Graco GM 3500 Instructions And Parts List Download Page 1 | Manualshive

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INSTRUCTIONS–PARTS LIST

307–863

Rev. K

Supersedes J

and PCN K

3.5 HORSEPOWER, GASOLINE-POWERED

GM 3500

Airless Paint Sprayer

3000 psi (210 bar) Maximum Working Pressure

Model 222–028, Series F

Basic Sprayer with Lo–Boy Cart

Model 231–077

Same as 222–028, with hose and gun, RAC IV

Dripless

Tip Guard, and 517 size SwitchTip

Model 221-040, Series F

Basic Upright Sprayer

Model 231-057

Same as 221–040, with hose and gun, RAC IV

Dripless

Tip Guard, and 517 size SwitchTip

Table Of Contents

Warnings

2

. . . . . . . . . . . . . .

Setup

8

. . . . . . . . . . . . . . . . .

Startup

10

. . . . . . . . . . . . . . . .

Flushing Guidelines

12

. . . . .

Troubleshooting

13

. . . . . . .

Repair

14

. . . . . . . . . . . . . . . .

Parts

30

. . . . . . . . . . . . . . . . .

Accessories

38

. . . . . . . . . . .

Technical Data

39

. . . . . . . . .

Dimensions

39

. . . . . . . . . . . .

Warranty

40

. . . . . . . . . . . . . .

GRACO INC.

P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

COPYRIGHT 1988, GRACO INC.

This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

Model 231-057
Shown

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.

FIRE AND

EXPLOSION HAZARD

SKIN INJECTION

HAZARD

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

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.

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.

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Summary of Contents for GM 3500

Page 1: ...ozzle 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 FIRE AND EXPLOSION HAZARD SKIN INJECTION HAZARD R...

Page 2: ...n when the tip is not installed Check diffuser operation regularly Follow the PRESSURE RELIEF PROCEDURE be low then remove the spray tip Aim the gun into a metal pail holding the gun firmly to the pail Using the lowest possible pres sure trigger the gun If the fluid emitted is not diffused into an irregular stream replace the diffuser immediately Tip Guard ALWAYS have the tip guard in place on the...

Page 3: ...ier or manufacturer for the maximum re sistance limits Use a resistance meter in the appropriate range for your hose to check the resistance If the resistance exceeds the recommended limits replace it immediately An un grounded or poorly grounded hose can make your system haz ardous Always read the chemical manufacturer s literature before us ing them in this sprayer FIRE OR EXPLOSION HAZARD Stati...

Page 4: ...ffuseur Le diffuseur du pistolet sert à diviser le jet et à réduire les risques d injection accidentelle quand l ajutage n est pas en place Véri fier le fonctionnement du diffuseur régulièrement Pour cette vé rification détendre la pression en observant la Marche à Sui vre Pour Détendre la Pression donnée plus loin enlever l ajutage du pulvérisateur Pointer le pistolet dans un seau en métal en le ...

Page 5: ... terre incorrecte peut entraîner des risques pour votre système Lisez aussi LES RISQUES D INCENDIE OU D EXPLOSION RISQUES D INCENDIE OU D EXPLOSION De l électricité statique est produite par le passage du fluide à grande vitesse dans la pompe et dans les tuyaux Si toutes les pièces de l appareil de pulvérisation ne sont pas convenable ment reliées ou à la masse ou à la terre des étincelles peuvent...

Page 6: ...rlo puede llevar al disparo imprevisto de la pistola Difusor El difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyección cuando no está instalada la boquilla Re visar con regularidad el funcionamiento del difusor Seguir el procedimiento de descarga de presión dado más abajo y después sacar la boquilla Apuntar la pistola a un balde metáli co sosteniéndola bien firme cont...

Page 7: ...nes Leer también la infor mación sobre RIESGO DE INCENDIO O EXPLOSION más arriba PELIGRO DE INCENDIO O EXPLOSION El flujo a alta velocidad del fluido al pasar por la bomba y man guera crea electricidad estática Si todas las partes del equipo pulverizador no tienen buena tierra pueden ocurrir chispas convirtiéndo al sistema en algo peligroso También pueden producirse chispas al enchufar o desenchuf...

