Graco 308304E Ultra 500 Airless Paint Sprayer Owner's Manual

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Graco 308304E Ultra 500 Airless Paint Sprayer Owner's Manual | Manualzz
INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
308–304
First choice when
quality counts.
Rev. E
Supersedes D
and PCN E
INSTRUCTIONS
220/240 VAC
ULTRA 500
AIRLESS PAINT SPRAYER
19.5 MPa, 195 bar (2750 psi) Maximum Working Pressure
Model 231–315 Series B
Complete sprayer on Lo-boy cart with hose,
gun, RAC IV DripLess Tip Guard
and SwitchTip
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
http://www.graco.com
COPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Repair Information . . . . . . . . . . . . . . . . . . . . . 18
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . 19
Drive Housing, Connecting Rod, and Crankshaft
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . . . 28
Parts Drawing – Loboy Sprayer . . . . . . . . . . . . . . . . . 31
Parts List – Loboy Sprayer . . . . . . . . . . . . . . . . . . . . . 32
Parts Drawing and List – Displacement Pump . . . . . 33
Parts Drawing – Pressure Control . . . . . . . . . . . . . . . 34
Parts List – Pressure Control . . . . . . . . . . . . . . . . . . . 34
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Supply Cord Replacement . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pressure Control Replacement . . . . . . . . . . . . . . . . . 22
The Graco Warranty and Disclaimers . . . . . . . . . . . . 36
Filter Board Replacement . . . . . . . . . . . . . . . . . . . . . . 23
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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
spraying 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.
Electrically disconnect all 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.
WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call Graco Technical Assistance at 1–800–543–0339.
Do not alter or modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page 35 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
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.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Wear hearing protection when operating this equipment.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.
WARNING
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,
checking 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 couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages,
free of charge.
FIRE AND
EXPLOSION HAZARD
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.
SKIN INJECTION
HAZARD
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.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Major Components
T
K
C
B
A
D
M
E
0137A
S
H
R
N
P
J
L
05203
Fig. 1
A
Motor
DC motor, 220/240 Vac, 50 Hz, 7A, 1 phase
B
Pressure Adjusting Knob
Controls fluid outlet pressure
C
ON/OFF Switch
Power switch that controls 220/240 Vac main power to sprayer
D
Drive Assembly
Transfers power from DC motor to the displacement pump
E
Fluid Filter
Final filter of fluid between source and spray gun
H
Displacement Pump
Transfers fluid to be sprayed from source through spray gun
J
50 ft (15 m) Main Hose
1/4 in. ID, grounded, nylon hose with spring guards on both ends
K
RAC IV Tip Guard
Reverse-A-Clean (RAC) tip guard reduces risk of injection injury
L
Contractor Gun
High pressure spray gun with gun safety latch
M
RAC IV Switch Tip
RAC switch tip uses high pressure fluid to remove clogs from spray
tip without removing tip from spray gun
N
3 ft (0.9 m) Hose
3/16 in. ID, grounded, nylon hose used between 50 ft hose and
spray gun to allow more flexibility when spraying
P
Primary Fluid Outlet
Single spray gun operation is connected here
R
Pressure Drain Valve
Relieves fluid outlet pressure when open
S
Pressure Control
Controls motor speed to maintain fluid outlet pressure at displacement pump oulet. Works with pressure adjusting knob.
T
Spray Gun Safety Latch
Gun safety latch inhibits accidental triggering of spray gun
308-304
5
Setup
WARNING
To reduce the risk of serious injury from static
sparking, injection, or over pressurization and
rupture of the hose or gun, all hoses must be electrically conductive, the gun must have a tip guard, and
each part must be rated for at least 21.0 MPa, 210
bar (3000 psi) Maximum Working Pressure.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions:
1. Always use grounded, flexible spray hose at
least 50 ft. (15 m) long.
2. Never use a wire braid hose as it is too rigid to act
as a pulsation dampener.
3. Never install any shutoff device between the filter
and the main hose. See Fig. 2.
4. Always use the main filter outlet for one gun operation. Never plug this outlet.
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Read the warning section FIRE OR EXPLOSION HAZARD on
page 2 for more detailed grounding
instructions.
6
308-304
NOTE: See Fig. 2 while doing the setup.
1. Fill the packing nut/wet-cup 1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
2. Connect the gun, 0.9 m (3 ft) hose and 15.1 m
(50 ft) hose. Screw the assembly onto the outlet
nipple. Don’t use thread sealant and don’t install
the spray tip yet!
3. Check the Electrical Service.
a. Electrical requirements: 220/240 V AC, 50 Hz,
7A (minimum).
b. Use a grounded electrical outlet located at least
6 m (20 ft) from the spray area.
b. Do not remove the grounding prong of the power
supply cord and do not use an adapter.
c.
Extension cord specifications: 10A, 3-wire,
grounding type. (Long lengths reduce sprayer
performance.)
4. Plug in the sprayer. Turn the ON/OFF switch
OFF. Plug the cord into a grounded electrical outlet.
5. Flush the pump to remove the oil left in to protect
pump parts after factory testing. See Flushing
on page 11.
6. Prepare the paint according to the manufacturer’s
recommendations. Remove any paint skin. Stir the
paint thoroughly. Strain the paint through a fine
nylon mesh bag (available at most paint dealers)
to remove particles that could clog the filter or
spray tip. This is an important step for trouble-free
paint spraying.
Setup
PRESSURE ADJUSTING KNOB
ON/OFF SWITCH
PRESSURE
DRAIN
VALVE
PACKING NUT/ WET–CUP
1/4 npsm(m) FLUID OUTLET NIPPLE
FILL 1/3 FULL WITH TSL
DO NOT INSTALL ANY SHUTOFF
DEVICE HERE
05204
Fig. 2
308-304
7
Startup
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that you
start it safely.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
NOTE: Flush the sprayer if this is a first-time startup.
See page 11.
NOTE: See Fig. 4 except where noted.
1. Put the suction tube into the paint container.
c.
Release the trigger. Engage the gun safety latch.
5. Check all fluid connections for leaks. Relieve
the fluid pressure before tightening connections.
6. Install the spray tip and tip guard. Engage the
gun safety latch. See Fig. 3. Install the spray tip
according to the instructions supplied with it.
7. Adjust the spray pattern.
a. Increase the pressure just until spray from the
gun is completely atomized. Use the lowest
pressure needed to get the desired results. This
reduces overspray and fogging, decreases tip
wear and extends the life of the sprayer.
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c.
2. Turn the pressure adjusting knob fully counterclockwise to zero pressure.
Test the spray pattern. T o adjust the pattern,
engage the gun safety latch, loosen the retaining
nut. Position the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern.
Then tighten the retaining nut.
