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Graco GM3500 Instructions-Parts List Manual

Airless paint sprayer
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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
4.0 HORSEPOWER, GASOLINE-POWERED
GM3500
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Model 231–579, Series A
Basic Sprayer with Lo-Boy Cart
Model 231–077
Same as 231–579, with hose and gun, RAC IV
Dripless
Tip Guard, and 517 size SwitchTip
Model 231–578, Series A
Basic Upright Sprayer
Model 231-057
Same as 231–578, with hose and gun, RAC IV
Dripless
Tip Guard, and 517 size SwitchTip
CAUTION
Always use a minimum hose length of 50 foot
(15 m) 1/4 inch ID or 50 foot (15 m) 3/8 inch ID. An
undersized hose may result in poor equipment
performance and damage to the clutch.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Airless Paint Sprayer
Graco Inc. is registered to I.S. EN ISO 9001
308–709
Rev. B
Supercedes Rev. A
Model 231-057 Shown
0136C

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Summary of Contents for Graco GM3500

  • Page 1 (15 m) 1/4 inch ID or 50 foot (15 m) 3/8 inch ID. An undersized hose may result in poor equipment performance and damage to the clutch. Model 231-057 Shown 0136C GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    Read all instruction manuals, tags, and labels before operating the equipment. Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. Do not alter or modify this equipment. Use only genuine Graco parts.

  • Page 3: Warnings

    WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin may look like just a cut, but it is a serious injury.

  • Page 4: Fire And Explosion Hazard

    WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. If there is any static sparking or you feel an electric shock while using this equipment, stop spray- ing immediately.

  • Page 5: Component Identification And Function

    Component Identification and Function 0015A 06905 Fig. 1 Pressure Control Switch ON/OFF, enables/disables clutch function Pressure Adjusting Knob Controls fluid outlet pressure Air Cleaner* Filters air entering the carburetor Fuel Tank* Holds 0.66 gallons (2.5 liters) of [(R+M)/2]; 86 octane gasoline Muffler* Reduces noise of internal combustion Spark Plug Cable*...

  • Page 6: Setup

    3. Two gun hookup. Unscrew the cap (L) from the secondary hose outlet. Connect an accessory hose and gun to the 1/4 npsm(m) nipple. 4. Fill the packing nut/wet-cup (216) 1/3 full with Graco Throat Seal Liquid (TSL), supplied, and keep it filled, to help extend the pump life.
  • Page 7 Setup 5. Check the engine oil level. Refer to the Honda 11. Keep the sprayer upright and level during engine manual, supplied. This is a summary of the operation and whenever it is being moved. Read information: Remove one of the oil fill plugs; (C) the last CAUTION on page 10.

  • Page 8: Fueling

    Fueling 2. Gasolines containing alcohol (gasohol). Do not WARNING use gasohol which contains methanol, if the gaso- hol does not contain cosolvents and corrosion Gasoline is extremely flammable and explosive inhibitors for methanol. Even if it does contain such under certain conditions. To reduce the risk of a fire additives, do not use the gasohol if it contains or explosion: more than 5% methanol.

  • Page 9: Startup

    Startup NOTE: Refer to Fig. 1 as you start the sprayer. 7. To start the engine: a. Turn the pressure adjusting knob (B) all the NOTE: When starting a sprayer that IS NOT PRIMED, way counterclockwise to the lowest pressure remove the spray tip.
  • Page 10 Startup 9. To start the pump: CAUTION a. Open the pressure drain valve (V). Always use the lowest needed fluid pressure and the lowest needed throttle (J) setting, to increase the life b. Turn the pressure control switch (A) to ON. of the sprayer.

  • Page 11: Maintenance

    Maintenance AFTER THE FIRST 20 HOURS OF OPERATION WARNING AND EACH 100 HOURS THEREAFTER: Change the oil. To reduce the risk of serious bodily injury always follow the Pressure Relief Procedure Warning on WEEKLY: Remove the air filter cover and clean the page 12 before checking, adjusting, cleaning or element.

