Graco GM3000, GM3000 231551, GM3000 231550, GM3000 231552, 231363 Instructions-parts List Manual
...
INSTRUCTIONS-PARTS LIST
308620
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GM3000 Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Model 231363, Series B
Basic Sprayer with Upright Cart
Model 231551
Same as 231363, with hose and gun, RACr X
HandTitet Tip Guard, and 517 size SwitchTipt
Model 231550, Series B
Basic Sprayer with Lo–Boy Cart
Model 231552
Same as 231550, with hose and gun, RACr X
HandTitet Tip Guard, and 517 size SwitchTipt
Rev. K
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.
06001B
Model 231363 Shown
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 16. . . . . .
Pressure Control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion, Clutch, Clamp, Field, & Engine 23. . . . . . . . . . .
Pinion Housing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness 27. . . . . . . . . . . . . . . . . . . . . . . . .
Clamp 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Clutch Housing 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 31. . . . . . . . . . . . . . . . . . . . .
Pressure Control Parts list 33. . . . . . . . . . . . . . . . . . . . . .
Upright Sprayer Parts Drawing 34. . . . . . . . . . . . . . . . . .
Upright Sprayer Parts List 35. . . . . . . . . . . . . . . . . . . . . .
Lo-Boy Sprayer Parts Drawing 36. . . . . . . . . . . . . . . . . .
Lo-Boy Sprayer Parts List 37. . . . . . . . . . . . . . . . . . . . . .
Parts List & Drawing – Complete Sprayers 38. . . . . . .
Pinion Assembly Parts list and Drawing 38. . . . . . . . . .
Accessories 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 39. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
equipment if you do not follow the instructions.
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 39 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Wear hearing protection when operating this equipment.
D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
3086202
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.
D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
D Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon dioxide which is colorless and odorless.
D Do not operate this equipment in a closed building.
308620 3
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.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Disconnect all electrical equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
D Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
D Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the sprayer.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.
NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of
charge. See page 39 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable
liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground
equipment, 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
cigarettes, arcs from connecting or disconnecting power cords
or turning 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
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
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
SKIN INJECTION
HAZARD
3086204
Component Identification and Function
T
L
S
Fig. 1
C
D
P
R
B
F
N
U
E
A
M
V
06001B
K
0015
J
H
G
0016
A Pressure Control Switch ON/OFF, enables/disables clutch function
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering the carburetor
D Fuel Tank* Holds 0.66 gallons (2.5 liters) of [(R+M)/2]; 86 octane gasoline
E Muffler* Reduces noise of internal combustion
F Spark Plug Cable* Routes electrical current to spark plug
G Fuel Valve* On/off valve to regulate fuel flow from gasoline tank to carburetor
H Choke* Enriches air/gasoline mixture for cold starting
J Throttle* Adjusts engine speed for large or small orifice spray tips
K Engine Switch* Enables/disables engine operation
L Fluid Outlet Hose and spray gun are connected here
M Pressure Control Controls clutch cycling to maintain fluid pressure.
N Engine* 4.0 HP gasoline engine
P Clutch Transfers power from engine to drive assembly
R Drive Assembly Transfers power from clutch to displacement pump
S Displacement Pump Provides fluid to be sprayed through spray gun
T Fluid Filter Filters fluid between source and spray gun
U Grounding Clamp and Wire Grounds sprayer system
V Pressure Drain Valve Relieves fluid pressure when open
* For more detailed explanations of these controls, refer to the Honda engine manual; supplied
308620 5
Setup
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and component
damage, follow these precautions.
1. Always use nylon spray hose. Never use a wire
braid hose; it is too rigid to act as a pulsation
dampener.
2. Fill packing nut/wetcup. Fill the packing nut/wetcup (A) 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. See Fig. 2.
3. Check the engine oil level. Refer to the Honda
engine manual, supplied. This is a summary of the
information: Remove one of the oil fill plugs (M);
the oil should be almost overflowing. See Fig. 3.
Add oil as necessary.
2. Always use a minimum hose length of 50 foot
(15 m) x 1/4 inch ID or 50 foot (15 m) x 3/8 inch
ID hose.
3. Never install any shutoff device between the filter
(21) and the main hose. See Fig. 2.
4. Always use the main filter outlet (20) for a one
gun operation. Never plug this outlet.
1. Connect hose and gun. (Refer to Fig. 2.)
a. Remove the plastic cap from the 1/4 npsm (m)
filter outlet nipple (20). Screw the main fluid
hose onto the nipple. Read the CAUTION,
above.
b. Connect the whip end hose between the main
fluid hose and the inlet adapter of the gun.
c. Do not use thread sealant, and do not install
the spray tip yet!
WARNING
Recommended lubrication oil: Use a high-quality,
detergent oil, SAE 10W–30, classified “FOR
SERVICE SG or SF”, for regular use and for
breaking–in a new engine.