GUN SAFETY
LATCH SHOWN
ENGAGED
3. Plug in the sprayer.
CAUTION
Do not run the pump without fluid in it for more than
30 seconds to avoid damage to the displacement
pump packings.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
Fig. 3
GUN SAFETY LATCH
SHOWN DISENGAGED
ON/OFF SWITCH
01020A
0137
PRESSURE ADJUSTING KNOB
4. Prime the pump.
a. Open the pressure drain valve (handle in downward position). Turn the ON/OFF switch to ON.
Slowly turn the pressure adjusting knob clockwise until the sprayer starts. When fluid comes
from the drain hose, close the valve (handle in
forward position).
b. Disengage the gun safety latch. See Fig. 3.
Following the warning, above, trigger the gun
until all air is forced out of the system and the
paint flows freely from the gun.
PRESSURE
DRAIN
VALVE
OUTLET NIPPLE
DRAIN HOSE
Fig. 4
05205
Startup
Cleaning a Clogged Tip
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
1. Clean the front of the tip frequently during the day’s
operation. First, relieve pressure.
4. Return the handle to the original position, disengage
the gun safety latch, and resume spraying.
5. If the tip is still clogged, engage the gun safety latch,
shut off and unplug the sprayer, and open the pressure drain valve to relieve pressure. Clean the spray
tip as shown on the RAC IV package.
TIP GUARD HANDLE
SHOWN IN SPRAYING
POSITION
TURN HANDLE 180,
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
GUN SAFETY
LATCH
SHOWN
ENGAGED
2. If the spray tip does clog, release the gun trigger, engage the gun safety latch, and rotate the RAC IV
handle 180. See Fig. 5.
3. Disengage the gun safety latch and trigger the gun
into a waste container. Engage the gun safety latch
again.
0137A
Fig. 5
308-304
9
Shutdown and Care
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
1. Check the packing nut/wet-cup daily. First relieve
pressure. Keep the wet-cup 1/3 full of TSL at all times
to help prevent fluid buildup on the piston rod and
premature wear of packings.
Tighten the packing nut just enough to stop leakage.
Over tightening causes binding and excessive packing wear. Use a round punch or brass rod and light
hammer to adjust the nut. Refer to Fig. 6.
6. Coil the hose and hang it on the hose rack when
storing it, even for overnight, to help protect the hose
from kinking, abrasion, coupling damage, etc.
PACKING NUT/
WET–CUP
TIGHTEN
Fig. 6
05206
2. Clean the fluid filter often and whenever the sprayer is stored. Follow the Flushing Guidelines on page
11 or refer to manual 307–273, supplied, for
the
cleaning procedure.
3. Lubricate the bearing housing after every 100
hours of operation. First relieve pressure. Remove
the front cover. Fill the bearing housing cavity with
SAE 10 non-detergent oil. See Fig. 7.
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
FILL BEARING HOUSING
CAVITY WITH SAE 10
NON-DETERGENT OIL
AFTER EVERY 100
HOURS OF OPERATION
FRONT
COVER
5. Flush the sprayer at the end of each work day and
fill it with mineral spirits to help prevent pump corrosion and freezing. See page 11.
CAUTION
To prevent pump corrosion, never leave water or any
type of paint in the sprayer when it is not in use. Pump
water or paint out with mineral spirits.
10
308-304
Fig. 7
05207
Flushing
NOTE: Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be
sprayed, or to store the sprayer. Use this chart to determine the required flushing order for the fluid you are
using, and then follow the procedure below for flushing.
*Use this category for flushing a brand new sprayer and flushing after storage.
System has
this fluid in it:
Next fluid to be
sprayed
sprayed.
*Oil-based
solvent or paint
Oil-based paint –
new color
Oil-based
solvent or paint
Oil-based
solvent or paint
Flushing order:
Flush 1
Flush 2
Mineral spirits none
Flush 3
Before you spray or store
sprayer:
none
Prime with oil-based paint
Water-based paint Mineral spirits Warm soapy
water
Clean water
Prime with water-based
paint
Prepare for
storage
none
Relieve pressure,
Leave drain valve open
Mineral spirits none
Water or water- Water-based paint Warm soapy
based paint
– new color
water
Clean water
none
Prime with water
Water or water- Oil-based paint
based paint
Warm soapy
water
Clean water
Mineral spirits
Prime with oil
Water or water- Prepare for
based paint
storage
Warm soapy
water
Clean water
Mineral spirits
Relieve pressure,
Leave drain valve open
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
1. Follow the illustrated Pressure Relief Procedure
on page 12. Engage the gun safety latch.
6. Do not run the pump dry for more than 30 seconds
to avoid damaging the pump packings!
7. Follow the illustrated Pressure Relief Procedure
on page 12. Engage the gun safety latch.
8. Unscrew the filter bowl and reinstall the clean
screen. Install the bowl and hand tighten.
9. Remove the suction tube and screen and clean
them separately.
2. Turn the pressure adjusting knob fully counterclockwise to zero pressure.
FILTER
BOWL
3. Remove the spray tip from the gun. Remove the
filter bowl and screen; see manual 307–273. Clean
the screen separately and install the bowl without
the screen to flush it. See Fig. 8.
SCREEN
4. Put the suction tube into a grounded metal pail
with 1/2 gallon of compatible solvent.
FILTER
SUPPORT
5. Start the sprayer. See page 8. To save the fluid
still in the sprayer, trigger the gun into another
container until the next fluid appears, then trigger
the gun back into the fluid you are pumping. Circulate the flushing fluid a couple of minutes to thoroughly clean the system.
PRESSURE
DRAIN VALVE
05208
Fig. 8
308-304
11
Troubleshooting
Pressure Relief Procedure
4.
To reduce the risk of serious bodily injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin,
or injury from moving parts or electric shock, always follow
this procedure whenever you shut of f the sprayer , when
checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you
stop spraying.
1.
Engage the gun safety latch.
2.
Turn the ON/OFF switch to OFF.
3.
Unplug the power supply cord.
1,5
2
Disengage the gun safety latch. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container
ready to catch the drainage. Leave the valve open until
you are 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 the tip guard
retaining nut or hose coupling to relieve pressure gradually,
then loosen completely. Now clear the tip or hose.
3
4
6
05209
Perform all Troubleshooting procedures before disassembling the sprayer.
MOTOR WON’T OPERATE
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Basic Fluid Pressure Problems 1. Check the pressure control knob setting. The 1. Slowly increase the pressure setting to see
motor will not run if it is at the minimum setting
if the motor starts.
(fully counterclockwise).
2. Check for a clogged spray tip or fluid filter. Re- 2. Relieve pressure, refer to the separate gun,
tip, or fluid filter instruction manual for
fer to the separate gun, tip, or fluid filter incleaning.
struction manual.
Basic Mechanical Problems
1. Check for frozen or hardened paint in the
1. Thaw. Plug in sprayer and turn on. Slowly
pump (19) and/or pressure control tube. Using
increase pressure setting to see if motor
a screwdriver, carefully try to rotate fan at back
starts. If it doesn’t, see NOTE 1, below.
of motor by hand. See page 17.
