Graco GM 3000 User manual

308660

Rev. B

INSTRUCTIONS

This manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

GM 3000r

AIRLESS PAINT SPRAYERS

Drive Housing Replacement Kit 238691

Pinion Housing Replacement Kit 238684

Drive Housing, Connecting Rod, Crankshaft

WARNING

INJECTION HAZARD

To reduce the risk of serious injury,

whenever you are instructed to relieve

pressure, follow the Pressure Relief

Procedure on page 8.

Removal

1. Relieve pressure.

2. Remove the displacement pump. See page 7.

3. Remove the pressure control (25). See page 3.

4. Remove the three drive housing screws and lock

washers (15, 16). See Fig. 1 on page 2.

5. Remove the two pinion housing screws (69) and

lock washers (16). See Fig. 1 on page 2.

6. Tap the lower rear of the drive housing (6) with a

plastic mallet to loosen the drive housing. Pull the

drive housing straight off the pinion housing.

CAUTION

Do not allow the gear (19) to fall; it may stay at-

tached to the drive housing or to the pinion housing.

Do not lose the thrust balls (6a and 2d) or let them

fall between the gears, which will damage the drive

housing if not removed. If the balls are not in place,

the bearings will wear prematurely.

7. Remove and inspect the crankshaft (8) and the

connecting rod (10).

Installation

8. Lubricate the inside of the drive housing bronze

bearing with SAE non-detergent oil.

9. Install the connecting rod.

10. Place the large washer (5) and then the small

washer (3) on the crankshaft (8).

11. Insert the crankshaft into the bearing in the drive

housing (6) and connecting rod (10).

12. If replacing the complete drive housing assembly

(6), brush bearing grease (supplied) on all gear

teeth. Then recoat the gear teeth with bearing

grease (supplied). Pack the remaining bearing

grease into the bottom part of the drive housing.

Use 3/4 tube of the grease. See Fig. 2.

13. Install gear (19).

14. Install new gasket (64).

15. Work backwards from step 5 to reassemble.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Graco Inc. is registered to I.S. EN ISO 9001

2308660

Drive Housing, Connecting Rod, Crankshaft

Fig. 1

1Torque to 100 in–lb (11 N.m)

2 Quantity of three

Quantity of one

Lubricate with SAE

non-detergent oil

REF A

05833A

06003

Fig. 2

Brush and recoat with

bearing grease

Pack with bearing grease (3/4 tube)

308660 3

Pressure Control

WARNING

INJECTION HAZARD

To reduce the risk of serious injury,

whenever you are instructed to relieve

pressure, follow the Pressure Relief

Procedure on page 8.

NOTE: See Fig. 3 for this procedure.

NOTE: The pressure control (25) cannot be repaired

or adjusted. If it has malfunctioned, replace it.

1. Remove the front cover (9). Remove the screws (65)

and lock washers (37). Lower the junction box (63).

2. Disconnect the harness connector (A) from the

control module inside the box (63).

3. Remove the screws (24). Pull forward on the

pressure adjusting knob and tip the pressure

control (25) forward and up to detach it from the

drive housing (6).

4. Guide the harness (A) through the pinion housing

and drive housing and remove the pressure con-

trol.

5. Guide the harness of the new pressure control

through the drive housing and pinion housing

passages.

6. Install the new pressure control. Tip the pressure

control down and back into the drive housing (6).

Do not pinch or damage the harness (A).

7. Loosely install the screws (24) and then torque

them to 21 in–lb (2.4 N.m).

8. Install the front cover (9). Connect the harness (A)

to the control module leads (B).

9. Install the junction box. Be sure no leads are

pinched against the mounting face of the pinion

housing.

06012

05834

Torque to

21 in–lb (2.4 N.m)

Fig. 3

4308660

Pinion, Clutch, Clamp, Field, & Engine

If servicing clutch components only, see Manual

308620.

If no service is needed for internal parts of pinion

housing, remove drive assembly (drive and pinion

housing) from clutch housing. See Manual 308620.

Pinion Housing Removal

WARNING

INJECTION HAZARD

To reduce the risk of serious injury,

whenever you are instructed to relieve

pressure, follow the Pressure Relief

Procedure on page 8.

NOTE: Refer to Fig. 4 for Steps 1 to 5.

1. Follow the Pressure Relief Procedure, page 8.

2. If the drive housing has not yet been removed,

follow steps 1 through 6 of DRIVE HOUSING, on

page 1.

3. Remove the two bottom screws (59) and lock-

washers (16) first, then remove the top three

screws (59) and lockwashers (16).

4. Pull the pinion housing (2) away from the clutch

housing (1). The armature (51b) will come with it.

5. Pull the armature (51b) off the hub (2h**)of the

pinion housing. Also see Fig. 5.

6. If replacing the complete pinion housing assembly

(2), brush bearing grease (supplied) on the pinion

shaft teeth. Then recoat the pinion shaft teeth with

bearing grease (supplied). Pack the remaining

bearing grease in the bottom part of the pinion

housing. Use 1/4 tube of the bearing grease.