21
A
46
20
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Maximum
Working Pressure. This is to reduce the risk of
serious injury caused by static sparking, fluid
injection or over-pressurization and rupture of the
hose or gun.
3086206
21 Fluid Filter
46 Pressure drain valve
20 1/4 npsm(m) fluid outlet
A Wetcup
Fig. 2
05832
Setup
4. Be sure your system is properly grounded
before operating it. Connect the sprayer to a true
earth ground with the grounding wire and clamp
(80) ; for example, a cold water pipe or a ground
rod driven into the earth.
5. Fill the gas tank. See Fueling, page 8.
6. Flush the pump to remove the lightweight oil
which was left in the pump to protect it from corrosion.
a. Before using water–base paint, flush with
mineral spirits, followed by soapy water, and
then flush with clean water.
b. Before using oil–base paint, flush with mineral
spirits, only.
c. See Flushing on page 13 for the flushing
procedure.
7. Prepare the paint according to the manufacturer’s
recommendations.
8. Keep the sprayer upright and level during
operation and whenever it is being moved. See the
CAUTION on page 10.
K
0015
L
a. Remove any skin that may have formed.
b. Stir the paint to mix the pigments.
c. Strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove the
particles that could clog the filter or spray tip.
This is probably the most important step
toward trouble–free spraying.
80
M
06906A
Fig. 3
308620 7
Fueling
WARNING
FIRE AND EXPLOSION HAZARD
Gasoline is extremely flammable and
explosive under certain conditions.
Always turn the engine switch (K) to off
before refueling. (Fig. 3)
Refuel in a well-ventilated area.
Do not smoke or allow flames or sparks in the area
where the engine is refueled or where the gasoline
is stored.
Do not overfill the tank. Make sure the gas fill cap
(L) is securely closed after refueling. (Fig. 3)
2. Gasolines containing alcohol (gasohol). Do not
use gasohol which contains methanol, if the gasohol does not contain cosolvents and corrosion
inhibitors for methanol. Even if it does contain such
additives, do not use the gasohol if it contains
more than 5% methanol or 10 % ethanol.
NOTE: The Honda engine warranty does not cover
the damage resulting from the use of gasolines containing a higher percentage of alcohol than mentioned
in step 2. See the Honda engine manual for more
information.
3. General. Do not use any oil and gasoline mixtures
or contaminated gasoline. Avoid getting any dirt,
dust or water in the fuel tank.
Be careful not to spill fuel when fueling. 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 gasoline
with a pump octane number of 86 or higher, or a
research octane number of 91 or higher. Unleaded
fuel minimizes the combustion chamber deposits.
4. Tank Capacity. 0.66 gallons (2.5 liters). Always
leave at least 1/2 in. (13 mm) at the top of the tank
for expansion.
5. Shut off the engine before refueling.
6. After refueling, tighten the fuel tank cap firmly.
3086208
Startup
Before You Start the Sprayer
1. See Flushing on page 12 to determine if you
should flush the sprayer.
2. Be sure the gas tank is full.
3. Check the engine oil level.
NOTE: The engine stops automatically, or will not
start, if it is low on oil. Refer to the oil fill procedure in
the Honda engine manual or to step 3, page 6.
4. Be sure the spark plug cable is firmly pushed
onto the plug.
Starting the Sprayer
NOTE: Refer to Fig. 1 as you start the sprayer.
1. When starting a sprayer that IS NOT PRIMED,
remove the spray tip.
2. Place the suction tube into the paint, water or
solvent container, depending on whether you are
flushing or are ready to spray.
3. Open the black fuel shutoff lever by pushing it in
the direction of the arrow.
4. Move the pressure control switch to OFF.
5. To start the engine:
a. Turn the pressure adjusting knob all the way
counterclockwise to the lowest pressure setting.
b. Slide the metal throttle lever away from the
fuel tank to maximum position (fully left).
c. If the engine is cold, close the choke by mov-
ing the gray lever.
d. If the engine is warm, close the choke by
moving the gray lever only half way or not at
all.
e. Turn the engine switch to ON.
WARNING
MOVING PARTS HAZARD
A rope which recoils too quickly may hit
someone and cause serious injury. The
rope could also jam in recoil assembly.
f. Hold the frame of the sprayer with one hand
and pull the starter rope rapidly and firmly.
Continue holding the rope as you let it return.
Pull and return the rope until the engine starts.
CAUTION
Never try to start the engine unless fluid pressure is
relieved and the pressure control switch is OFF.
Trying to start the engine when it is pressurized
could damage the recoil system.
g. Open the choke as soon as the engine starts,
except in cold weather. In cold weather, leave
the choke closed for 10 to 30 seconds before
opening it to keep the engine running.