2. Check displacement pump connecting rod pin 2. Push pin into place and secure with spring
(20). It must be completely pushed into conretainer.
necting rod (9) and retaining spring (21) must
be firmly in groove of connecting rod. See Fig.
32.
3. Check for motor damage. Remove drive
3. Replace motor (2) if fan won’t turn. See
housing assembly (6). See page 24. Try to ropage 26.
tate fan by hand.
Basic Electrical Problems
1. Check pressure control safety circuit.
2. Turn pressure control ON/OFF switch to
OFF to RESET. If the pressure control safety continues to trip, see ELECTRICAL
SHORT on page 16.
2. Check electrical supply with volt meter. Meter 2. Reset building circuit breaker; replace
should read 200–250 VAC.
building fuse. Try another outlet.
3. Check extension cord fordamage. Check ex- 3. Replace extension cord.
tension cord continuity with a volt meter.
4. Check sprayer power supply cord (314) for
damage such as broken insulation or wires.
4. Replace power supply cord. See page 20.
5. Check motor brush leads, terminals and brush 5. Tighten terminal screws; replace brushes.
length. Brush length should be 1/2” (12 mm)
See page 19.
minimum. See page 19.
NOTE 1: Thaw the sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm
area. Do not try to start the sprayer until it has thawed completely. If paint hardened (dried) in the sprayer, the pump packings and/or
pressure control must be replaced. See page 28 (Displacement Pump) or 22 (Pressure Control).
12
308-304
MOTOR WON’T OPERATE (Continued)
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Follow Pressure Relief Proce- 1. Check leads from motor to be sure they are
securely fastened and properly mated.
dure on page 13. Remove gun
from hose. Remove pressure
control.
WHAT TO DO
When check is not OK refer to this column
1. Replace loose terminals; crimp to leads. Be
sure male terminal blades are straight and
firmly connected to mating part.
Clean circuit board male terminals. Replace loose or damaged terminals. Securely reconnect leads.
2. Check for loose motor brush lead connections 2. Tighten terminal screws. Replace brushes
and terminals. See page 19.
if leads are damaged. See page 19.
3. Check brush length which should be 12 mm
(1/2 in.) minimum. See page 19.
3. Replace brushes. See page 19.
NOTE: The brushes do not wear at the same
rate on both sides of the motor . Check both
brushes.
4. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush. See page 19.
5. Check motor brushes for
holders. See page 19.
4. Replace spring if broken. Realign spring
with brush. See page 19.
binding in brush 5. Clean brush holders. Remove carbon with
small cleaning brush. Align brush leads
with slot in brush holder to assure free vertical brush movement.
6. Check motor armature commutator for burn 6. Remove motor and have motor shop resurspots, gouges and extreme roughness. Reface commutator if possible. See page 26.
move motor cover and brush
inspection
plates to check. See page 19.
7. Check motor armature for shorts using arma- 7. Replace motor. See page 26.
ture tester (growler) or perform spin test. See
page 17.
8. Check pressure control board (301) by substi- 8. Replace with new pressure control board
tuting with a good pressure control board. See
(301). See page 22.
page 22.
Refer to the wiring diagram on 9. Check filter board. Connect volt meter to TP7 9. Temporary bypass to check (Replace filter
and ON/Off switch TP3.Connect a jumper
board?)
page 35 to identify test points
from
TP4
to
TP8.
Plug
in
sprayer
.
Meter
(TP).
should read 200 to 250 VAC. Unplug sprayer.
Remove jumper.
1. Check power supply cord (314). Disconnect 1. Replace power supply cord. See page 20.
TP1 female (neutral) and TP2 female and
connect volt meter to these leads. Plug in
sprayer. Meter should read 200 to 250 V AC.
Unplug sprayer. Reconnect TP2.
2. Check ON/OFF switch (307). Disconnect TP3 2. Replace ON/OFF switch. See page 21.
and TP4 and connect volt meter to TP3 and
TP4 terminal on the ON/OFF switch. Plug in
sprayer and turn ON. Meter should read 200
to 250 VAC. Turn off and unplug sprayer. Reconnect TP3.
3. Check motor terminal cutoff switch. Connect 3. Allow motor to cool. Correct cause of overheating. If switch remains open after motor
volt meter to TP1 female and TP6 female.
cools, check continuity between TP4 fePlug in sprayer and turn on. Meter should read
200 to 250 VAC. Turn off and unplug sprayer.
male and TP5 female with ohmmeter . If
open, replace motor.
4. Check all terminals for damage or loose fit.
Reconnect TP1, TP2, TP3, TP4, TP5, and
TP6 connectors.
4. Replace damaged terminals and reconnect securely.
308-304
13
LOW OUTPUT
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low Output
1. Check for worn spray tip.
1. Follow Pressure Relief Procedure Warning then replace tip. See your separate gun
or tip manual.
2. Check to see that pump does not continue to 2. Service pump. See pages 28–30.
stroke when gun trigger is released. Plug in
and turn on sprayer. Prime with paint. Trigger
gun momentarily, then release and engage
safety latch. Relieve pressure, turn off and unplug sprayer.
3. Check electrical supply with volt meter. Meter 3. Reset building circuit breaker; replace
should read 200–250 VAC.
building fuse. Repair electrical outlet or try
another outlet.
4. Check extension cord size and length; must
be at least 1.5 mm 2 (12 AWG) wire and no
longer than 100m (300 ft).
4. Replace with a correct, grounded extension cord.
5. Check +, –, M+ and M– leads from motor to
pressure control circuit board (B1) for damaged or loose wires or connectors. Inspect
wiring insulation and terminals for signs of
overheating. See page 26.
5. Be sure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or damaged
wiring. Securely reconnect terminals.
6. Check for loose motor brush leads and termi- 6. Tighten terminal screws. Replace brushes
if leads are damaged. See page 19.
nals. See page 19.
7. Check for worn motor brushes which should
be 12 mm (1/2 in.) minimum. See page 19.
7. Replace brushes. See page 19.
8. Check for broken and misaligned motor brush 8. Replace spring if broken. Realign spring
springs. Rolled portion of spring must rest
with brush. See page 19.
squarely on top of brush.
9. Check motor brushes for
holders. See page 19.
binding in brush 9. Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holder to assure free vertical brush movement.
10.Check stall pressure. Gauge should read 17.0 10.Replace with new pressure control board
MPa, 170 bar (2500 psi) minimum.
(301). See page 22.
11. Check pressure control board (301) by substi- 11. Replace with new pressure control board
tuting with a good pressure control board. See
(301). See page 22.
page 22.
12.Check motor armature for shorts by using an 12.Replace motor. See page 26.
armature tester (growler) or perform spin test.
See page 17.
14
308-304
NO OUTPUT
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor runs and pump strokes
1. Check paint supply.
1. Refill and reprime pump.
2. Check for clogged intake strainer.
2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings.
