Graco 330GS User manual

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309654A
Read warnings and instructions.
Related Manuals
309653 – Operation
309652 – Tool Tips
307806 – Pump Repair
ti3274A
REPAIR and PARTS
330GS Airless Gas Sprayer
Model 246418
3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure
Parts

3096542
Fire and explosion hazard: Solvent and paint fumes can ignite or explode.
To help prevent a fire and explosion:
DUse only in an extremely well ventilated area.
DEliminate all ignition sources; such as pilot lights, cigarettes and plastic drop cloths (static arc hazard).
Do not plug or unplug power cords or turn lights on or off in spray area.
DGround Sprayer, object being sprayed, paint and solvent pails.
DHold gun firmly to side of grounded pail when triggering into pail.
DUse only conductive airless paint hose.
DDo 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 reac-
tion, with the possibility of explosion.
DDo not fill fuel tank while engine is running or hot.
DDo not flush with gasoline.
Fluid injection and high pressure hazard: High pressure spray or leaks can inject fluid into the body.
To help prevent injection, always:
DEngage trigger safety latch when not spraying.
DKeep clear of nozzle and leaks.
DNever spray without a tip guard.
DDo PRESSURE RELIEF if you stop spraying or begin servicing sprayer.
DDo not use components rated less than sprayer Maximum Working Pressure.
DNever allow children to use this unit.
If high pressure fluid pierces your skin, the injury might look like “just a cut”. But it is a serious wound!
Get immediate medical attention.
WARNING
Exhaust hazard: Exhaust contains poisonous carbon monoxide which is odorless and colorless. This
equipment must be used in well ventilated work areas only.
Alcohol and drug hazard: Do not operate this equipment under the influence of alcohol or while taking
medication that impairs your senses or reactions.

309654 3
CONTROLS
Engine Controls
Pump On/Off Switch
Engine On/Off Switch
Trigger Lock
Drain Valve
Pressure Control
Locked Unlocked

3096544
Maintenance
WARNING
Page 2
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pump switch to OFF and turn pressure
control knob fully counterclockwise.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
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 tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose.
CAUTION
For detailed engine maintenance and specifications,
refer to separate Honda Engines Owner’s Manual,
supplied.
DAILY: Check engine oil level and fill as necessary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
DAILY: Check and fill the gas tank.
DAILY: Remove air filter cover and clean element.
Replace element, if necessary. If operating in an
unusually dusty environment: check filter daily and
replace, if necessary.
DAILY: Check level of TSL in displacement pump
packing nut. Fill nut, if necessary. Keep TSL in nut to
help prevent fluid buildup on piston rod and premature
wear of packings.
AFTER THE FIRST 20 HOURS OF OPERATION:
Drain engine oil and refill with clean oil. Reference
Honda Engines Owner’s Manual for correct oil viscos-
ity.
AFTER EVERY 25 HOURS OF OPERATION:
The hour meter will flash SVC (service). When flash-
ing:
Dchange engine oil using SAE30 or 10W–30 deter-
gent oil.
DInspect pump’s inlet ball checks for nicks, scratches
or damage which would prevent a good seal.
Replace if worn.
DInspect pump rod and pump sleeve for excessive
wear. Replace if needed.
SPARK PLUG: Use only BPR6ES (NGK) or
W20EPR–U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug
wrench when installing and removing plug.

309654 5
Troubleshooting
Relieve pressure;page 4.
PROBLEM CAUSE SOLUTION
Engine won’t start Engine switch is OFF Turn engine switch ON
Engine is out of gas Refill gas tank.
Engine oil level is low Try to start engine. Replenish oil, if necessary.
Spark plug cable is disconnected or damaged Connect spark plug cable or replace spark
plug
Cold engine Use choke
Fuel shutoff lever is OFF Move lever to ON position
Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times.
Clean or replace spark plug. Start engine.
Keep sprayer upright to avoid oil seepage.
Engine operates, but dis-
placement pump does not
operate
Error code displayed? Reference pressure control repair. Page 14.
Pump switch is OFF Turn pump switch ON.
Pressure setting is too low Turn pressure adjusting knob clockwise to
increase pressure.
Fluid filter is dirty Clean filter. Page 19.
Tip is clogged Clean tip or tip filter. Manual 309653.
Displacement pump piston rod is stuck due to
dried paint
Repair pump. Manual 307806.
Connecting rod is worn or damaged Replace connecting rod. Page 7.
Drive housing is worn or damaged Replace drive housing. Page 8.
Electrical power is not energizing clutch field Check wiring connections. Page 11.
Reference pressure control repair. Page 14.
Reference wiring diagram. Page 20.
With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch test points on control board.
Remove 7–pin connector from control board
and measure resistance across clutch coil. At
70_F, the resistance must be between 1.2
±0.2Ω ; if not, replace pinion housing.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly
positioned
Replace clutch. Page 9.
Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 9.