  • Page 12: Flushing

    Pressure Relief Procedure 1. Engage the gun safety latch. WARNING 2. Turn the engine switch to OFF. 3. Move the pressure control ON/OFF switch to OFF. INJECTION HAZARD 4. Disengage the gun safety latch. Hold a metal part The system pressure must be manually of the gun firmly to a grounded metal pail.

  • Page 13: Suction Tube Storage

    Flushing 5. Start the sprayer. See page 10. To save the fluid in CAUTION the sprayer, trigger the gun into another container until the next fluid appears, then trigger the gun NEVER allow water to freeze in the pressure control. back into the fluid you are pumping.

  • Page 14: Troubleshooting

    See Fig. 1, page 5. Water frozen in pressure control Return pressure control to authorized Graco dealer for repair. Engine won’t “pull over” Oil seepage into combustion Remove spark plug. Pull starter rope 3 or chamber 4 times.
  • Page 15 Troubleshooting PROBLEM CAUSE SOLUTION Displacement pump output Pump inlet screen clogged Clean. low on upstroke Piston ball check not seating Service piston ball check. See page 18. Piston packings worn or damaged Replace packings. See page 18. Sleeve gasket in displacement Replace.

  • Page 16: Pressure Control Replacement

    Pressure Control Replacement WARNING FIL- INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 12. 1. Relieve pressure. To the pump. To the filter. 2. Disconnect the pressure control while holding the fitting or elbow (A) firmly.

  • Page 17: Displacement Pump

    (27) to 90 5 ft-lb (120 7 N m). 221* 4. Tighten the packing nut (216) only enough to stop leaking. Fill the nut 1/2 full with Graco TSL. 5. Assemble the remaining parts. 204* 202* Face of bear-...

  • Page 18: Bearing Housing And Connecting Rod

    Bearing Housing and Connecting Rod WARNING CAUTION To reduce the risk of serious bodily injury always Use only the locating pins (F) to align or seat the follow the Pressure Relief Procedure Warning on bearing housing (21) with the drive housing (20). page 12 before checking, adjusting, cleaning or shutting down the sprayer.

  • Page 19: Drive Housing

    Drive Housing WARNING CAUTION To reduce the risk of serious bodily injury always DO NOT drop the gear cluster (18) when removing follow the Pressure Relief Procedure Warning on the drive housing (20). The gear cluster is easily page 12 before checking, adjusting, cleaning or damaged.

  • Page 20: Pinion, Clutch, Clamp, Field & Engine

    Pinion, Clutch, Clamp, Field & Engine Disassembling these parts can start from the pinion If starting from the pinion housing, first follow Steps housing or from the clutch, if no pinion service is 1 to 6 of Drive Housing, on page 19, and then needed.
  • Page 21 Pinion Housing Lubricate inner and outer diameters Detail A Lubricate teeth Directional arrow on roller clutch must face the small bearing (19c) Lubricate exterior Back is shown Press fit small bearing (19c) and clutch roller (s) here Fig. 14 Repairing the Pinion Round steel bar to NOTE: Use a hydraulic press if you purchase the push on shaft (19b)

  • Page 22: Clutch

    Clutch NOTE: The clutch assembly (4) includes the armature 3. Remove the bottom two screws (10) from the (4a) and rotor (4b). The armature and rotor must be clutch housing (2) and then the top three screws. replaced together so they wear evenly. 4.

  • Page 23: Engine

    Engine NOTE: The engine must be removed before the Field, 3. Lift the engine carefully and place it on a work Clamp or Clutch Housing can be removed. bench. 1. Working under the mounting plate (A) of the cart, remove the screw (15) which holds the clutch 4.

  • Page 24: Field & Wiring Harness

    Field & Wiring Harness NOTE: Refer to Fig. 19. 3. Pull the plastic caps (B) off the wire screws (33) in both places on the field. Loosen the screws and release the wires (29). 1. Remove the engine from the cart. See page 23. 4.