3. Tighten; use thread sealant or sealing tape
on threads if necessary.
4. Check to see if intake valve ball and piston ball 4. Remove intake valve and clean. Check
are seating properly. See page 28.
balls and seats for nicks; replace if necessary. See page 28. Strain paint before using to remove particles that could clog the
pump.
5. Check for leaking around throat packing nut 5. Replace packings. See pages 28–33. Also
check piston valve seat for hardened paint
which may indicate worn or damaged packor nicks and replace if necessary. Tighten
ings. See page 28.
the packing nut/wet-cup.
Motor runs but pump does not 1. Check displacement pump connecting rod pin 1. Replace pin if missing. Be sure retainer
(20). See page 30.
spring (42) is fully in groove all around constroke
necting rod. See page 30.
2. Check connecting rod assembly (68) for dam- 2. Replace connecting rod assembly . See
age. See page 24.
page 24.
3. Be sure crank in drive housing rotates; plug in 3. Check drive housing assembly for damage
sprayer and turn on briefly to check. Turn off
and replace if necessary. See page 24.
and unplug sprayer. See page 24.
EXCESSIVE PRESSURE FLUCTUATIONS
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Spray pattern variations.
1. Be sure leads to pressure control circuit board 1. Reconnect securely. See Fig. 33.
(B1) are firmly connected. Be sure all male terminals blades are centered and firmly connected to female terminals. See Fig. 33.
2. Check maximum working pressure.
WHAT TO DO
When check is not OK refer to this column
2. Replace with a new pressure control board
(301). See page 22.
3. Check pressure control board (301) by substi- 3. Replace with a new pressure control board
(301). See page 22.
tuting with a good pressure control board. See
page 22.
4. Check LOW OUTPUT section, page 14.
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor is hot and runs intermittently.
1. Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible.
is located is no more than 32C (90F) and
sprayer is not located in direct sun.
3. Determine if sprayer was turned on, pressur- 3 Turn off sprayer whenever you stop sprayized, but not operating for long periods of time.
ing for a while and relieve fluid pressure.
ELECTRICAL SHORT
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Building circuit breaker opens
as soon as sprayer switch is
turned on.
1. Check all electrical wiring for damaged insula- 1. Repair or replace any damaged wiring or
tion, and all terminals for loose fit or damage.
terminals. Securely reconnect all wires.
Also check wires between pressure control
and motor which are encased in conduit (1).
See page 26.
CAUTION
Any short in any part of the
motor power circuit will cause
the control circuit to inhibit
sprayer operation. Correctly
diagnose and repair all shorts
before checking and replacing control board.
2. Check for missing inspection plate gasket
(see page 26), bent terminal forks or other
metal to metal contact points which could
cause a short.
WHAT TO DO
When check is not OK refer to this column
2. Correct faulty conditions.
3. Check motor armature for shorts. Use an ar- 3. Replace motor. See page 26.
mature tester (growler) or perform spin test.
See page 17. Inspect windings for burns.
4. Check pressure control board (301) by substi- 4. Replace with a new pressure control board
(301). See page 22.
tuting with a good control board. See page 22.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.
1. Check Basic Electrical Problems on page 12. 1. Perform necessary procedures.
2. Check ON/OFF switch (307) See page 21. Be 2. Replace ON/OFF switch. See page 21.
sure the sprayer is unplugged! Disconnect
wires from switch. Check switch with ohmmeter. The reading should be infinity with the ON/
OFF switch OFF, and zero with the switch ON.
3. Check for damaged or pinched wires in the
pressure control. See page 22.
3. Replace damaged parts. See page 22.
Sprayer quits after sprayer op- 1. Check Basic Electrical Problems on page 12. 1. Perform necessary procedures.
erates for 5 to 10 minutes.
2. Check electrical supply with volt meter. Meter 2. If voltage is too high, do not operate
should read 200 to 250 VAC.
sprayer until corrected.
3. Check tightness of pump packing nut. Overtightening tightens packings on rod, restricts
pump action, and damages packings.
.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings, if
necessary. See page 28.
Spin Test
lutions before coming to a complete stop. If the motor
does not spin freely, the armature is shorted and the motor must be replaced. See page 26.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
1
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
F
J
For checking armature, motor winding and brush electrical continuity.
Fig. 9
Setup
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Relieve pressure. Remove the drive housing. See page
24.
05210
Relieve pressure. Connect the two black motor leads together with a test lead. T urn the motor fan by hand at
about two revolutions per second.
Remove the motor shield (1), the fan cover (F) and the
inspection covers (J). See Fig. 9.
If there is uneven or no turning resistance, check the following: broken brush springs, brush leads, motor leads;
loose brush terminal screws, motor lead terminals; worn
brushes. Repair parts as needed. See page 19.
Remove the pressure control/cover(301). Disconnect
the – and + leads from the motor to the pressure control/
cover terminals M–, and M+. See Fig. 10.
Armature Short Circuit Test
Relieve pressure. Quickly turn the motor fan by hand. If
there are no shorts, the motor will coast two or three revo-
If there is still uneven or no turning resistance, replace the
motor. See page 26.
301
M–
–
M+
+
04790
Fig. 10
General Repair Information
CAUTION
To reduce the risk of a pressure control malfunction:
Always use needle nose pliers to disconnect a
wire. Never pull on the wire, pull on the connector.
Mate wire connectors properly. Be sure the flat
blade of the insulated male connector is centered
in the wrap-around blade of the female connector.
Route wires carefully to avoid interference with
the other connections of the pressure control. Be
sure the wires are not pinched between the cover
and the control box.
ELECTRIC SHOCK HAZARD
To reduce the risk of serious injury, including electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the repair.
Shut off the sprayer and unplug it as soon as you
complete the inspection. Reinstall all covers, gaskets, screws and washers before operating the
sprayer.
3. If the sprayer does not operate properly, review
the repair procedure again to verify that everything
was done correctly. If necessary, see the
Troubleshooting Guide, pages 12 – 16, to help
identify other possible problems and solutions.
CAUTION
Tool List
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet
Adjustable wrench
Adjustable, open-end
wrench
Torque wrench
WARNING
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings.
4. Reinstall the motor shield before regular operation of the sprayer and replace it if it is damaged. The cover directs cooling air around the motor to help prevent overheating. It can also help
reduce the risk of burns, fire or explosion; see the
WARNING, below.
WARNING
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
2. Test your repair before regular operation of the
sprayer to be sure the problem is corrected.
18
308-304
FIRE AND EXPLOSION HAZARD
During operation, the motor and drive
housing become very hot and could
burn your skin if touched. Flammable
materials spilled on the hot, bare motor could
cause a fire or explosion. Always have the motor
shield in place during regular operation to reduce
the risk of burns, fire or explosion.
Motor Brush Replacement
NOTE: Replace the brushes when they have worn to
less than 12 mm (1/2 in). Note that the brushes
wear dif ferently on each side of the motor , so
check them both. Brush Repair Kit 222–157 is
available. A new spring clip, P/N 1 10–816 may
be purchased separately.