Page 8: ...r install a ball valve or shutoff device be tween the filter and the 50 ft 15 m hose 4 Always use the main filter outlet for one gun operation Never plug this outlet 1 Connect hose and gun Remove the plastic cap plug from the 1 4 npsm m outlet nipple 57 As semble the 50 ft 15 m hose 121 3 ft 0 9 m whip hose 12 and gun 123 and connect them to the outlet nipple 2 DO NOT use thread sealant on the hos...

Page 9: ... and explosive under certain conditions To reduce the risk of a fire or explosion Always shut off the engine B before refueling 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 filler cap is securely closed after refueling Be careful not to spill fuel when fueling ...

Page 10: ...he engine starts f Open the choke J In cold weather leave the choke closed for 10 to 30 seconds before opening it to keep the engine running Other wise open the choke as soon as the engine starts 8 Disengage the gun safety latch 9 To start the pump a Open the pressure drain valve 53 b Turn the pressure control switch A to ON c Slowly increase the pressure knob B until the pump starts to cycle slow...

Page 11: ...Y Check the engine oil level and fill as necessary DAILY Check and fill the gas tank AFTER THE FIRST 20 HOURS OF OPERATION AND EACH 100 HOURS THEREAFTER Change the oil WEEKLY Remove the air filter cover and clean the element In very dusty environments check the filter daily Replace the element as needed Replacement elements can be purchased from your local HONDA dealer WEEKLY Check the level of th...

Page 12: ...ressure control Doing so prevents the sprayer from being started and causes serious damage to the pressure control Pump the water out with mineral spirits WARNING To reduce the risk of static sparking and splashing when flushing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of a grounded metal pail 1 Follow the illustrated Pressure Relief Procedure on...

Page 13: ...on chamber Remove spark plug Pull starter rope 3 or 4 times Clean and replace plug Try to start Keep sprayer upright to avoid oil leakage See last CAUTION on page 10 Engine operates but dis placement pump doesn t Pressure control switch turned OFF Turn on Pressure setting too low Increase pressure Displacement pump outlet filter dirty Clean filter Tip or tip filter clogged Clean tip or tip filter ...

Page 14: ...utch worn or damaged Replace See page 24 Paint leaks into wet cup Loose wet cup Tighten just enough to stop leakage Throat packings worn or damaged Replace packings See page 18 Displacement rod worn or damaged Replace rod See page 18 Low fluid delivery Pump inlet screen clogged Clean Pressure setting too low Increase pressure See Startup Step 11 page 10 Engine RPM too low Increase throttle setting...

Page 15: ...ourdon tube 2 Working under the engine mounting plate of the cart disconnect the red black and white wires For the Upright cart remove the three nuts 61 and lockwashers 9 from the capscrews 62 For the Lo boy cart remove the two screws 62 and washers 9 See Fig 6 3 Remove the wire clamp 32 Remove the pres sure control See Fig 6 4 Remove the pressure control cover 76 and the mounting bracket 67 See F...

Page 16: ...guide the new pressure control wires through the wire clamps 32 Fasten the wire clamps to the cart with the same screws lockwashers and nuts 62 9 61 which hold the bracket 67 to the cart See Fig 6 on page 15 For the Lo boy carts guide the pressure control wires through the single wire clamp 32 and in stall the screws 62 and washers 9 to hold the bracket 67 to the cart See Fig 6 on page 15 5 Perfor...

Page 17: ...814 Swivel B Part No 156 823 Tee C Part No 104 984 Nipple D Part No 162 453 NEW 50 foot 15 2 m 3000 psi 210 bar flexible nylon airless spray hose E Part No 223 541 NEW spray tip size 0 025 to 0 029 3 8 in ignition wrench or nut driver 5 gallon pail of water or mineral spirits Fig 8 01201 A B C D E Set Up 1 Follow the Pressure Relief Procedure Warning on page 2 2 Set up the system as shown in Fig 8...

