub (19f) onto the shaft (19b) all the way
to the large bearing (19d).
7. Install the shaft assembly (19a), pushingit to the
shoulder of the housing(19n).
8.
Install the rings (19e
and 19k).
9. Skip ahead to
Reassembly,page29, Step 7, orcontinue at the next section.
REPAIR
ROUND STEE
BAR TO PUSH
I
DETAIL A
CUTAWAY VIEW OF PINION HOUSING
SHOWING PLACEMENT OF SMALL
BEARING (19c)
PRESS PLATFORM
PLACEMENT OF STEEL BLOCKS AND
BAR STOCK WHEN PRESSING OFF
LARGE BEARING
PRESS FIT
SMALL
BEARING
(19c) HERE
I
I
194
19n
19e
Lubricate inner and
outer diameters
Lubricate teeth
Lubricate Inner
and outer diameters
Lubricate exterior
307-893 23
Clutch Assembly
REPAIR
NOTE: The clutch assembly (4) includes the armature 5. The armature (4a) was removed when
pulling off the
(4a) and rotor (4b). The armature
and rotor must
be replaced togetherso that they wear evenly.
NOTE: If the pinion assembly (19)
is not yet separated
from the clutch housing, follow Steps
1 to 4. Othewise, start at Step5.
on
1. Follow thePressure Relief Procedure Warning
page 13.
2. Disconnect the hose (59) fromthe displacement
pump.
3. Removing the bottomtwo screws first, remove the
five screws(10) and lockwashers (1 1) from the front
of the clutch housing (2).
of the bearing housing (21)
4. Tap lightly on the back
to loosen the assembly
( D ) from
with a plastic mallet
the clutch housing.Pull the assembly away.
pinion housing. Remove the armature
from the pinion shaft.
6. There aretwo ways to remove the
rotor (4b).
a. Remove the four socket head capscrews(16)
and lockwashers (11). Install two of the
screws' in the threaded holes in the rotor.
Alternately tighten the screws until the rotor
comes off. See Fig 24-1.
b. You can use a standard steering wheel puller.
However, you need to provide two screws
(B), size 1/4-28 x 3 or 4 in. long. Install the
four screws and lockwashers (6) of the tool
(A) in the threaded holes of the rotor. Tighten
the capscrew (C) of the tool until the rotor
comes off. See the detailin Fig 24-1.
6,or con7. Skip aheadto Reassembly,page 29, Step
tinue on the next page.
REPAIR
Engine
NOTE: The engine must be removed before the
Field, Clamp or Clutch Housing can beremoved.
A
1. Working under the mounting plate (A)
of the cart,
remove the screw (15), lockwasher (80) and
washer (34) holding the clutch housing
(2) to the
cart. See Fig 25-1.
TO ENGINE
2. Stillworking underthe mounting plate, remove the
two nuts (61) and lockwashers(9), and thenpull
of the engine.Disthe screws(14) out of the base
connectthe redwire from the engine lead
(B). Disconnect the black and white wires from the field.
Pull the wires carefully through the grommets
(66)
before removing the engine. See Fig25-1 and
25-2.
3. Lift the engine carefully and place on
it a work
bench.
4. Remove the Field and Wiring Harness, Clamp
and Clutch Housing.See pages26 and 27.
5. Skip aheadto Reassembly, page 28,Step 1.
NOTE: All service to the engine must be performed
by an authorized HONDA dealer.
VIEW FROM UNDER ENGINE MOUNTING PLATE
Fig 25-2
A
Fig 25-1
307-893 25
~~
~~
Field and Wiring Harness
REPAIR
NOTE: Refer to Fig 26-1.
1. Remove the engine from the cart. See page
29.
2. Loosen the four setscrews
(12) holding the field
( 6 )to
the clutch housing (2) and pull out the field.
3. Pull the plastic caps(6) off the wire screws(33) in
both placeson the field. Loosen the screws and
release the wires.
4. Skip ahead toReassembly,page 28, Step 4.
Fig 26-1
26 307-893
REPAIR
Clamp
Clutch Housing
NOTE: Removing the clamp requires a standard steer- NOTE: Refer to Fig 27-2.
ing wheeipuller. However, you will need to pro(9)
Remove the four capscrews (8) and lockwashers
vide two screws (B), size 1/4-28 x 3 or 4inches
holding the clutch housing
(2) to the engine.
long.
2. Remove the capscrew (15), lockwasher (80) and
NOTE: Refer to Fig 27-1,
washer (34) from below the mounting plate
(D).