5. Inspect the commutator for excessive pitting, burning or gouging. A black color on the commutator is
normal. Have the commutator resurfaced by a
qualified motor repair shop if the brushes seem to
wear too fast.
CAUTION
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
When installing the brushes, follow all steps carefully to avoid damaging the parts.
6. Install a new brush so the lead is in the long slot of
the holder. See Fig. 13.
BRUSH HOLDER
NOTE: Read the GENERAL REP AIR INFORMATION
on page 18 before doing this procedure.
SHORT SLOT
LONG SLOT
1. Relieve pressure.
BRUSH
2. Remove the motor shield (1). Remove the inspection covers (J) and gaskets on each side of the
motor. See Fig. 11.
SPRING
CLIP
1
Fig. 13
NOTE: SPRING MUST COIL
IN THIS DIRECTION
01227
7. Slide the terminal under the terminal screw washer
and tighten the screw. Be sure the motor lead is
still connected at the screw. See Fig. 14.
Fig. 11
J
05210
SPRING
SPRING CLIP
3. Push in the spring clip to release its hooks from
the brush holder. Pull out the spring clip. See Fig.
12.
SPRING
BRUSH
HOOK
BRUSH LEAD
TERMINAL SCREW
BRUSH
Fig. 14
SPRING CLIP
P/N 110–816
Fig. 12
MOTOR LEAD
TERMINAL
01227
8. Place the spring on the brush as shown in Fig. 13.
01227
4. Loosen the brush lead terminal screw. Pull the
brush lead away, leaving the motor lead terminal in
place. Remove brush and spring. See Fig. 14.
9. Install the spring clip and push it down to hook the
short slots in the housing. See Fig. 13.
10. Repeat for the other side.
11. Test the brushes.
a. Remove the pump connecting rod pin.
b. With the sprayer OFF, turn the pressure control knob fully counterclockwise to minimum
pressure. Plug in the sprayer.
c.
Turn the sprayer ON. Slowly increase the
pressure until the motor is at full speed.
d. Inspect the brush and commutator contact
area for excessive arcing. Arcs should not
“trail” or circle around the commutator surface.
WARNING
CAUTION
Do not run the sprayer dry for more than 30 seconds while checking the brushes to avoid damaging the displacement pump packings.
12. Install the brush inspection covers and gaskets.
13. Break in the brushes. Operate the sprayer for at
least one hour with no load. Install the connecting
rod pin.
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
Power Supply Cord Replacement (Fig. 15)
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
NOTE: Read the GENERAL REPAIR INFORMATION
on page 18 before doing this procedure.
307
317
1. Relieve pressure.
2. Remove the pressure control board/cover (301).
3. Disconnect the power supply cord (314),
both leads from the ON/OFF switch (307), and
the green wire to the grounding screw (317).
4. Loosen the strain relief bushing (315) and remove
the power supply cord (314).
5. Install the new power supply cord in the reverse
order.
6. Install the proper plug on the other end of the power supply cord. Follow all local codes to select the
proper plug.
Fig. 15
301
315
314
04791
On/Off Switch Replacement (Fig. 16)
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
8. Powder the inside of the rubber boot (309) with
talcum powder, then shake the excess out of the
boot.
9. Install the nut and rubber boot and tighten.
10. Reconnect all wires.
NOTE: Read the GENERAL REP AIR INFORMATION
on page 18 before doing this procedure.
309
1. Relieve pressure.
2. Remove the pressure control board/cover (301).
308
3. Disconnect the two wires from the ON/OFF switch
(307). See Fig. 15.
4. Using a 5/8 in. socket wrench, remove the nut and
rubber boot (309). Remove the switch guard (308).
See Fig. 16.
D
5. Remove the ON/OFF switch (307).
6. Install the new switch so the internal tab of the
pressure control housing (D) engages with the vertical groove in the threads of the switch.
7. Install the switch guard (308), aligning the internal
tab with the groove in the threads.
307
Fig. 16
04795
308-304
21
Pressure Control Replacement
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
1. Relieve pressure.
2. Disconnect the filter/drain valve assembly and the
pump supply hose at the pressure control while
holding the pressure control fitting (A) firmly. See
the CAUTION, below. See Fig. 17.
CAUTION
Do not allow the fittings (A) to turn when removing
or connecting the hose and filter/drain assembly.
Do not over tighten the screws when attaching the
pressure control board/cover. Turning the fittings or
over tightening the screws may shift the calibration
of the pressure control.
3. Remove the four mounting screws and washers
(302, 303, 304) from the pressure control board/
cover (301). See Fig. 18.
4. Carefully remove the pressure control board/cover
(301) so as not to stress the cables.
5. Remove the potentiometer cable (310) from the
pressure control board/cover (301).
6. Disconnect the pressure control board/cover black/
white M+ and black M– leads from the motor +
and– leads.
7. Disconnect the red motor leads from the TS leads
on the pressure control board/cover (301).
8. Disconnect the brown power lead (L1) from the
filter board.
9. Disconnect the blue lead (L2) from the filter board.
10. Loosen the ground terminal screw (317) and disconnect the ground lead (C).
11. Pull off the pressure control board/cover.
TO PUMP
A
301
A
FILTER/DRAIN
VALVE ASSEMBLY
TO GUN
Fig. 17
05211
Pressure Control Replacement
12. Reassemble in the reverse order; attach ground
wire (C), power leads (L1 and L2), the red leads to
the TS terminals on the circuit board (B1), the M+
and M– leads, and the potentiometer cable to the
connector on B1. Carefully route the wires away
from the filter board. Attach the pressure control
board/cover (301) using the four mounting screws
and washers (302, 303, 304),
WARNING
Do not attempt to adjust or calibrate the pressure
control. If the pressure control is faulty, replace it.
301
302
B1
304
L1
C
303
304
317
L2
310
TS
04790
Fig. 18
Filter Board Replacement
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
1. Relieve pressure.
2. Perform the Pressure Control Replacement procedure steps 2 through 11.
3. Remove the three screws holding the filter board in
place and remove the filter board.
4. Reassemble in the reverse order; replace filter
board, attach ground wire (C), power leads (L1
and L2), the red leads to the TS terminals on the
circuit board (B1), the M+ and M– leads, and the
potentiometer cable to the connector on B1. Carefully route the wires away from the filter board. Attach the pressure control board/cover (301) using
the four mounting screws and washers (302, 303,
304),
Drive Housing, Connecting Rod, and
Crankshaft Replacement (Fig. 20)
5. Remove the screws (12), spacers (15), screws
(16) and the motor shield (1).
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
on page 18 before doing this procedure.
NOTE: See Fig. 20 for Steps 1 to 15 unless otherwise
noted.