Page 18: ...plug 205 Unscrew the packing nut 216 See Fig 12 3 Tap the piston rod 224 down and then pull it out the bottom of the cylinder 219 See Fig 12 4 Remove the throat packings See Fig 12 5 Clamp the flats of the piston rod 224 in a vise Loos en the piston 222 Unscrew the nut 211 from the piston Remove the piston packings WARNING To reduce the risk of serious bodily injury from pump rupture use only tool...

Page 19: ...inst the piston to 10 5 in lb 1 2 N m to seat the packings and then back off and finger tighten 211 Fig 15 222 204 224 0029 1 Apply one drop of sealant to these threads 1 4 Note the alignment of the piston 222 to the piston nut 211 and maintain this alignment through Steps 4 5 and 6 5 Apply ONE drop of adhesive supplied with the repair kit to the piston threads Place the ball 225 on the piston Han...

Page 20: ...cleaning or shutting down the sprayer NOTE Steps 1 to 10 refer to Fig 18 1 Remove the pump See page 18 2 Remove the four screws 73 and lockwashers 74 from the bearing housing 21 3 While pulling the connecting rod assembly 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...

Page 21: ...g 20 The gear cluster is easily damaged The gear may stay engaged in either the drive housing or the pinion housing DO NOT lose the thrust balls 20c and 19j located at each end of the gear cluster The balls which are heavily covered with grease usually stay in the shaft recesses but they could be dislodged If they are caught between the gears and not removed the balls will seriously damage the dri...

Page 22: ... on page 2 before checking adjusting cleaning or shutting down the sprayer NOTE Refer to Fig 20 for Steps 1 to 3 except where noted 1 Remove the two bottom screws 10 first and then remove the top three screws 10 2 Pull the pinion housing 19n away from the clutch housing 2 The armature 4a will come with it 3 Pull out the armature 4a CAUTION Do not lose the thrust ball 19j Refer to the CAU TION on p...

Page 23: ...ely follow steps 1 to 9 below Disassemble only as far as needed for the parts being replaced NOTE The old bearing 19d will be damaged as it is removed Have one on hand if you need to remove it for any reason 1 If replacing the small bearing 19c or roller clutch 19s press the old ones out of the pinion housing 19n 2 Remove the small ring 19e from the hub 19f Remove the snap ring 19k from the bearin...

Page 24: ...the bottom two screws 10 from the clutch housing 2 and then the top three screws 4 Tap lightly on the back of the bearing housing 21 with a plastic mallet to loosen the assembly D from the clutch housing 2 Pull the assembly away the armature 4a will come with it Remove the armature from the pinion shaft 5 Remove the four capscrews 16 Install two of the screws in the threaded holes in the rotor 4b ...

Page 25: ...black and white wires 29 from the field Pull the wires carefully through the grommets 66 before removing the engine See Fig 24 and 25 3 Lift the engine carefully and place it on a work bench 4 Remove the Field and Wiring Harness Clamp and Clutch Housing as instructed on pages 26 and 27 5 Skip ahead to Reassembly page 28 Step 1 NOTE All service to the engine must be performed by an authorized HONDA...

Page 26: ...the four setscrews 12 holding the field 6 to the clutch housing 2 and pull out the field 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 4 Pull off the field 5 Skip ahead to Reassembly page 28 Step 4 Fig 26 33 29 B 6 2 12 Ref 29 ...

Page 27: ...l A in two of the threaded holes in the clamp Tighten the screws C until the clamp comes off 3 Skip ahead to Reassembly page 28 Step 3 or continue to the right Fig 27 2 3 16 B C A Torque to 125 in lb 14 N m Clutch Housing NOTE Refer to Fig 28 1 Remove the four capscrews 8 and lockwashers 48 which hold the clutch housing 2 to the en gine 1 2 Remove the engine key 13 3 Pull off the clutch housing 2 ...

Page 28: ...tscrew holes in the field and the clutch housing 2 Tighten the setscrews 12 oppositely and evenly to 25 in lb 2 8 N m See Fig 29 6 Place the engine 1 assembly on the cart Align the mounting holes Guide the engine wire D and wiring harness 29 from the field through the appropriate grommets 66 in the mounting plate E Install the serrated flange screws 14 lock washers 9 and nuts 61 and torque to 15 f...

