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308-709

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.
 Do not use the equipment until you identify and correct the problem.

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.

Keep the spray area free of debris, including solvent, rags, and gasoline.

Disconnect all electrical equipment in the spray area.

Extinguish all open flames or pilot lights in the spray area.

Do not smoke in the spray area.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not operate a gasoline engine in the spray area.

Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).

Use only electrically conductive hoses.

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.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of all moving parts when starting or operating the sprayer.

Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.

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 34 to order.

Summary of Contents for GM3500 SPRAYER 231-078

Page 1: ...Same as 231 579 with hose and gun RAC IVr Driplesst Tip Guard and 517 size SwitchTipt Model 231 578 Series A Basic Upright Sprayer Model 231 057 Same as 231 578 with hose and gun RAC IVr Driplesst Tip...

Page 2: ...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 i...

Page 3: ...or servicing the equipment Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure...

Page 4: ...r fingers Keep clear of all moving parts when starting or operating the sprayer Before servicing the equipment follow the Pressure Relief Procedure on page 12 to prevent the equipment from starting un...

Page 5: ...Throttle Adjusts engine speed for large or small orifice spray tips K Engine Switch Enables disables engine operation L Secondary Fluid Outlet Secondary Hose and spray gun are connected here M Pressu...

Page 6: ...ener 3 Never 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 op eration Never plug this outlet 1 Connect hose and gun...

Page 7: ...Use the ground wire 47 provided 7 Fill the gas tank See the Fueling section below 8 Flush the pump to remove the lightweight oil which was left in the pump to protect it from rust Refer to the Flushi...

Page 8: ...If the engine knocks or pings use a higher octane gasoline Unleaded fuel minimizes combustion chamber deposits 2 Gasolines containing alcohol gasohol Do not use gasohol which contains methanol if the...

Page 9: ...engine when it is pres surized will damage the recoil system 7 To start the engine a Turn the pressure adjusting knob B all the way counterclockwise to the lowest pressure setting b Pull the metal th...

Page 10: ...supplied with the tip 307 848 if you are using a RAC IV 11 Adjust the engine speed and pump pressure Trigger the gun onto a test paper to check the spray pattern and atomization Turn the pressure adju...

Page 11: ...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 t...

Page 12: ...or hose end coupling to Relieve the pressure gradually then loosen com pletely Now clear the tip or hose Flushing NOTE Several flushes are often required to thoroughly clean the system and prepare it...

Page 13: ...and install the bowl without the screen to flush it See Fig 5 4 Put the suction tube into a grounded metal pail with 1 2 gallon of compatible solvent 5 Start the sprayer See page 10 To save the fluid...

Page 14: ...amber 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...

Page 15: ...tch 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...

Page 16: ...ure control cover 76 so as not to stress the cables 5 Disconnect the black and white wires of the pres sure control cable 314 from the pressure control cover 6 Disconnect the potentiometer cable assem...

Page 17: ...25 from working loose due to vibration If the pin works loose it or other parts could break off due to the force of the pump action These partscould be projected through the air and result in serious...

Page 18: ...the bronze bearing C in the bearing housing 21 and the inside of the connecting rod link D with high quality motor oil Liberally pack the roller bearing E in the connecting rod assembly 22 with beari...

Page 19: ...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 w...

Page 20: ...g on page 12 before checking adjusting cleaning or shutting down the sprayer NOTE Refer to Fig 13 for Steps 1 to 3 except where noted 1 Remove the two bottom screws 10 first and then remove the top th...

Page 21: ...d parts separately 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 re...

Page 22: ...e 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 housin...

Page 23: ...he red wire D from the engine lead B Disconnect the black and white wires 29 from the field Pull the wires carefully through the grommets 62 before removing the engine See Fig 17 and 18 3 Lift the eng...

Page 24: ...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...

Page 25: ...in two of the threaded holes in the clamp Tighten the screw C until the clamp comes off 3 Skip ahead to Reassembly page 26 Step 3 or continue to the right Fig 20 2 3 16 B C A 03480 1 Torque To 125 10...

Page 26: ...lign the setscrew holes in the field and the clutch housing 2 Tighten the setscrews 12 oppositely and evenly to 27 3 in lb 3 33 N m See Fig 22 6 Place the engine 1 assembly on the cart Align the mount...

Page 27: ...lutch kits with an autogap style armature include a cardboard spacer 186 857 to set the proper gap This spacer is for use only during installation 9 Clean the face of the armature 4a With the flat sid...

Page 28: ...ail above See manual 307 273parts 5 Ref 36 40 44 37 46 Handle Detail 39 23 69 70 22 20 20a 20b 18 Ref No 19 10 11 20c 11 24 21 26 27 25 28 94 34 48 17 51 34 88 73 59 Ref 55 58 68 39 50 75 57 91 53 1 3...

Page 29: ...ng 4 33 109 033 SCREW slotted 6 32 x 3 16 in 2 34 112 818 CAPSCREW hex hd flanged 5 16 18 x 3 4 in 1 35 238 685 CART 1 36 238 187 CART HANDLE HOSE RACK 1 37 183 350 WASHER plain 0 90 in 2 38 108 691 P...

Page 30: ...14 47 49 48 35 38 1 30 31 91 83 Ref 55 Model 231 578 88 1 1 2 4 2 See manual 307 806parts 1 3 4 2 Label See page 33 for parts See detail above See manual 307 273parts 5 01449B Ref 36 40 45 37 46 Handl...

Page 31: ...183 350 WASHER plain 0 90 in 2 38 108 691 PLUG tubing 2 39 109 032 SCREW recess pnh self tap F No 10 24 x 1 4 in 4 40 192 027 SLEEVE 2 41 106 062 WHEEL semi pneumatic 2 42 101 242 RING retaining 2 43...

Page 32: ...M3500 Basic Lo Boy Sprayer See parts list on page 29 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 PINI...

Page 33: ...10 236 352 POTENTIOMETER pressure adjustment 1 311 112 382 NUT shaft sealing 1 312 112 373 KNOB 1 313 185 565 LABEL 1 314 237 674 CONDUCTOR 1 315 109 078 CONNECTOR 1 316 112 376 LOCKNUT 1 317 100 078...

Page 34: ...suction 1 6 181 072 STRAINER 1 0161 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...

Page 35: ...npsm from fluid filter Wetted Parts Displacement Pump Carbon Steel Plastic Leather Filter Aluminum Carbon Steel Stainless Steel NOTE For information on converting your sprayer to one that can safely...

Page 36: ...or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought wit...

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