6. Unlock the gun trigger safety.
308620 9
Startup
7. Prime the pump:
a. Place the suction tube in the bucket of paint,
water, or solvent.
b. Open the pressure drain valve.
c. Set engine speed to idle.
d. Move the pressure control switch to ON. Turn
the pressure adjusting knob slowly until the
sprayer starts.
e. Run the pump until fluid is flowing smoothly
from the pressure drain valve, indicating the
pump is primed.
f. Move the pressure control switch to OFF.
g. If the pump was primed with water or solvent,
remove the suction tube from the water or
solvent and place it in the paint. Repeat steps
b through f.
h. Close the pressure drain valve.
8. When the pump is primed:
h. Relieve pressure by opening the pressure
drain valve.
i. Close the pressure drain valve.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury from
fluid injection, never operate the spray
gun with the tip guard removed.
9. Install the spray tip in the gun. See the separate
tip instruction manual, 308–644, supplied.
10. Move the pressure control switch to ON.
11. Adjust the engine speed and pump pressure.
Unlock the gun trigger safety. Trigger the gun onto
a test paper to check the spray pattern and atomization. Turn the pressure adjusting knob until you
get a good pattern. Then slowly lower the throttle
setting as far as you can without changing the
spray pattern.
a. Remove the spray tip.
b. Set the engine speed to full flow.
c. Move the pressure control switch to ON. Turn
the pressure adjusting knob slowly until the
sprayer starts.
d. Unlock the gun trigger safety.
e. Trigger the gun into the pail until fluid flows
from the gun. If pumping solvent or solvent–
based paint, hold a metal part of the gun firmly
against a grounded metal pail.
f. Release the gun trigger and lock the gun
trigger safety.
g. Move the pressure control switch to OFF.
CAUTION
Always use the lowest needed fluid pressure and the
lowest needed throttle setting, to increase the life of
the sprayer. Higher settings cause excessive clutch
cycling, premature tip wear and premature pump
wear.
CAUTION
Close the black fuel shutoff lever 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 startup very difficult.
30862010
Startup
CAUTION
Operating the sprayer with the pump not primed can
lead to premature packing wear and/or damage to
the pump.
Maintenance
Loss of Prime to Pump
Introduction of air into the pump, either by changing
fluids or due to a suction leak, may result in the loss of
prime to the pump. If the pump loses prime, no fluid is
pumped.
To prime the pump, relieve the pressure on the system
by opening the drain valve and following the instruction
on Prime the pump, page 10.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 12.
DAILY: Check the engine oil level and fill as neces-
sary.
DAILY: Check and fill the gas tank.
AFTER THE FIRST 20 HOURS OF OPERATION
Drain the oil and refill with clean oil.
WEEKLY: Remove the cover of the air filter and
clean the element. Replace the element, if necessary.
If operating in an unusually dusty environment, check
the filter daily and replace it, if necessary.
Replacement elements may be purchased from your
local Honda dealer.
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. Fill the nut, if necessary. Keep
TSL in the nut to help prevent fluid buildup on the
piston rod and premature wear of the packings.
Monthly: Remove the front cover (9) and fill the
cavity in the connecting rod with non-detergent motor
oil 1/4 in. below the surface. See Fig. 4.
AFTER EACH 100 HOURS OF OPERATION:
Change the oil. Refer to the engine manual for additional maintenance instructions.
SPARK PLUG: Use only an (NGK) BPR6ES or a
(NIPPON DENSO) W20EPR-U plug. Gap the plug to
0.028 to 0.031 inch (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing the plug.
Fig. 4
Fill to .25 in. below surface with non-detergent
motor oil.
9
06011
308620 11
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
D are instructed to relieve the pressure,
D stop spraying,
D check or service any of the system equipment,
D install or clean the spray tip.
Flushing
When to Flush
1. Engage the gun safety latch.
2. Turn the engine switch to OFF.
3. Move the pressure control ON/OFF switch to OFF.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. Trigger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the pressure
drain valve open until you are ready to spray
again.
7. Disconnect the spark plug cable.
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 the tip guard retaining nut or hose end coupling
to Relieve the pressure gradually, then loosen completely. Now clear the tip or hose.
1. New Sprayer. This sprayer was factory tested in
lightweight oil,which was left in to protect the pump
parts.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean water flush.
Before using oil–base paint, flush with mineral
spirits.
2. Changing Colors.
such as mineral spirits or water.
3. Changing from water–base to oil–base paint. Flush
with warm, soapy water, then mineral spirits.
4. Changing from oil–base to water–base paint.
with mineral spirits, followed by warm, soapy
water, and then a clean water flush.
Flush with a compatible solvent
Flush
CAUTION
To prevent pump corrosion or damage to pump
components, never leave water or any type of paint
in the sprayer when it is not in use. Pump the water
or the paint out with mineral spirits.
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 the pressure. Leave the drain
valve open.
Oil base paint: flush with 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 the
pressure. Leave the drain valve open.
6. Startup after storage.
Before using water–base paint, flush out the
mineral spirits with soapy water, and then with
clean water.
When using oil–based paint, flush out the mineral
spirits with the paint to be sprayed.
30862012
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