3096546
PROBLEM CAUSE SOLUTION
Pump output is low Strainer (32) is clogged Clean strainer.
Piston ball is not seating Service piston ball. Manual 307806.
Piston packings are worn or damaged Replace packings. Manual 307806.
O-ring in pump is worn or damaged Replace o-ring. Manual 307806.
Intake valve ball is not seating properly Clean intake valve. Manual 307806.
Intake valve ball is packed with material Clean intake valve. Manual 307806. Do not
leave sprayer under pressure for more than 5
minutes when spraying texture and not actively
spraying.
Engine speed is too low Increase throttle setting.
Clutch is worn or damaged Replace clutch. Page 9.
Pressure setting is too low Increase pressure.
Gun tip is clogged Unclog tip. Manual 309653.
Fluid filter dirty Clean filter.
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4
in. hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum perfor-
mance (50 ft minimum).
Excessive paint leakage into
throat packing nut
Throat packing nut is loose Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings are worn or damaged Replace packings. Manual 307806.
Displacement rod is worn or damaged Replace rod. Manual 307806.
Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections.
Reprime pump. Manual 309408.
Tip is partially clogged Unclog tip. Manual 309653.
Fluid supply is low or empty Refill fluid supply. Prime pump. Check fluid
supply often to prevent running pump dry.
Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well. Reas-
semble valve.
Pump packings are worn Replace pump packings. Manual 307806.
Paint is too thick Thin the paint according to the supplier’s
recommendations
Engine speed is too high Decrease throttle setting before priming pump.
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other
when new and may cause noise
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
High engine speed at no
load
Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load
l
oa
d
Worn engine governor Replace or service engine governor

309654 7
Bearing Housing and Connecting Rod
Removal
1. Relieve pressure;page 4.
2. Fig. 2. Remove screws (43) and front cover (42).
3. Remove drain hose (101). Unscrew suction tube
(31) from pump, hold wrench on pump intake valve
(A) to keep pump from loosening.
4. Fig. 1. Use screwdriver to push up retaining spring
(45) at top of pump. Push out pin (44) from con-
necting rod cross link.
Fig. 1 7675B
44
45
5. Fig. 2. Loosen retaining nut (16). Unscrew and
remove displacement pump (17).
6. Remove four screws (40) and lockwashers (27)
from bearing housing (52).
7. Pull connecting rod and lightly tap lower rear of
bearing housing (52) with plastic mallet to loosen
from drive housing (20). Pull bearing housing and
connecting rod assembly off drive housing.
8. Inspect crank (B) for excessive wear and replace
parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (C) in
bearing housing (52) with high-quality motor oil.
Liberally pack top roller bearing (E), lower bearing
(D) inside connecting rod assembly with bearing
grease.
2. Assemble connecting rod (53) and bearing housing
(52).
3. Clean mating surfaces of bearing and drive hous-
ings.
4. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (20) with
holes in bearing housing (52). Push bearing hous-
ing onto drive housing or tap into place with plastic
mallet.
CAUTION
DO NOT use bearing housing screws (40) to align
or seat bearing housing with drive housing. Align
these parts with locating pins (F), to avoid prema-
ture bearing wear.
5. Install screws (40) and lockwashers (27) on bear-
ing housing. Torque evenly to note 3 value in Fig. 2.
6. Refer to Displacement Pump, Installation, page 15.
Torque to 200 in-lb (22.6 Nm)
Pack with bearing grease 114819
Oil
3
2
1
Fig. 2
32
31
17
16
154
43
42
29
40
27
44
45
53
82
78
20
30 52
ti3568a
1C
B
2
3
D
E
A
F