1. Loosen thetwo screws (16) on the clamp
(7), work- 3.
ing through theslot at the bottomof the clutch housing (2)..
2. Install two screws (B) of the tool (A) in two of the
threaded holes in the clamp. Tighten the screw
(C)
until the clamp comes
off.
4,
Remove the engine key
(13).
Pull off the clutch housing (2).
1, con5. Skip aheadto Reassembly, page 28, Step or
tinue on the next page.
3. Skip aheadto Reassembly, page 28, Step 3, or continue to the right.
Fig 27-1
Fig 27-2
307-893 27
REASSEMBLY
1. Install the clutch housing (2), capscrews (8)and
lockwashers (9) on the engine. SeeFig 2&1.
2. Install the engine shaftkey (13). See Fig 28-1,
3. Slide the clamp (3) onto the engine shaft, making
sure youmaintain the 1.41in. +/- 0.01 (35.8 mm) dimension shownin Fig 28-2.
To check the dimension, place a rigid, straight steel
bar (B) across the face of the
clutch housing (2). Using an accurate measuring device, check thedistance between the bar and the offace
the clamp. Adjust the clamp as necessary, and then torque the two
screws to 115-125 in-lb.(l3-15 Nm).
4. Connect the wires (29).to the screws (33)in both
places on the field.Pull the plastic caps(C) up and
snapoverthescrews. Guide the wiresofthe harness
(96) through theslot in the clutch housing. Slide the
field (6) in the clutch housing (2). Make sure the
setscrew holes in the field and clutch
the housing (2)
align, and thentighten the setscrews (12) oppositely
and evenly, torquing to
25-30 in-lb (2.9 to 3.4 Nm).
See Fig 28-1.
Fig 28-2
CONNECT WIRING HARNESS(29)
HERE BEFORE SLIDING FIELD
(6)
INTO HOUSING (2)
Fig 28-1
28 307-893
SIDE CUTAWAY VIEW OF
CLUTCH HOUSING
REASSEMBLY
5. Place the'engine (1) assembly on the cart, aligning
the mounting holes, and carefully guiding the engine
wire (D) and wiring harness (29) from the field,
through theappropriategrommets (66) in the mounting plate(E). Secure the engine with the capscrews
(14), lockwashers (9) and nuts (61). Secure the
clutch housing (2) with the capscrews (15), lockwasher (80) and washer (34). Under the mounting 7.
plate, connect the engine wireto the red wire and
connect the black and white wires. See Fig 29-1.
6. Making sure the face of the
rotor (4b) and the field
is
free of all oil and contaminants, install the rotor,
lockwashers (11) and capscrews (16). Torque the
capscrews to6.5 to 7.5 ft-lb (8.8to 10 Nm). See
Fig 29-1.
Fig 29-1
I t
.
-
After installing the rotor(4b), pull the engine recoil
rope to assure that the engine turns over and there is
no friction between the rotor (4b)
and the field (6). If
there is friction, recheck the
clamp dimension. See
Step 3on page 29.
Making sure theface of the armature (4a) is clean,
assemble the armature to the shaftin the pinion
housing (19n) until the armature contacts the ring
(19k). See Fig 29-1.
8. Assemble thepinion (19) to the clutch housing using
capscrews (10) and lockwashers1).
(1See Fig 29-1.
VIEW FROM UNDERSIDE OF ENGINE
MOUNTING PLATE
307-893 29
Model 231478, Series A
PARTS LIST
GM3500 Sprayer with Upright
Cart
Includes items 1 to 96
REF
NO.
PART NO. DESCRIPTION
1
' 108479
2
183-512
3 183-517
4 221-044
4a
4b .ROTOR
6 183-513
7
108400
8 109-031
ENGINE, GASOLINE, 3.5 HP
HOUSING, CLUTCH
CLAMP, MOUNTING, ROTOR
CLUTCH KIT
INCLUDES ITEMS4a & 4b
.ARMATURE
QTY
1
1
1
1
1
1
REF
NO. PART NO. DESCRIPTION
40
41
42
43
44
45
46
47
QTY
183-194 SLEEVE
2.
