Graco ASM Zip Spray 3400G Use and care manual

311207C
Repair and Parts
3400G Airless Gas
Sprayer
-For the application of architectural paints and coatings-
Model 249616
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Related
Manuals
Operation
311206
Pump
311061
Gun
309971
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Warnings
2311207C
Warnings
The following are general warnings are related to the setup, use, grounding, maintenance and repair of this equip-
ment. Additional more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the
manual, refer back to these pages for a description of the specific hazard.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable
and can ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• When flammable liquid is used in or near sprayer or for flushing or cleaning, keep sprayer at least 20
ft (6 m) away from explosive vapors.
• Keep a fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
311207C 3
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine ASM
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your ASM distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon mon-
oxide can cause death. Do not operate in an enclosed area.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
WARNING

Table of Contents
4311207C
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bearing Housing and Connecting Rod . . . . . . . . . 9
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pinion Assembly/Rotor/Field/Shaft/Clutch . . . . . 11
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Control Transducer . . . . . . . . . . . . . . 17
Pressure Adjust Potentiometer . . . . . . . . . . . . . 17
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 19
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List & Drawing - Pinion Assembly . . . . . . . 23
Parts Drawing - Sprayer . . . . . . . . . . . . . . . . . . . . 24
Parts List - Sprayer . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ASM Standard Warranty . . . . . . . . . . . . . . . . . . . . 28
ASM Information . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Controls
311207C 5
Controls
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Maintenance
6311207C
Maintenance
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
FIG. 1
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. Then clear
tip or hose.
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 operation.
DAILY: Check and fill gas tank.
DAILY: Remove air filter cover and clean element.
Replace element, if necessary. If operating in an unusu-
ally dusty environment, check filter daily and replace
when necessary.
AFTER THE FIRST 20 HOURS OF OPERATION:
Drain engine oil and refill with clean oil. Reference
Honda Engines Owner’s Manual for correct oil viscosity.
AFTER EVERY 25 HOURS OF OPERATION:
• Change engine oil using SAE30 or 10W-30 deter-
gent oil.
• Inspect pump’s inlet ball checks for nicks, scratches,
or damage which would prevent a good seal.
Replace if worn.
• Inspect 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.
/.
/&&
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CAUTION
For detailed engine maintenance and specifications,
refer to separate Honda engines Owner’s Manual,
supplied.

Troubleshooting
311207C 7
Troubleshooting
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 level 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 17.
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 6.
Tip is clogged Clean tip or tip filter. Manual 309971.
Displacement pump piston rod is stuck
due to dried paint
Repair pump. Manual 311061.
Connecting rod is worn or damaged Replace connecting rod. Page 9.
Drive housing is worn or damaged Replace drive housing. Page 10.
Electrical power is not energizing clutch
field
Check wiring connections. Page 25. Reference
pressure control repair. Page 17. Reference
wiring diagram. Page 25.
With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch and 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 ±
0.2 Ω, if not, replace pinion housing.
Have pressure control checked by authorized
dealer.
Clutch is worn, damaged, or incorrectly
positioned
Replace clutch. Page 14.
Pinion assembly is worn or damaged. Repair or replace pinion assembly. Page 11.
Relieve pressure; page 6.

Troubleshooting
8311207C
Pump output is low Strainer (32) is clogged Clean strainer.
Piston ball is not seating Service piston ball. Manual 311061.
Piston packings are worn or damaged Replace packings. Manual 311061.
O-ring in pump is worn or damaged Replace o-ring. Manual 311061.
Intake valve ball is not seating properly Clean intake valve. Manual 311061.
Intake valve ball is packed with material Clean intake valve. Manual 311061. 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 14.
Pressure setting is too low Increase throttle setting.
Gun tip is clogged Unclog tip. Manual 309971.
Fluid filter is 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 maximum).
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 311026.
Displacement rod is worn or damaged Replace rod. Manual 311026.
Fluid is splitting from gun Air in pump or hose Check and tighten all fluid connections. Rep-
rime pump.
Tip is partially clogged Unclog tip. Manual 311206.
Fluid supply is low or empty Refill fluid supply. Prime pump. check fluid sup-
ply 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 311061.
Paint is too thick Thin the paint according to the supplier’s rec-
ommendations.
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
idea
Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load
Worn engine governor Replace or service engine governor
PROBLEM CAUSE SOLUTION

Bearing Housing and Connecting Rod
311207C 9
Bearing Housing and Connecting Rod
Removal
1. Relieve pressure; page 6.
2. FIG. 3. 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. 2. Use screwdriver to push up retaining spring
(45) at top of pump. Push out pin (44) from connect-
ing rod cross link.
FIG. 2
5. Loosen retaining nut (55). Unscrew and remove dis-
placement 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. Lib-
erally 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 housing
onto drive housing or tap into place with plastic mal-
let.
5. Install screws (40) and lockwashers (27) on bearing
housing. Torque evenly to 200 in-lb.
6. Refer to Displacement Pump, Installation, page 19.
FIG. 3
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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 premature bear-
ing wear.
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20
99
78 82
53
45 44 27 40 128
29
43
42
132
101
95
32
31
17
131
130
55
52
30
159

Drive Housing
10 311207C
Drive Housing
Removal
1. Relieve pressure; page 6.
2. FIG. 4. Remove bearing housing. do steps 1-7 of
Bearing Housing and Connecting Rod procedure on
page 9.
3. FIG. 4. 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 hous-
ing. 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 protrud-
ing from large shaft of drive housing (20). Place sil-
ver colored washer (20h) on pinion housing. Align
gears and push new drive housing straight onto pin-
ion 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. 4. Install bearing housing. Do steps 1-6 of Bear-
ing Housing and Connecting Rod procedure on
page 9.
FIG. 4
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%
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1
2
Torque to 125 in-lb
Apply remaining grease to these areas