NOTE: Stop the sprayer at the bottom of its stroke to
get the crank (57) in its lowest position. If the crank
must be lowered manually, carefully rotate the blades
of the fan with a screwdriver.
1. Remove the displacement pump. See page 28.
2. Remove the connecting rod (9). Inspect it for wear
or damage. Replace the rod, if necessary.
3. Turn the displacement rod so the pin hole faces
straight back. Insert a hex key wrench through the
hole and unscrew the screw (8) located in the back
of the drive housing. See Fig. 19.
8,7
Fig. 19
See Step 3 for
procedure
01579
4. Remove the other two screws (8) and lockwashers
(7) from the top front of the drive housing (6).
7. Lightly tap the lower rear of the drive housing (6)
with a plastic mallet to loosen it from the front of
the motor. Then pull the drive housing straight off.
8. Inspect the drive housing (6) for excessive wear
and replace parts as needed.
9. Pull the crankshaft (57) out. Inspect it for wear or
damage and replace it, if necessary. Be sure the
thrust bearings (57a and 57b) are in the proper
place on crankshaft.
10. Evenly lubricate the inside of the bronze bearing in
the drive housing with high quality motor oil. Liberally pack the roller bearing and gears with bearing
grease.
11. Carefully align the drive housing and front of the
motor with the locating pins. Push the drive housing onto the motor, or tap it into place with a plastic
mallet.
12. Reinstall the motor shield (1), screws (16) and
screws (12) and spacers (15).
CAUTION
DO NOT use the drive housing screws (8) to try to
align or seat the housing to the motor; doing so will
not ensure proper alignment, but will cause premature bearing wear.
1
1
6. Remove the two screws (58) and lockwashers (7)
holding the motor to the drive housing.
13. Install the screws (8) and lockwashers (7) on the
bearing housing and tighten evenly.
14. See Installing the Pump on page 30.
15. Reinstall the front cover and screws (11,13). Reconnect the suction tube (14) and pump outlet
hose (23).
Drive Housing, Connecting Rod,
and Crankshaft Replacement
1
1
2
Fill cavity with SAE non-detergent motor oil
7
58
15
57b
12
57
1
9
8
7
6
16
57a
11
24
24
26
21
13
23
20
19
05212
Fig. 20
Motor Replacement (Fig. 21 and 22)
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
on page 18 before doing this procedure.
1. Relieve pressure.
2. Remove the motor shield (1).
3. Remove the pressure control board/cover (301).
Disconnect the four motor leads. See figure 21.
4. Loosen the conduit connector nut on the conduit
connector (318) at the pressure control.
12. Remove the two screws (58) and lockwashers (7)
from the motor (2).
13. Tap the drive housing (6) with a plastic mallet to
loosen it from the front of the motor (2), and then
pull the drive housing straight off.
CAUTION
DO NOT drop the gear cluster (26) when removing
the drive housing (6). The gear cluster may stay engaged in the motor front end bell or the drive housing.
DO NOT lose the thrust balls (24) located at each end
of the gear cluster (26) or drop them between gears.
The balls, which are heavily covered with grease,
usually stay in the shaft recesses, but could be dislodged. If caught between gears and not removed,
the balls will seriously damage the drive housing. If
the balls are not in place, the bearings will wear prematurely.
5. Swing the conduit (41) away from the conduit connector (318).
6. Remove the conduit seal (31) from around the
conduit elbow coming into the pressure control.
Pull the motor leads through the elbow, one at a
time.
CAUTION
Always pull the motor leads one at a time to avoid
loosening the terminals, which could result in a bad
connection and poor sprayer performance.
7. Loosen the connector nut on the connector elbow
(39) at the motor and pull the conduit (41) away
from the motor. Pull the leads through the conduit,
one at a time.
8. Unscrew the connector elbow (39) from the
motor.
9. Pull the wires through the elbow, one at a time.
10. Remove the front cover (11).
11. Remove the two drive housing capscrews (8) and
lock washers (7)..
14. While supporting the motor (2) to keep the
sprayer from tipping, remove the four motor
mounting screws (4). Lift off the motor.
15. Install the new motor (2).
16. Liberally apply bearing grease to the gear cluster
(26). The gear area should have approximately 4
total ounces of grease, Grease is supplied with
the drive housing replacement kit. Be sure the
thrust balls (24) are in place.
17. Place the bronze-colored washer (57a) and then
the silver-colored washer (57b) on the shaft protruding from the big gear in the drive housing (6).
18. Align the gears and push the drive housing (6)
straight onto the front of the motor (2) and locating
pins.
19. Continue reassembling the sprayer. Use a turning
motion on the conduit (41) when feeding wires
through it. Install the conduit seal (31) around the
wires in the conduit elbow (318) at the pressure
control to keep contaminants from entering the
motor conduit. See the Detail in Fig. 22.
Motor Replacement
DETAIL
Shows position of
conduit seal (31) in
conduit connector (318)
B1
31
M+
318
+
M–
–
01232
MOTOR
POWER CORD
04772
Fig. 21
2
7
58
1
16
24
57b
LIBERALLY APPLY GREASE
26
57b
39
6
4
7
23
8
11
17
318
11
10
9
41
301
13
70
40
05213
Fig. 22
Displacement Pump Repair (Fig. 23 – 32)
Disassembling the pump.
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 whenever you are instructed to relieve pressure.
1. Unscrew the intake valve (223) and remove all
parts. See Fig. 25.
220
221*
*204
*202
11
223
Fig. 25
02396
2. Remove the plug (205). Unscrew the packing nut
(216). See Fig. 26.
3. Tap the piston rod (224) down and pull it out the
bottom of the cylinder (219). See Fig. 26.
223
23
4. Remove the throat packings. See Fig. 26.
14
Fig. 23
05214
20
205
216
*209
21
*213
Fig. 24
56
207*
224
01579
Removing the pump.
1. Flush the pump. Relieve pressure.
2. Remove the front cover (11). See Fig. 23
*208
Fig. 26
02397
5. Clamp the piston rod (224) in a vise. Loosen the
nut (211). Unscrew the piston valve (222). Remove
the piston packings. See Fig 27.
3. Unscrew the suction tube (14) from the pump,
holding a wrench on the pump intake valve (223)
to keep the pump from loosening. See Fig. 23
4. Disconnect the pump outlet hose (23). See Fig. 23
5. Use a screwdriver to push aside the retaining
spring (21) at the top of the pump. Push the pin
(20) out the rear. See Fig. 24.
6. Push the retaining spring (21) up. Push the pin
(20) out the rear.
224
211
Fig. 27
222
02398
Displacement Pump Repair
WARNING
1
To reduce the risk of serious bodily injury from pump
rupture, use only tool 224–786 to remove the sleeve.
If the sleeve is stuck, send the cylinder to your Graco
distributor for removal.
6. Remove the sleeve (218) whenever your service
the pump. Use special tool, Part No. 224–786 only.
Screw the nut (H) into the cylinder (219). Screw
down the rod (J) to push the sleeve out. See Fig.