Page 29: ...4b slide the armature onto the hub F in the drive pinion assembly just until the chamfered end of the hub 19f protrudes through the armature See Detail B Fig 31 There will be significant resistance At tach the cardboard spacer supplied with the clutch kit to the face of the armature Engage the tabs on the spacer with the slots in the armature Brace the cart against a wall to keep it from rolling P...

Page 30: ...0 11 48 8 3 7 6 4b 4a 30d 16 11 33 29 11 16 12 66 1 35 15 80 34 32 61 9 95 96 88 10 14 47 50 49 41 44 42 43 30g 30e 30f 30b 30c 30a 30h 55 51 58 56 57 54 87 104 53 45 Model 222 028 Series F 61 9 77 92 63 96 76 105 65 67 66 9 62 See page 35 for parts 01450A 30c Ref 30h 96 Label See page 34 for parts See page 36 for parts ...

Page 31: ... SCREW slotted bdgh 6 32 x 3 16 2 34 108 851 WASHER plain type B 3 8 1 35 222 612 CART 1 41 106 062 WHEEL semi pneumatic 2 42 101 242 RING retaining 2 43 104 811 HUBCAP 2 44 154 636 WASHER 5 8 size 16 ga 4 45 108 982 CONNECTOR tube 1 47 222 011 GROUNDING CLAMP WIRE 1 48 104 008 LOCKWASHER 4 49 100 078 SCREW pan hd No 8 x 5 16 1 50 157 021 LOCKWASHER internal No 8 1 51 214 570 FLUID FILTER Includes...

Page 32: ...29 66 13 12 10 11 48 8 16 11 34 80 15 14 47 49 50 9 100 61 9 32 41 44 42 43 35 38 1 2 3 104 79 53 97 Ref 102 106 87 55 51 58 57 56 105 30 31 Ref 36 40 45 37 46 39 Handle Detail Ref 59A 54 59B 59A 62 102 57 Ref 59B Model 221 040 Series F 01449A 88 98 See page 35 for parts 1 3 4 2 Label See page 34 for parts See page 36 for parts 1 1 1 2 4 3 1 5 See detail above 5 ...

Page 33: ...snap 2 46 108 068 PIN spring straight 3 16 2 47 222 011 GROUNDING CLAMP WIRE 1 48 104 008 LOCKWASHER 4 49 100 078 SCREW pan hd No 8 x 5 16 1 50 157 021 LOCKWASHER internal No 8 1 51 214 570 FLUID FILTER Includes one each of items 55 and 57 See 307 273 for parts 1 52 181 867 LABEL WARNING on engine 1 53 221 077 VALVE pressure drain 1 54 178 034 TAG WARNING at filter 1 55 100 040 PLUG 1 56 220 285 C...

Page 34: ...0 Basic Lo Boy Sprayer See parts list on page 31 1 122 121 123 0160 Parts Pinion Assembly Ref No 19 Pinion Housing Includes items 19a to 19f and 19s Ref No Part No Description Qty 19a 223 189 PINION SHAFT ASSEMBLY Includes items 19b to 19f and 19s 1 19b 183 681 SHAFT pinion 1 19c 109 001 BEARING needle 1 19d 109 002 BEARING ball 1 19e 108 880 RING retaining external 1 19f 183 515 HUB armature 1 19...

Page 35: ... 178 965 V PACKING poly 3 214 181 338 WASHER backup 1 215 178 969 GLAND female 1 216 179 809 NUT packing 1 218 185 213 SLEEVE cylinder 1 219 185 211 CYLINDER 1 220 185 214 GUIDE ball 1 221 178 938 PIN ball stop 1 222 218 036 VALVE piston 1 223 222 437 VALVE intake 1 224 222 438 ROD piston 1 225 105 444 BALL 1 These parts are also included in Repair Kit 222 588 which may be purchased separately Kee...