7. Install new gasket (64) (supplied).

8. Reassemble to drive housing.

CAUTION

Do not lose the thrust ball (2d). Refer to the CAU-

TION on page 1 for more information

NOTE: To disassemble the pinion, go to page 5. To

disassemble more of the sprayer, see Manual 308620.

To reassemble the sprayer from this point, skip ahead

to Reassembly, page 6, Step 1.

05836A

Fig. 4

51b

See page 5.1

2Brush with bearing grease

3Pack with bearing grease (1/4 tube).

308660 5

Pinion Housing

Fig. 5

Detail A 2k

2a 2b

Lubricate inner and

outer diameters

Lubricate teeth

Lubricate exterior

Directional

arrow on roller

clutch must

face the small

bearing (2n)

06005

Press fit small

bearing (2n)

and clutch roller

(s) here

Back of pinion

housing

1.53

2d 2e

Repairing the Pinion (Fig. 13)

NOTE: Use a hydraulic press if you purchase the pin-

ion parts individually. Otherwise, use Repair Kit

223189, which includes the shaft and bearings preas-

sembled and lubricated.

If using Repair Kit 223189, follow Steps 1 to 7, below.

1. Remove the small ring (2j) from the hub (2h) and

the large ring (2k) from the bearing recess of the

housing (2a).

2. Push on front of the shaft (2f) to force the bearing

and hub assembly out of the housing (2a).

3. Press the small bearing (2n) and roller clutch (2m)

out of the pinion housing (2a). Remove the new

bearing and roller clutch from the shaft of the kit

and press it into the housing to the dimension

shown. Directional arrow of roller clutch (2m) must

face bearing (2n). See Detail A.

4. Inspect o-ring (2p) and replace if necessary.

5. Install the shaft assembly, pushing it to the shoul-

der of the housing (2a).

6. Install rings (2k and 2j). Ring (2k) must be installed

with bevel facing back of pinion housing.

7. Go to Reassembly, page 29, Step 7, or continue

on page 24.

If you purchased parts separately, follow steps 1 to

9, below. Disassemble only as far as needed for the

parts being replaced.

NOTE: The old bearing (2g) will be damaged as it is

removed. Have one on hand if you need to remove it

for any reason. Always replace bearing 2g if installing

a new hub 2h.

1. To replace small bearing (2n) or roller clutch (2m),

press the old one out of the pinion housing (2a).

2. Remove the small ring (2j) from the hub (2h). Re-

move the snap ring (2k) from the bearing recess of

the housing (2a).

KEY

A Round steel bar to

push on shaft (2f)

B Hydraulic press

C Steel bar stock

D Two steel blocks

E Press platform

Fig. 6

01427

3. Push on the front of the shaft (2f) to force the

bearing and hub assembly out of the housing (2a).

4. Using a hydraulic press, place pieces of steel

bar stock on the inner race of the large bearing

(2g) and press the shaft through the hub and bear-

ing. See Fig. 6.

5. Apply lubricant to the parts as shown in Fig. 5.

6. Press fit the following parts:

DSmall bearing (2n) and then the roller clutch

(2m), with the directional arrow facing the

small bearing, into the rear of the housing (2a).

See Detail A in Fig. 5.

DLarge bearing (2g) to shoulder of shaft (2f).

DHub (2h) onto the shaft (2f) all the way to the

large bearing (2g).

7. Install the shaft assembly, pushing it to the shoul-

der of the housing (2a).

8. Install the rings (2k and 2j).

9. Skip ahead to Reassembly, page 6, Step 1.

6308660

Reassembly

NOTE: With the autogap style armature, the gap be-

tween the rotor and the armature is critical for proper

operation. The clutch kits with an autogap style arma-

ture include a cardboard spacer (p/n 186–857) to set

the proper gap. This spacer is for use only during

installation.

1. Clean the face of the armature (51b). With the flat

side of the armature facing the rotor (51a), slide

the armature onto the hub (2h) in the drive/pinion

assembly (D) just until the chamfered end of the

hub (2h) protrudes through the armature. See

Detail B, Fig. 7. There will be significant resis-

tance. Attach 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 arma-

ture or bend tabs over outside diameter of arma-

ture.

Brace the cart against a wall to keep it from rolling.

Push the drive/pinion assembly onto the clutch

housing (1). There will be significant resistance.

When the mating surfaces of the drive/pinion as-

sembly and the clutch housing (1) are flush, re-

move the drive/pinion assembly. Remove the

cardboard spacer.

2. Assemble the drive assembly (D) to the clutch

housing (1), using the capscrews (59) and lock-

washers (16). See Fig. 7.

05843A

Fig. 7

51b

51a

Torque the screw to 7 ft–lb (9.5 N.m).

The face must be clean.

Spline

To engine alternator.