106062 WHEEL
2
2
101-242 RING, RETAINING
2
104-811
HUBCAP
154-636 WASHER, 5/8" SIZE; 16GA
2
179-777 BUTTON. SNAP ~-~
2
108-068 PIN. SPRING. STRAIGHT. 3/16
2
222-011
CLAMP, GROUNDING; 25 FT
17.6 MI WIRE 1
49 100-078 SCREW. HEX WASHER HD:
MACH; NO. 6-32 X 0.38"
50
157-021 LOCKWASHER, INTERNAL
51
214-570
FLUID FILTER
SEE 307-273 FOR PARTS
181-867' LABEL,WARNING
52
PRESSURE DRAIN VALVE
53
222-198
54
178-034' TAG, WARNING
22C-285
CAP
56
57
162453 NIPPLE. HEX: 114 NPSM X
114 NPT, 1-3/16" LONG
58
100-840 ELBOW, STR,1/4-18 NPT (M X F)
218-083
HOSE, FLUID, GROUNDED, NYLON;
59
1/4" ID CPLD 1/4 NPSM(F);2 9 (715
MM); SPRING GRDS BOTH ENDS
100-188
NUT. HEX. 5/16-18
61
62
CAPSCREW. HEX HD; 5/16-18
101-344
UNC-2A X'.625
63
221-039 PRESSURE CONTROL SWITCH
SEE PARTS LISTON PAGE 34
64
106075 SCREW, MACH, OVHD, THD
FRMG; NO 6-24 X1/2",TYPE "C"
2
66
109-099 BUSHING, SNAP
1
BRACKET, MOUNTING
67
183-392
68
SCREW, MACH, FILH;
107-209
4
NO. E 3 2 X 1"
69
1
LABEL, ID, GM3500, FRONT
183-519
70
2
RIVET.BLIND
102-556
71
1
183-037 HANGAR, PAIL
2
108-662 NUT, RETAINER
72
107-21 0 CAPSCREW, SCH; 3/6-16
73
4
U N Q A X 1-1/2"
4
74
106-115 LOCKWASHER, SPRING; 3/8"
1
179-959 COVER, PRESSURE CONTROL
76
1
77
183-51 8 LABEL, ID, GM3500. SIDE
2
79
100-016 LOCKWASHER, SPRING,114"
100-133 LOCKWASHER, SPRING;,375
80
86
THROAT SEAL LIQUID,8OZ.
206-994
87
164-672 ADAPTER, 1/4-18 NPSM X 318 NF'T
88
183-035 BRACKET'
LABEL, WARNING
92
177-762
~
"
~
~.
~
1
FIELD
PIN, DOWEL: 5/16 X1"
1
CAPSCREW,'1/4 SCH;
4
5/16-24X 1"
9
100-21 4 LOCKWASHER, 5/16
5
100-644 CAPSCREW, SCH; 1/4-20
10
11
UNC3A X . 7 5
17
11
105-51 0 LOCKWASHER. SPRING: 1/4"
,4
l o a 8 0 1 SETSCREW, 1 / 4
12
1
183-401 KEY, PARALLEL;3/16 SO X 7/8"
13
102-547 CAPSCREW, HEX HD; 5/16-18
14
2
UNG2A X ,875"
100-469 CAPSCREW, HEX HD;
15
1
3/8-16 UNG2A X . 7 5
6
16
108-803 SCREW, HEX SOC HD
17
1
179-885 LABEL, WARNING, HP
1
221442 GEARREDUCER
18
19
PINION & PINION HOUSING
1
SEE PARTS LIST ON PAGE 33
DRIVE HOUSING
222-203
20
1
INCLUDES ITEMS 20a- 2Oc
1~
20a 178-967 .WASHER, BRONZE
1
20b 107-089 .WASHER. SILVER
1
2oc 107-327 .GREASE, 10 0 2 TUBE
1
21
218-035 BEARING HOUSING
1
22
218-034
1
179-899 COVER, HOUSING
23
107-21 8 CAPSCREW. SCH:1/4-20 X 2.75"
2
24
1
25
176-818 PIN
,,
1
26
176-817 SPRING, RETAINING
1
27
176-941
NUT. HEX
218-347
D~SPLACEMENT PUMP
28
SEE 307-793 FOR PARTS
1
SEE PAGE 35 FOR REPAIR KIT
1
221-183
CONDUCTOR, ELECTRICAL
29
30
180-573 TUBE, SUCTION,5 GAL.;3/4" PIPE 1
1
31
181472 STRAINER
32
108-868 CLAMP
2 .
