Graco GM 3000 User manual

308660
Rev. B
INSTRUCTIONS
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
ECOPYRIGHT 1996, GRACO INC.
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)
3
2 Quantity of three
Quantity of one
Lubricate with SAE
non-detergent oil
4
16
15
10
9
25
6
16
5
8
3
65
6a
2d
A
26
23
REF A
19
68
1
1
2
3
4
2
69
64
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
25
24
63
37
A
9
6
Torque to
21 in–lb (2.4 N.m)
Fig. 3
1
1
65
B

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
59
16
1
51b
2
See page 5.1
1
2
2Brush with bearing grease
3Pack with bearing grease (1/4 tube).
3
2d

308660 5
Pinion Housing
Fig. 5
2c
Detail A 2k
2a 2b
2j
2h
2g
2f
2n
Lubricate inner and
outer diameters
Lubricate teeth
Lubricate exterior
2m
2m
Directional
arrow on roller
clutch must
face the small
bearing (2n)
06005
1
3
4
2
1
2
3
4
5
6
Press fit small
bearing (2n)
and clutch roller
(s) here
Back of pinion
housing
5
6
1.53
2n
2d 2e
2p
4
4
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
É
É
É
É
É
É
01427
2g
2h
A
B
C
D
E
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
A
78
61
51b
16
51a
53
1
48
57
62
58
77
16
59
1
3
4
2
Torque the screw to 7 ft–lb (9.5 N.m).
The face must be clean.
1
2
Spline
4
2
To engine alternator.
Detail B
5
52
2h
D
60
50
Chamfered end of hub (2h)
5
06007
6Apply low strength thread locker.
7Torque to 100 in.-lb (Nm).
7
6
6

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
1
2
Torque to
50 ft–lb (68 N.m)
Apply sealant
11
12
2
17
1
107
Model 231363 Shown
18
Fig. 8
22

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
8
Fig. 9
11
12
123
10
102
1Torque to
50 ft–lb (68 N.m)
1
17
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