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Graco GM 3500 Instructions-Parts List Manual

Airless paint sprayer
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INSTRUCTIONS-PARTS LIST
3.5 HORSEPOWER, GASOLINE-POWERED
GM 3500
AIRLESS PAINT SPRAYER
3000 psi (210 bar) MAXIMUM WORKING PRESSURE
LO-BOY CART
Model 222-028, Series F
Basic Sprayer
Model 231-077
Complete sprayer, with hose and gun, RAC IV
Dripless
Tip Guard, and 517 size SwitchTip
UPRIGHT CART
Model 221-040, Series F
Basic Sprayer
Model 231-057
Complete sprayer, with hose and gun, RAC IV
Dripless
Tip Guard, and 517 size SwitchTip

TABLE OF CONTENTS

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NOTE: This is an example of the DANGER label on your sprayer.
This label is available in other languages, free of charge.
See page 38 to order.
Spray painting, flushing or cleaning equipment with flammable liq-
uids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip-
ment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga-
rettes, arcs from connecting or disconnecting power cords or turn-
ing light switches on and off.
Failure to follow this warning can result in death or serious injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
This manual contains IMPORTANT
WARNINGS and INFORMATION
READ AND RETAIN FOR REFERENCE
2
8
9
10
11
12
13
14
30
38
39
39
40
FIRE AND
EXPLOSION HAZARD
COPYRIGHT 1988, GRACO INC.
Liquids can be injected into the body by high pressure airless spray
or leaks - especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental trig-
gering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In
case
of
accidental
"Surgical Treatment".
Failure to follow this warning can result in amputation or serious
injury.
307-863
Rev H
Supersedes G and PCN H
MODEL 231-057 SHOWN
SKIN INJECTION
HAZARD
skin
injection,
seek
immediate

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  • Page 1: Table Of Contents

    Failure to follow this warning can result in death or serious injury. Failure to follow this warning can result in amputation or serious injury. READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 COPYRIGHT 1988, GRACO INC.

  • Page 2: Warnings

    WARNINGS HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals before operating the equipment. FLUID INJECTION HAZARD Safety Latch General Safety This equipment generates very high fluid pressure. Spray from Whenever you stop spraying, even for a moment, always set the the gun, leaks or ruptured components can inject fluid through gun safety latch in the closed or “safe”...
  • Page 3 DO NOT expose Graco hoses to tempera- ALL FLUID HOSES MUST HAVE STRAIN RELIEFS ON BOTH tures above 180 F (82 C) or below –40 F (–40 C).
  • Page 4 AVERTISSEMENT La pulvérisation à haute pression peut causer de blessures très graves. Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité. Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel. RISQUES D’INJECTION Consignes générales de sécurité Verrou de sécurité...
  • Page 5 RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL Consignes générales de sécurité TOUS LES TUYAUX FLEXIBLES DOIVENT AVOIR DES RES- SORTS SPIRALE DE PROTECTION AUX 2 BOUTS! Les spira- toute utilisation anormale de l’appareil du pulvérisation ou des les de protection contribuent à éviter la formation de pliures, de accessoires comme, par exemple, la mise sous une pression boucles ou de nœuds sur les tuyaux qui pourraient entraîner la excessive, les modifications de pièces, l’utilisation de produits...
  • Page 6 ADVERTENCIA EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES. SOLO PARA USO PROFESIONAL. RESPECTE LOS AVISOS DE ADVERTENCIA. Lea y entienda todo el manual de instrucciones antes de manejar el equipo. PELIGRO DE INYECCION DE FLUIDO Seguridad general Aparatos de seguridad de la pistola pulverizadora Este equipo general un fluido a una presión muy alta.
  • Page 7 PELIGRO POR MAL USO DEL EQUIPO Seguridad general Presión del sistema Cualquier mal uso del equipo pulverizador o los accesorios, tal Esta pulverizadora puede desarrollar 210 barías (3000 psi) de como sobre presurización, modificación de piezas, uso de ma- PRESION DE TRABAJO MAXIMA. Asegurar que todo el equipo teriales y productos químicos incompatibles, o utilización de pie- pulverizador y sus accesorios tienen la capacidad para aguan- zas dañadas o desgastadas, puede hacen que se rompan y...

  • Page 8: Setup

    4. Always use the main filter outlet for one gun operation. Never plug this outlet. 3. Fill the Packing Nut/Wet–Cup 1/3 full with Graco Throat Seal Liquid (TSL), supplied, and keep it filled, to help ex- tend the pump life. Fig 8–1...

  • Page 9: Fueling

    SETUP 4. Check the engine oil level. Refer to the Hon- da engine manual, supplied. This is a summa- ry of the information: Remove one of the oil fill plugs; the oil should be almost overflowing. GAS FILL CAP See Fig 9–1. Add oil as necessary. Recommended lubrication oil: Use a high–qu- ality, detergent oil, SAE 10W–40, classified “FOR SERVICE SE or SF”, for regular use...