Detail B

Chamfered end of hub (2h)

06007

6Apply low strength thread locker.

7Torque to 100 in.-lb (Nm).

308660 7

Displacement Pump

WARNING

INJECTION HAZARD

To reduce the risk of serious injury,

whenever you are instructed to relieve

pressure, follow the Pressure Relief

Procedure on page 8.

NOTE: Packing Repair Kit 238692 is available. Refer-

ence numbers of parts included in the kit are marked

with an asterisk, i.e., (121*). For the best results, use

all the new parts in the kit, even if the old ones still look

good.

NOTE: To minimize down time, and for the best sprayer

performance, clean the transducer (22) whenever you

repack the pump. Replace these parts as needed.

Removing the pump (See Fig. 8.)

1. Flush the pump, if possible. Relieve pressure. Stop

the pump with the piston rod (107) in its lowest

position, if possible.

2. Use a screwdriver to push the retaining spring (12)

up and push out the pin (11).

3. Loosen the screws (17). Remove the pump (18).

118

05844

Torque to

50 ft–lb (68 N.m)

Apply sealant

107

Model 231363 Shown

Fig. 8

8308660

Displacement Pump

Installing the pump (See Fig. 8 and 9.)

1. Mount the pump on the drive housing. Tap it into

the alignment pins with a soft hammer. Tighten the

screws (17) to 50 ft-lb (68 N.m).

WARNING

MOVING PARTS HAZARD

Be sure the retaining spring (12) is firmly

in the groove all the way around, to

prevent the pin (11) from working loose

due to vibration. See Fig. 9.

If the pin works loose, it or other parts could break

off due to the force of the pump action. These parts

could be projected into the air and result in serious

injury or property damage, including the pump

connecting rod or drive housing.

2. Align the hole in the rod (107) with the connecting

rod assembly (10). Use a screwdriver to push the

retaining spring (12) up and push in the pin (11).

Push the retaining spring (12) into place around

the connecting rod.

3. Tighten the packing nut (102) just enough to stop

leakage, but no tighter. Fill the packing nut/wet-cup

1/3 full with Graco TSL. Push the plug (123) into

the wet-cup.

0600

Fig. 9

123

102

1Torque to

50 ft–lb (68 N.m)

Pressure Relief

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:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dinstall or clean the spray tip.

Pressure Relief Procedure

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 com-

pletely. Now clear the tip or hose.

Graco Headquarters: Minneapolis

International Offices: Belgium, Korea, China, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

3/1996, Rev 8/2006

www.Graco.com

Table of contents

Other Graco Paint Sprayer manuals

Graco

Graco 231-315 Series Operation manual

Graco

Graco Ultra Max II 695 Instruction Manual

Graco

Graco DURON Performance 395 A Series Operation manual

Graco

Graco 17G807 Guide

Graco

Graco 805-074 Series A User manual

Graco

Graco HYDRA-MASTIC 206-718 Operation manual

Graco

Graco FT500 Use and care manual

Graco

Graco 222625 Operation manual

Graco

Graco 231-581 A Series Operation manual

Graco

Graco XTR 310743G User manual

Graco

Graco FinishPro II 295 Use and care manual

Graco

Graco 231-825 Operation manual

Graco

Graco GMAX II 5900 User manual

Graco

Graco RoadLazer RoadPak User manual

Graco

Graco XT Series User manual

Graco

Graco Magnum DX 232735 Operating instructions

Graco

Graco 237 A Series Operation manual

Graco

Graco 220–856 D Series User manual

Graco

Graco HTX 313888B User manual

Graco

Graco Merkur G15W Series Parts list manual

Graco

Graco TexSpray HTX 258740 User manual

Graco

Graco EM 490 Operation manual

Graco

Graco 254973 User manual

Graco

Graco Series A User manual

Popular Paint Sprayer manuals by other brands

SNOWJOE

SNOWJOE Sunjoe 24V-GS-LTW-RM Operator's manual

Binks

Binks SV100 Service manual

Fimco

Fimco LG-4-3-1 owner's manual

AG SPRAY

AG SPRAY FS-ATV-25BL owner's manual

Nordson

Nordson MicroMax 2 manual

Bonide

Bonide 051 Operation and service instructions

zogics

zogics Z-DAS instruction manual

KISANKRAFT

KISANKRAFT KK-KBS-165 Operation manual

Matrix

Matrix SG 650 Translation of the original instructions

Anest Iwata

Anest Iwata SGA-3 Installation, use & maintenance instruction manual

paasche

paasche VV Instructions and parts list

Carlisle

Carlisle DeVilbiss JGA-510 Service manual

Gardena

Gardena 11120 Operator's manual

Conrad

Conrad Hobby Airbrush K3 operating instructions

wiwa

wiwa 14025 R/F operating manual

DeVilbiss

DeVilbiss LUNA2i Operation manual

WAGNER

WAGNER W 125 manual

My Clean Buddy

My Clean Buddy PW018 user manual