Page 36: ...1 305 157 021 LOCKWASHER No 8 internal 2 306 100 284 NUT hex msc 8 32 UNC 2a 1 307 108 219 RECTIFIER bridge 1 308 220 979 CONDUCTOR red 2 309 220 978 CONDUCTOR red white black 1 310 100 035 SCREW mach slotted pan hd No 8 x 5 16 1 311 108 783 SCREW mach flat hd 8 32 x 0 812 1 312 162 453 NIPPLE hex 1 4 18 npsm 2 313 108 852 CONNECTOR 45_ 1 314 100 840 ELBOW str 1 4 18 npt m x f 2 316 222 352 TRIAC ...

Page 37: ...311 305 306 303 304 302 307 308 RED 310 305 313 309 BLACK RED WHITE 322 309 Top view of pressure control on lo boy cart REF 322 324 314 Ref 309 317 318 319 316 320 310 305 303 304 302 308 RED 317 318 319 316 308 RED 320 300 311 305 306 307 301 0150 0148A 0165A Rectifier 307 connections GROUND BLACK RED WHITE ...

Page 38: ...suction 1 6 181 072 STRAINER 1 1 5 6 2 3 1 4 SUCTION TUBE KIT 208 259 55 gallon 200 liter size For Upright Cart Sprayers Includes Ref No Part No Description Qty 1 156 589 UNION 90 ADAPTER 3 4 npt f x 3 4 np f swivel 1 2 214 961 HOSE coupled 3 4 npt mbe 3 4 ID nylon 6 ft 1 8 m spring guard one end 1 3 156 591 ELBOW 90 3 4 npt x 1 1 2 24 NS 1 4 156 593 PACKING o ring nitrile rubber 1 5 100 220 THUMB...

Page 39: ...ut hose or gun Weight dry without packaging 109 lb 49 kg Height 30 25 in 768 mm Length 29 5 in 749 mm Width 22 25 in 565 mm Model 222 028 Lo Boy Cart without hose or gun Weight dry without packaging 95 lb 43 kg Height 22 5 in 571mm Length 32 0 in 813 mm Width 18 5 in 470 mm Manual Change Summary This sprayer now complies with the European Commu nity Directives that are required in order to use the...

Page 40: ... be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warr...

Page 41: ...r manual or keep this sheet with your manual Assembly No Series Letter Change Part That Changed Ref No Part Description Description of Change Model 222 028 and 221 040 221 077 53 VALVE pressure drain Replaced by 237 677 222 011 47 GROUNDING CLAMP WIRE Replaced by 237 686 100 078 49 SCREW mach hex washer head No 8 x 3 8 Replaced by 112 798 157 021 50 LOCKWASHER internal No 8 Deleted Other Changes 0...

Page 42: ...no burrs on the outside edge of the rotor to After installing the rotor 4b check the clearance between the outside diameter of the rotor and the inside diameter of the field 6 The clearance must be 006 in 15 mm minimum all the way around Use a piece of 006 in brass shim stock to check If necessary loosen the field setscrews 12 adjust the position of the field and then tighten the setscrews Page 39...

Page 43: ...er Outlet Size 1 4 npsm m Fluid Filter Material aluminum stainless steel carbon steel 60 mesh 250 micron reusable SST screen Pump Material stainless steel carbon steel polyurethane Delrin Packing Material leather UHMWPE Spray Hose Requirements grounded 50 ft 15 m minimum 1 4 in I D non wire braid spring guards on both ends Application Sprays fluids from light specialty coatings to latex and block ...

Page 44: ...ayer with upright cart Ref Upright LoBoy No Part No Part No Description 1 187 147 187 190 Strainer 2 180 573 183 769 Suction Tube 3 186 495 183 281 Bypass Tube 4 222 580 Same Displacement Pump 4a 185 213 Same Sleeve 4b 222 438 Same Piston Rod 4c 218 036 Same Piston 4d 222 437 Same Intake Valve 5 218 035 Same Bearing Housing 6 218 034 Same Connecting Rod 7 222 203 218 032 Drive Housing 8 185 953 Sa...

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