  • Page 10: Startup

    START UP NOTE: Refer to Fig 11–1 as you start the sprayer. 8. Disengage the gun safety latch. NOTE: When starting a sprayer that IS NOT PRIMED, 9. To start the pump: remove the spray tip. a. Open the pressure drain valve. 1.

  • Page 11: Maintenance

    START UP STARTER ROPE PRESSURE CONTROL ON/OFF SWITCH PRESSURE ADJUSTING KNOB GAS FILL CAP ENGINE OIL LIGHT CLUTCH ENGINE ON/OFF SWITCH THROTTLE LEVER GRAY CHOKE LEVER BLACK FUEL PAIL HANGER SHUTOFF LEVER SPARK PLUG MAIN HOSE CABLE SUCTION TUBE GUN SAFETY LATCH SHOWN ENGAGED GUN SAFETY...

  • Page 12: Flushing Guidelines

    FLUSHING GUIDELINES NOTE: Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be sprayed, or to store the sprayer. Use this chart to determine the required flushing order for the fluid you are using, and then follow the procedure below for flushing.

  • Page 13: Troubleshooting Guide

    Connect cable on top of engine or replace spark spark plug damaged plug. 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 4 times.
  • Page 14 PROBLEM CAUSE SOLUTION Displacement pump output low on Pump inlet screen clogged Clean. 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 pump Replace.
  • Page 15 PRESSURE CONTROL REPLACEMENT WARNING 2. Working under the engine mounting plate of the cart, disconnect the red, black and white wires. For the Up- To reduce the risk of serious bodily injury, always follow the Pressure Relief Procedure Warning on right cart, remove the three nuts (61) and lockwash- page 13 before repairing the sprayer.
  • Page 16 PRESSURE CONTROL REPLACEMENT 5. Disconnect the red, black and white wires from the 8. Reassemble in the reverse order. rectifier (307) which are sheathed with the conductor (309). Unscrew the connector (313 or 105) from the For the Upright carts, guide the new pressure control control box, pulling the conductor and wires out with wires through the wire clamps (32).
  • Page 17 PRESSURE CONTROL CALIBRATION WARNING USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury, which can result from component rupture, electric shock, fire, explosion or moving parts. This procedure sets the sprayer to 2600–3000 psi NEVER attempt to increase the fluid outlet pressure (182–210 bar) MAXIMUM WORKING PRESSURE.
  • Page 18 DISPLACEMENT PUMP WARNING To reduce the risk of serious bodily injury, always fol- low the Pressure Relief Procedure Warning on page 13 before repairing the sprayer. Removing the pump. See Fig 18–1. 1. Flush the pump. Relieve pressure. 2. Hold the intake valve (223) with a wrench and unscrew the suction tube (30).
  • Page 19 222–586 to remove 204* (1.2 N.m.) to seat the sleeve. If the sleeve is stuck, send the cylinder the packings, and to your Graco distributor for removal. APPLY ONE then back off and fin- DROP ger tighten.
  • Page 20 4. Tighten the packing nut (216) only enough to stop ing (21). Hold the pin (25) up to the pin hole in the con- leaking. Fill the nut 1/2 full with Graco TSL. necting rod (22) and continue screwing in the pump until the pin slides easily into the hole.
  • Page 21 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 13 before repairing the sprayer. damaged.
  • Page 22 PINION, CLUTCH, CLAMP, FIELD & ENGINE If starting from the clutch , see page 24. Disassembling these parts can start from the pinion hous- ing or from the clutch, if no pinion service is needed. If starting from the pinion housing , first follow Steps 1 to 6 of DRIVE HOUSING, on page 21, and then continue with the procedure below.
  • Page 23 PINION HOUSING DETAIL A CUTAWAY VIEW OF PINION HOUSING (19n) BACK OF PINION HOUSING (19n) PRESS FIT Lubricate inner SMALL BEARING (19c) Lubricate teeth outer diameters AND CLUTCH ROLLER (S) HERE Directional arrow on roller clutch must face the small bearing (19c) Lubricate Lubricate inner and exterior...
  • Page 24 CLUTCH NOTE: The clutch assembly (4) includes the armature 3. Remove the bottom two screws (10) from the clutch (4a) and rotor (4b). The armature and rotor must housing (2) and then the top three screws. be replaced together so they wear evenly. 4.
  • Page 25 ENGINE NOTE: The engine must be removed before the Field, Clamp or Clutch Housing can be removed. 1. Working under the mounting plate (A) of the cart, remove the screw (15), lockwasher (80) and washer (34) which hold the clutch housing (2) to the cart.
  • Page 26 FIELD & WIRING HARNESS NOTE: Refer to Fig 26–1. 3. Pull the plastic caps (B) off the wire screws (33) in both places on the field. Loosen the screws and re- lease the wires (29). 1. Remove the engine from the cart. See page 25. 4.
  • Page 27 CLAMP CLUTCH HOUSING NOTE: A standard steering wheel puller is required to re- NOTE: Refer to Fig 27–2. move the clamp. Two 1/4–28 x 3 or 4 in. long screws are also needed. 1. Remove the four capscrews (8) and lockwashers (48) which hold the clutch housing (2) to the engine (1).
  • Page 28 REASSEMBLY To check the dimension, place a rigid, straight steel bar (B) across the face of the clutch housing (2). Use an accurate measuring device to measure the dis- tance between the bar and the face of the clamp. Ad- just the clamp as necessary.
  • Page 29 REASSEMBLY 6. Be sure the face of the rotor (4b) and the field is free 7. Clean the face of the armature (4a). With the flat side of all oil and contaminants. Install the rotor, lock- of the armature facing the rotor (4b), slide the arma- washers (11) and capscrews (16).