3096548
Drive Housing
Removal
1. Relieve pressure;page 4.
2. Fig. 3. Remove bearing housing. Do steps 1–7. of
Bearing Housing and Connecting Rod proce-
dure on page 7.
3. Fig. 3. Remove two screws (82) and lockwashers
(78).
4. Remove four screws (77) and lockwashers (78)
from pinion housing (85).
5. Lightly tap around drive housing (20) to loosen
drive housing. Pull drive housing straight off pinion
housing. Be prepared to support gear cluster (79),
which may also come out.
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (79) and
to areas called out by note 2. Use full 0.62 pint
(0.29 liter) of grease.
2. Place bronze colored washer (20g) on shaft pro-
truding from large shaft of drive housing (20).
Place silver colored washer (20h) on pinion hous-
ing. Align gears and push new drive housing
straight onto pinion housing and locating pins (B).
3. Install four screws (77) and lockwashers (78) from
pinion housing (85).
4. Install two screws (82) and lockwashers (78).
5. Fig. 3. Install bearing housing. Do steps 1–6 of
Bearing Housing and Connecting Rod proce-
dure on page 7.
Fig. 3
Torque to 125 in-lb
1
2Apply remaining grease to these areas
77 78
20h
20g
82
78
20
85
B
79
B
66 68
68
66
1
2
2
ti3566a

309654 9
Pinion Assembly/Rotor/Field/Shaft/Clutch
Removal
If pinion assembly (85) is not removed from clutch
housing (70), do steps 1–4. Otherwise, start at step 5.
1. Relieve pressure;page 4.
2. Remove drive housing; page 8.
3. Disconnect field cable (X) from pressure control
and motor.
Fig. 4
X
TI3420A
Y
4. Fig. 5. Remove five screws (77) and lockwashers
(78) and pinion assembly (85).
77
78
77
78
Fig. 5 8700A
85
70
5. Fig. 6. Place pinion assembly (85) on bench with
rotor side up.
6. Remove four screws (84) and lockwashers (78).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
8701B
Fig. 6
E
84
78
85
7. Fig. 7. Remove retaining ring (85e).
8. Tap pinion shaft (85d) out with plastic mallet.
Fig. 7
85e
85d
8703B
9. Fig. 8. Use an impact wrench or wedge something
between armature (100) and clutch housing to hold
engine shaft during removal.
10. Remove four screws (75) and lockwashers (78).
11. Remove armature (100).
Fig. 8
75
78
100
8704A

30965410
Pinion Assembly/Rotor/Field/Shaft/Clutch
Installation
1. Fig. 9. Lay two stacks of two dimes on smooth
bench surface.
2. Lay armature (100) on two stacks of dimes.
3. Press center of clutch down on bench surface.
Fig. 9
100
8705A
0.12 ±.01 in. (3.0 ±.25 mm)
dimes
4. Install armature (100) on engine drive shaft.
5. Install four screws (84) and lockwashers (78) with
torque of 125 in-lb.
6. Fig. 7. Tap pinion shaft (85d) in with plastic mallet.
7. Install retaining ring (85e) with beveled side facing
field.
8. Fig. 6. Place pinion assembly on bench with rotor
side up.
9. Apply locktite to screws. Install four screws (84)
and lockwashers (78). Alternately torque screws to
125 in-lb (14 Nm) until rotor is secure. Use
threaded holes to hold rotor.
10. Fig. 5. Install pinion assembly (85) with five screws
(77) and lockwashers (78).
11. Fig. 4. Connect field cable (X) to pressure control.
NOTE: When connecting the field cable (X) to the
pressure control, make sure the cable coupling ring (Y)
has fully detented in the lock position. This will prevent
the field cable connector from loosening or separating
during use. Fig. 4.
Clamp
Removal
1. Fig. 10. Loosen two screws (71) on clamp (74),
2. Push screwdriver into slot in clamp (74) and re-
move clamp.
Installation
1. Fig. 10. Install engine shaft key (73).
2. Tap clamp (74) on engine shaft (A) with plastic
mallet.
3. Press clamp (74) onto engine shaft (A). Maintain
dimension shown in note 2, Fig. 10. Chamfer must
face engine.
Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (70). Use accurate
measuring device to measure distance between
bar and face of clamp. Adjust clamp as necessary.
Torque two screws (71) to 125 ±10 in-lb (14 ±1.1
Nm). Fig. 10
71
70
B
03483
1
3
2
Face of clutch housing
Torque to 125 ±.10 in-lb (14 ±1.1 Nm)
1
2
3
1.550 ±.010 in. (39.37 ±.25 mm)
73
74
A
4Chamfer this side
4