28.
J
225*
1
211
222
Fig. 29
0029
4. Note the alignment of the piston (222) to the piston nut (211) and maintain this alignment through
Steps 5, 6 and 7.
5. Apply ONE drop of adhesive, supplied with the
repair kit, to the piston threads. Place the ball
(225*) on the piston. Hand tighten the piston into
the rod (224) just until the nut (211) contacts the
rod. See Fig. 29. Place the flats of the rod in a
vise.
H
219
6. Tighten the nut (211) onto the rod (224) to 25 N.m.
Use two wrenches to maintain the alignment as
mentioned in Step 4.
218
Fig. 28
224
Apply one drop of
sealant to these
threads
0028
Assembling the pump.
NOTE: For the best results, use repair kit 222–587,
and use all the kit parts. Parts included in the kit are
marked with an asterisk, (202*), in the text and drawings.
7. Stack the throat packings into the top of the cylinder (219). Install the packing nut (216) loosely. See
Fig. 31.
8. Install the new o–ring (202*) on top of the sleeve
(216). Insert the piston rod (224) assembly into the
top of the sleeve. Slide the sleeve assembly into
the bottom of the cylinder. Note that the tapered
end of the sleeve is the bottom. See Fig. 30.
NOTE: Soak the packings in oil, and coat the rod and
inside of the cylinder with oil.
NOTE: Alternate leather and plastic packings as
shown in Fig. 31. Be sure the lips of the v–packings
face the direction shown. Incorrect installation damages the packings and results in pump leakage.
1
Tapered end
224
202*
218
1. Check the piston rod (224) and the inside of the
sleeve (218) for scoring or scratches. If these parts
are damaged, new packings will not seal properly.
2. Stack the piston packings onto the piston (222) as
shown in Fig. 31.
3. Tighten the piston nut (211) onto the piston to 0.7
N.m.
219
1
Fig. 30
0030
9. Assemble and install the intake valve. Use a new
packing (202*). Tighten the valve to 64 N.m. See
Fig. 31.
Displacement Pump Repair
Installing the pump
1
Lips of throat v–packings must face up
2
Lips of piston v–packings must face down
3
Lips of U–cup packing must face down
1
Torque to 95 N.m
4
Leather
2
Face of bearing housing
5
Poly
6
Torque to 64 N.m
9
20
224
21
2
205
6
216
1
*209
56
22
Fig. 32
1
1. Screw the pump 3/4 of the way into the bearing
housing (6). Hold the pin (20) up to the pin hole in
the connecting rod (9) and continue screwing in
the pump until the pin slides easily into the hole.
See Fig. 32.
213*
*207
5
1
4
*208
225*
219
*210
211
*206
2
2. Align the top threads of the pump cylinder flush
with the face of the bearing housing and so the
outlet nipple (22) is straight back. See Fig. 32.
218
*202
5
*215
*214
WARNING
212*
2
4
203*
3
222
*202
204*
223
Fig. 31
Be sure the retaining spring (21) is firmly in the
groove of the connecting rod, all the way around, to
prevent it from working loose due to vibration. Refer
to Fig. 32.
If the pin works loose, parts could break off due to the
force of the pumping action. These parts could be
projected through the air and result in serious bodily
injury, sprayer damage or property damage.
*221
220
01579
6
0085
3. Push the retaining spring (21) into the groove of
the connecting rod, all the way around. Tighten the
locknut (56) very tight – 95 N.m, to prevent it loosening and damaging the threads of the bearing
housing. See Fig. 32.
4. Assemble the remaining parts.
Parts Drawing – Loboy Sprayer
Model 231–315, Series A
Ref 73
1
Danger or Warning Label
2
Identification Label
3
On outside of cover
4
On inside of cover
5
See page 34
6
This side
7
Other side
1
69
66
2
27
1
55
30
91
90
2
16
85
76
15
38
1
70
57b
2
7
12
39
33
4
26
57
6
2
11
71
9
8
7
86
16
64
58
14
6
57a
28
7
67
24
75
4
42
10
21
13
17
20
56
73
5
40
5
3
44
23
45
95
53
19
60
68
22
318
5
59
41
69
78
Ref 91
54
05216
308-304
31
Parts List – Loboy Sprayer
Model 231–315, Series A
Ultra 500, 230 Volt
Includes items 1 to 91
Ref.
No.
Part No.
Description
1
181–612
2
222–052
3
4
5
6
6a
7
8
9
10
11
12
154–636
110–963
156–823
223–100
110–293
105–510
107–445
218–359
100–040
181–611
108–709
13
14
15
16
17
19
107–209
170–113
108–663
108–865
109–014
222–584
20
21
22
176–818
176–817
162–453
23
235–575
24
26
27
28
29
100–069
218–364
185–952
105–521
206–994
30
31
33
181–609
107–447
220–678
38
39
40
185–954*
108–460
41
065–312
42
44
45
49
52
106–062
101–242
104–811
107–264
107–267
SHIELD, MOTOR,
includes one of item 24
1
MOTOR, ELECTRIC, 1/2 HP
includes items 24, 49 and 52
1
WASHER, 5/8” ID
2
SCREW, hex head, no. 5/16–18 x .25” 9
UNION, 1/4 npsm swivel x 1/4 npt
1
DRIVE HOUSING
1
. GREASE
1
5
LOCKWASHER, spring, 1/4”
3
CAPSCREW, sch, 1/4–20 x 1.5”
CONNECTING ROD
1
PLUG, pipe, 1/4”
1
COVER, drive housing
1
SCREW, pnh, Type I,
8–32 unc–3a x 1”
2
4
SCREW, filh, no. 8–32 x 1”
TUBE, suction
1
SPACER
2
6
SCREW, pan head, no. 8 x 3/8”
SPACER
2
DISPLACEMENT PUMP
see page 33 for parts
1
PIN, straight, hdls
1
SPRING, retaining
1
NIPPLE, hex, 1/4 npsm x 1/4 npt,
1–3/16”
2
HOSE, grounded, nylon, 1/4” ID, 21 3/4”
(736 m) long, spring guard both ends 1
BALL, stainless steel, 1/4” dia.
1
GEAR REDUCER
1
LABEL, DANGER
1
PLUG, plastic
2
THROAT SEAL LIQUID,
8 oz. (0.27 liter) not shown
1
LABEL, identification
1
SEAL, conduit see page 34
2
CART KIT
Includes items 3, 44, 90
1
LABEL, DANGER
1
CONNECTOR, conduit, 45
1
PRESSURE CONTROL
see parts list on page 34
1
CONDUIT, electrical,
specify length when ordering
0.79 ft
WHEEL, semi–pneumatic
2
RING, retaining
2
HUBCAP
2
2
TERMINAL see page 35
2
TERMINAL, female see page 35
Qty.