109-033 SCREW, MACH, SLOTTED,
33
2
BDGH: 6-32 X 311 6
1
108-851 WASHER, PLAIN; TYPE."8";3/8"
34
1
35
222-01 8 CART
1
220-91 8 HANDLE & HOSE RACK
36
2
37
183-350 WASHER, PLAIN, 0.90"
2
38
108-691 PLUG, TUBING
39 109-032
SCREW, MACH, TYPE11;
Parts List& Drawing continuedon the next page.
RECESS PNH; SELF-TAP " F
NO. 10-24 X 1/ 4
4 'Extra warning labels available free
of charge.
I
. .
307-893 31
PARTS LIST& DRAWING
REF
NO. PART NO. DESCRIPTION QTY
94
214-701
95
210-541
96
220-9955
HOSE, GROUNDED, NYLON;3/16"ID;
CPLD 1/4 NPSMIFI: 3 FT 10.9 MI:
SPRING GUARDS'BOTH ENDS"
1
HOSE, GROUNDED, NYLON; 1/4"ID;
CPLD 1/4 NPSM(FBE); 50 FT (15 M);
SPRING GUARDS BOTHENDS
1
CONTRACTOR SPRAY GUN;
INCLUDES RAC IV DRIPLESS TIP
GUARD AND 517 SIZE SWITCHTIP.
SEE 307-614 FOR PARTS
1
94
32 307-893
PARTS LIST
Ref No. 19
Pinion and HousingAssembly
REF
NO. PART NO. DESCRIPTION
19a
19b
19c
19d
19e
191
221-043 PINION SHAFT ASSEMBLY
INCLUDES ITEMS 19b- 19f
183-681 .SHAFT, PINION
109401 .BEARING, NEEDLE
109-002
.BEARING. BALL
108-860 .RING, RETAINING, EXTERNAL
183-515 .HUB, ARMATURE
QTY
1
1
1
1
1
1
NOTE: Items 19g to 19n are not included
in a kit. Order
them separatelyas needed.
199 105-684
BEARING, BALL. LARGE
19h 107-088
BEARING. BALL, SMALL
19j
100-069 BALL, SST
19k 109+00 RING, RETAINING, INTERNAL
19m 105-489 .PIN, DOWEL
19n 183-516 HOUSING, PINION
1
1
1
1
2
1
19e
307-893 33
~~
PARTS LIST
PRESSURE CONTROL
Part No. 221439
Includes items 300 to 31 4
REF
REF
300 221-033 BASIC PRESSURE CONTROL 1
INCLUDES REPLACEABLE
ITEMS 301 TO 305
1
301 183466' .LABEL. WARNING
302 105-679 .ON/OFF SWITCH
1
303 105-659 .BOOT, ON/OFF SWITCH
1
304 107-255 .GUARD, LOCKING
1
305 157-021 LOCKWASHER, NO.
8, INT.
2
306 100-284
NUT, HEX, MSC,6-32 UNC-2A
1
RECTIFIER, BRIDGE
307 108-219
.1
308 220-979
CONDUCTOR, ELECTRICAL, RED 3
309 220-978
NO. PART NO. DESCRIPTION QTY
~~
~~
~~~
~~~~
302
34 307-893
NO. PART NO. DESCRIPTION
310
100-035
31 1
108-783
312
162453
313
314
108852
100440
~
~~
CONDUCTOR, ELECTRICAL
RED, WHITE, BLACK 1
SCREW, MACH, SLOTTED
PAN HD; NO.8 X 5/16" 1
SCREW, MACH, FLAT HD
NO. 8-32 UNC-2A X ,812"
NIPPLE. HEX: 1/4 NPSM X
114 NPT, 1-3/iv LONG
CONNECTOR, 45O
ELBOW, STR. 1/4-18 NPT (M X F)
'Extra warning labels availablefree
QTY
1
2
1
2
ACCESSORIES
TECHNICAL DATA
DISPLACEMENT PUMP REPAIRKIT 220-845
Repair instructions included.
Engine . . . . . . . . . . . . . . . . . . .3.5 horsepower,Honda
Maximum Working Pressure . . . . . 3000 psi (210 bar)
Fuel Tank Capacity . . . . . . . . . 0.66 gallons (2. 5liter)
Maximum tip Size. . . . . . . . . . . . . 1 gun with0.031 tip
2 guns with0.021 tips
Inlet Paint Strainer. . . . . . . . . 16 mesh, (1 190micron)
Stainless Steel Screen, reusable
Outlet Paint Filter. . . . . . . . . . . 60 mesh (250 micron)
Stainless Steel Screen, reusable
,314 npt(m)
Pump Inlet Size .....................