  • Page 30: Parts

    PARTS DRAWING – BASIC LO-BOY SPRAYER Model 222–028, Series F 96 76 SEE PAGE 36 77,92 GM3500 Basic Sprayer FOR PARTS LABELS with Lo–Boy Cart DANGER LABEL Ref No. 19 SEE PAGE 34 FOR PARTS LABEL LABEL SEE PAGE 35 FOR PARTS Ref 30h 01450...
  • Page 31 PARTS LIST – BASIC SPRAYER Model 222–028, Series F GM 3500 Basic Sprayer with Lo–Boy Cart NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 108–879 ENGINE, gasoline 101–242 RING, retaining 183–512 HOUSING, clutch 104–811 HUBCAP 183–517 CLAMP, mounting, rotor 154–636 WASHER, 5/8”...
  • Page 32 PARTS DRAWING – BASIC SPRAYER Model 221–040, Series F Handle Detail GM3500 Basic Sprayer with Upright Cart Ref 36 DANGER LABEL Ref No. 19 SEE PAGE 34 FOR PARTS 92,77 LABEL LABELS Ref 59B SEE PAGE 36 FOR PARTS LABEL SEE PAGE 35 FOR DETAIL...
  • Page 33 PARTS LIST – BASIC SPRAYER Model 221–040, Series F GM 3500 Basic Sprayer with Upright Cart NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 108–879 ENGINE, gasoline 104–008 LOCKWASHER 183–512 HOUSING, clutch 100–078 SCREW, pan hd, No. 8 x 5/16”...
  • Page 34 PARTS LIST & DRAWING – COMPLETE SPRAYER MODEL 231–057 GM3500 Airless Paint Sprayer with Upright Cart Includes items 120 to 123 MODEL 231–077 GM3500 Airless Paint Sprayer with Lo–Boy Cart Includes items 121 to 124 NO. PART NO. DESCRIPTION 221–040 GM3500 Basic Upright Sprayer See parts list on page 33 223–541...
  • Page 35 PARTS LIST & DRAWING – DISPLACEMENT PUMP Model 222–580, Series A Sleeved Displacement Pump Includes items 202 to 225 NO. PART NO. DESCRIPTION 108–526* PACKING, o–ring 107–093* SEAL, u–cup, poly 105–445* BALL 179–810 PLUG 178–939* V–PACKING, leather 178–940* V–PACKING, leather 178–942* GLAND, male *209...
  • Page 36 PARTS LIST & DRAWING – PRESSURE CONTROL Part No. 222–369 – Replacement Pressure Control forAll GM3500 Sprayers Part No. 222–369 includes all items marked with a . It does not include unmarked items. For Upright sprayers, order the Basic Control, 222–369, and/or items 309, 312, 313, and 314 as needed. For the Lo–Boy sprayers, order the Basic Control, 222–369, and items 309 and/or 322 as needed.
  • Page 37 Pressure Control For Upright Sprayers 311,305 ,306 WHITE BLACK RECTIFIER (307) CONNECTIONS 310 ,305 BLACK Pressure Control for Lo–Boy Sprayers 311,305 ,306 WHITE GROUND Ref 309 BLACK WHITE 310 ,305 TOP VIEW OF PRESSURE CONTROL ON LO–BOY CART...

  • Page 38: Accessories

    160–327 UNION, 90 swivel; 3/4 npt(m x f) visibility. 170–705 ADAPTER, intake Order the labels directly from Graco, free of 170–706 HOSE, 1” ID x 48”; nylon charge. Toll Free: 1–800–328–0211 170–957...

  • Page 39: Technical Data

    Inlet Paint Strainer ... . 16 mesh (1190 micron) nated hydrocarbons, contact Graco Product Ser- Stainless Steel screen, reusable vice, at 1–800–328–0211. DIMENSIONS Model 220–040...

  • Page 40: Warranty

    Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for twenty–four months from the date of sale and...

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