  • Page 25: Clamp

    Clamp NOTE: A standard steering wheel puller is required to remove the clamp. Two 1/4–28 x 3 or 4 in. long screws are also needed. NOTE: Refer to Fig. 20. 1. Loosen the two screws (16) on the clamp (3), working through the slot at the bottom of the clutch housing (2).

  • Page 26: Reassembly

    Reassembly 1. Install the clutch housing (2), capscrews (8) and Torque oppositely and evenly to lockwashers (9) on the engine. Torque the caps- 3 in-lb (3 .33 N m) crews (8) to 200 10 in-lb (23 1.1 N m). Slot See Fig.
  • Page 27 Reassembly 7. Be sure the face of the rotor (4b) and the field are 9. Clean the face of the armature (4a). With the flat free of all oil and contaminants. Remove any burrs side of the armature facing the rotor (4b), slide the on the outside edge of the rotor.
  • Page 28 Parts – Basic Lo-Boy Cart Model 231–579 Handle Detail Ref 36 Ref No. 19 Label See detail above See page 33 for parts See manual 307–806 parts See manual 307–273 parts 33 29 11 16 88, 73 Ref 55...
  • Page 29 Parts – Basic Lo-Boy Sprayer Model 231–579 Part No. Description Part No. Description 108–879 ENGINE, gasoline 238–187 CART HANDLE & HOSE RACK 183–512 HOUSING, clutch 183–350 WASHER, plain, 0.90 in. 183–517 CLAMP, mounting, rotor 108–691 PLUG, tubing 221–044 CLUTCH ASSEMBLY 108–868 CLAMP Includes items 4a and 4b...
  • Page 30 Parts – Basic Upright Sprayer Handle Detail Model 231–578 Ref 36 Ref No. 19 Label See detail above See page 33 for parts Ref 55 See manual 307–806 parts See manual 307–273 parts 50,73 Ref 55...
  • Page 31 Parts – Basic Upright Sprayer Model 231–578 Part No. Description Part No. Description 108–879 ENGINE, gasoline 192–027 SLEEVE 183–512 HOUSING, clutch 106–062 WHEEL, semi–pneumatic 183–517 CLAMP, mounting, rotor 101–242 RING, retaining 221–044 CLUTCH ASSEMBLY 104–811 HUBCAP Includes items 4a and 4b 100–020 LOCKWASHER, spring, 3/16 in.

  • Page 32: Pinion Assembly

    Sprayer with Lo–Boy Cart Includes items 121 to 124 Part No. Description 231–578 GM3500 Basic Upright Sprayer See parts list on page 31 223–541 HOSE, grounded, nylon, 1/4 in. ID, cpld 1/4 npsm(f), 50 ft (15 m),’ spring guards both ends 214–701...

  • Page 33: Pressure Control

    Parts List – Pressure Control Basic Pressure Control for the GM3500 Sprayers Part No. Description Part No. Description 112–373 KNOB 239–056 ENGINE CONTROL BOARD 185–565 LABEL 107–251 SCREW, panhead, 10–24 x 1 inch 237–674 CONDUCTOR 112–610 SCREW, panhead, 10–24 x 2 inch 109–078...

  • Page 34: Accessories

    Description drawing below shows the best placement of these 156–589 UNION, 90 ADAPTER, 3/4 npt(f) x labels for good visibility. 3/4 np(f) swivel Order the labels directly from Graco, free of 214–961 HOSE, coupled 3/4 npt(mbe) charge. Toll Free: 1–800–328–0211 3/4 in.

  • Page 35: Technical Data

    ......22.25 in. (565 mm) Graco Phone Number TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you: 1–800–328–0211 Toll Free.

  • Page 36: Graco Warranty

    Graco distributor to the original purchaser for use. With the exception of any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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