53
214–570
54
55
56
57
237–677
181–610
176–762
218–242
57a
57b
58
59
60
61
180–131
107–434
101–682
178–034
100–509
220–955
62
214–701
63
223–541
64
65
66
67
68
100–214
100–188
103–473
183–275
221–020
69
70
71
73
75
76
78
85
86
90
91
95
103–927
187–146
181–607
176–920
185–955
185–470
109–046
185–499
110–240
178–342
183–281
110–220
FILTER, fluid
Includes one of 10 and 22, see manual
307–273 for additional parts
1
PRESSURE DRAIN VALVE
1
LABEL, identification
1
1
NUT, hex, 1–1/2–18
CRANKSHAFT ASSEMBLY,
includes items 57a and 57b
1
. BEARING
1
. BEARING
1
SCREW, socket head, 1/4–20 x 0.62 ” 2
TAG, WARNING
1
PLUG, square head, 1/4 npt(m)
1
SPRAY GUN, airless
see 307–614 for parts
1
HOSE, grounded, nylon, 3/16” ID, 3 ft
(0.9 m) long, spring guards both ends 1
HOSE, grounded, nylon, 1/4” ID, 50 ft
(15 m) long, spring guard both ends
1
6
LOCKWASHER, spring, 5/16”
6
NUT, heavy hex, 5/16–18 unc–2a
TIE, wire strap
3
SPACER
2
ELBOW, 90, 1/2 npsm swivel x
3/4 npt(f)
1
2
CLAMP, hose
STRAINER
1
LABEL, identification
1
HOSE, suction
1
LABEL, DANGER, French
1
1
BRACKET, shield
UNION, adapter, swivel x 3/8 npt(m) 1
2
BRACKET, shield mounting
2
NUT, retaining, Type U
2
CLIP, large
DRAIN TUBE
1
SWIVEL
1
Replacement Danger and Warning labels, tags and
cards are available at no cost.
63
61
62
Parts Drawing & List – Displacement Pump
Model 222–584, Series A
Includes items 202 to 225
205
Ref.
No.
Part No.
Description
202*
203*
204*
205
206*
207*
208*
209*
210*
211
212*
213*
214*
215*
216
218
219
220
221*
222
223
224
225*
108–954
105–522
105–445
180–656
176–749
176–755
176–754
176–757
176–750
176–751
176–882
176–997
180–161
180–073
176–758
183–571
183–562
183–559
183–555
218–197
221–098
183–563
105–444
PACKING, o–ring, PTFE SEAL, u–cup, polyurethane
BALL, sst
PLUG 1
V–PACKING, leather
V–PACKING, leather
GLAND, male
GLAND, female
GLAND, male
NUT, hex, retaining
V–PACKING, plastic
V–PACKING, plastic
WASHER, backup
GLAND, female
NUT, packing
SLEEVE, cylinder
CYLINDER
GUIDE, ball
PIN, ball stop
VALVE, piston
VALVE, intake
ROD, piston
BALL
Qty.
2
1
1
2
2
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
216
224
*209
225*
211
*207
210*
213*
*208
212*
*206
215*
203*
219
214*
222
220
221*
*202
* These parts are also included in Repair Kit
222–587, which may be purchased separately.
218
204*
NOTE: This pump uses sleeve removal tool 224–786.
202*
223
0089
Parts Drawing – Pressure Control
309
306
313
312
308
301
302
311
305
304
310
307
303
317
319
316
304
320
315
318
314
04791
Parts List – Pressure Control
Basic Pressure Control for the ULTRA) 500 Sprayer
REF
NO.
PART NO.
301
302
303
304
305
306
307
308
309
310
238–073
107–251
112–610
100–020
189–095
290–034*
111–826
107–255
105–659
236–352
DESCRIPTION
QTY
BOARD, pressure control
SCREW,panhead, 10–24 x 1”
SCREW,panhead, 10–24 x 2”
WASHER, lock, #10
HOUSING, cast
LABEL, caution
SWITCH, toggle
GUARD, locking
BOOT, switch
POTENTIOMETER, pressure
adjustment
*Extra Warning and Caution lables are available free.
1
2
2
4
1
1
1
1
1
1
REF
NO.
PART NO.
311
312
313
314
315
316
317
318
319
320
108–358
112–768
185–565
237–822
105–746
112–376
100–078
108–460
189–286*
237–491
DESCRIPTION
SEAL, shaft
KNOB, control
LABEL, knob
CORD, power
BUSHING, strain relief
LOCKNUT
SCREW, hexhead, 8–24 x .375
CONNECTOR, conduit
LABEL, warning
BOARD, filter
QTY
1
1
1
1
1
1
4
1
1
1
Wiring Diagram
WIRING DIAGRAM
PRESSURE
TRANSDUCER
ON/OFF SWITCH
CIRCUIT
BOARD
(B1)
POTENTIOMETER
TP1 (behind)
TP2
BROWN (L1)
BLUE (L2)
TP7
TP4 (behind)
TP3
73b
BLACK/WHITE
M+
TP6
TP8
FILTER
BOARD
TP5
BLACK
M–
BLUE
73a
BLUE(L2)
– +
RED
BLACK
M–
GREEN/YELLOW
GREEN/YELLOW
GROUND
WIRE
BROWN
POWER SUPPLY CORD
MOTOR
WINDINGS
THERMAL SWITCH
Fig. 33
04772
Technical Data
Power Requirements . . . . . . . . . . . . . . 230 VAC, 50 Hz,
1 phase, 7 amp minimum
Working Pressure Range . . . . . . . . . . . . . . 0–19.5 MPa,
0–195 bar (0–2750 psi)
Cycles/liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Maximum Delivery . . . . . . . . . . . . . . . . . . . . . 1.8 liter/min
Power Cord . . . . . . . . . . . . . No. 14 AWG, 3 wire, 2.6 m
Inlet Paint Strainer . . . . . . . . . . . . . . . . . . . . . 1190 micron
Stainless steel screen, reusable
Outlet Paint Filter . . . . . . . . . . . . . . . . . . . . . . . 250 micron
Stainless steel screen, reusable
Pump Inlet Size . . . . . . 3/4 npt(m) with 20 ID chamfer
Fluid Outlet Size . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted Parts:
Displacement Pump . . . Carbon steel, Polyurethane,
UHMW polyethylene, Delrin, Leather
Filter . . . . . . Aluminum, Carbon steel, Stainless steel,
Dimensions
Manual Change Summary
Weight (dry w/o packaging) . . . . . . . . . . 36 Kg (approx.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 mm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686 mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 mm
NOTE: Delrin
This manual was revised to include the changes from
PCN E.
308-304
35
The Graco Warranty and Disclaimers
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from
defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the
exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of
sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment
is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental 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 within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
Sales Offices: Atlanta, Chicago, Detroit, Los Angeles
Foreign Offices: Belgium; Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
55440–1441
http://www.graco.com
36
308-304
PRINTED IN U.S.A.
308–304 October 1993 Revised September 1997

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