Fluid Outlet Size. . . . . . . . . . 1/4 npsm from fluid filter
Wetted Parts:
Displacement Pump . . . . . . Stainless steel,PTFE
Carbon steel, Leather,
UHMW polyethylene, Brass, Copper
Filter . . . . Aluminum, Carbon steel, Stainless Steel,
SUCTION TUBE KITS
For Upright cartGM3500 Sprayers
Kit 208-920 5 gallon (19 liter)-size
Includes:
REF
NO. PART NO. DESCRIPTION QTY
1
2
101-618
160-327
3
4
176705
170-706
.~~
170-957
181-072
5
6
CLAMP, HOSE
UNION, 90 DEG SWIVEL:
3 4 NPT(M X F)
ADAPTER, INTAKE
HOSE, 1"ID X 48"; NYLON
TUBE, SUCTION
STRAINER
NOTE: PTFE s a registered trademarkof the
Company.
DIMENSIONS
MODEL 231-078
Kit 208-259
Includes:
REF
NO. PART
Weight (dry w/o packaging). . . . . . . . . . . 109 Ib (49 kg)
30.25 in. (768mm)
Height. ......................
29.5 in. (749 mm)
Length .......................
22.25 in. (565 mm)
Width .......................
55 gallon (200 liter) size
NO.
1
156-589
2
214-961
3
156-59 1
DESCRIPTION QTY
4
156-593
5
100-220
THUMBSCREW, 5116-18x 1"
6
176-684
ADAPTER, BUNG
7
156-592 TUBE, RISER
8.
159-100 RETAINER, SCREEEN
SCREEN, FILTER
9
161 -377
10 159-101
NUT, SCREEN RETAINER
1
1
1
1
1
1
1
1
1
t
THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
Graco warrantsall equipment manufacturedit and
by bearing its name tofreefromdefectsin
be
materialand
workmanship on the dateof sale by an authorized Graco distributor to the original purchaser for use. As
purchaser's sole remedy for breach
of this warranty, Gracowill, for a period of twelve months from theof date
sale, repair or replace any art
of the equipment provendefective,with the exceptionof defects in parts on
the drive train$ear box on M and GM sprayers or power trainEHon
& GH s rayers, whichwill be repaired
or replacedfortwenty-four months from the date of for
sale
Gas-H draulic ( H) and Gas Mechanical (GM)
s rayers and for thirty-six monthsfrom the date
of sale for Electric- echanical (EM) and Electric-Hydraulic
(kiJ Sprayers. This warranty applies only when the equipment
is installed, operated and maintained in accor ance wlth Graco'swritten recommendations.
E
\Ir
l
This warranty does not cover, and Graco
shall not be liable
for, any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate
or improper maintenance, negligence,
accident, tampering, or substitution
of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused b the incompatibility with Graco equipment
of structures, accessories, equipment or materials not supplie
CY by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warrantyis conditioned upon the repaidreturn of the equipment claimed to be defective to an authorked Gracodistributorfor verificationo6he claim. If the claimed defectis verified, Gracowill repair or replace
free of charge any defective
parts. The equipmentwill be returned to the original purchaser transportation
repaid. If inspection of the equipment does not disclose any defect
in material or workmanship,repairswill
ge made at a reasonable charge, which charges may include theofcosts
parts, labor and transportation.
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASERS SOLE AND EXCLUSIVE REMEDY AND ARE IN
LIEU OF ANY OTHER WARRANTIES (EXPRESS
OR IMPLIED), INCLUDINGWARRANTYOF MERCHANTABILITY
OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE,AND OF ANY NON-CONTRACTUAL LIABILITIES.
INCLUDING PRODUCT LIABILITIES,BASED ON NEGLIGENCEOR STRICT LIABILITY. EVERY FORM OF LIABILI N FOR DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED.INNOCASESHALLGRACOSLIABILITYEXCEEDTHEAMOUNTOFTHEPURCHASEPRICE.ANYACTlON
FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO (2) YEARS OF THE DATE OF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANTY.
.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED
WARRANTIESOFMERCHANTABlLliYAND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR
COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by
Graco (suchas electric motor, switches, hose, etc.) are subject to the warranty,ofiftheir
any,
manufacturer.
Graco will provide purchaserwith reasonable assistance in making any claim forofbreach
these warranties.
'
Factory Branches:Atlanta, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies:
Canada; England; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1444
PRINTED INU.S.A. 307493 3-88
36 307-893
-~
/