308799E Ultra Max 1095 Airless Paint Sprayer, 120VAC

308799E Ultra Max 1095 Airless Paint Sprayer, 120VAC
INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
308799
Rev. E
First choice when
quality counts.t
INSTRUCTIONS
120 VAC, 15A
ULTRArMAX 1095
AIRLESS PAINT SPRAYER
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
Model 232150, Series A
Basic sprayer on Upright cart without
hose or gun
Model 232151 Series A
Complete sprayer on Upright cart with hose,
gun, RAC IVt DripLesst Tip Guard
and SwitchTipt
U.S. PATENT NO. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
7690A
Related Manuals
Displacement Pump . . . . . . . . . . . . . . . . . . . . . 308798
.
Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307614
.
Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308644
..
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
ECOPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . .
Component Function and Identification . . . . . . . . . . . .5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . .
Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . 9. .
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
...
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
..
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
...
General Repair Information . . . . . . . . . . . . . . . . . . . .16
.
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . .18
.
Power Supply Cord Replacement . . . . . . . . . . . . . . 19
.
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . .19
.
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . .21
.
Bearing Housing & Connecting Rod Replacement . 24
Warning Symbol
Caution Symbol
Drive Housing Replacement . . . . . . . . . . . . . . . . . . .25
.
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 27
..
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . .29
.
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Parts Drawing – Sprayer . . . . . . . . . . . . . . . . . . . . . .32
.
Parts List – Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . 33
..
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
..
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 36
..
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
..
Symbols
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
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 your Graco distributor .
Do not alter or modify this equipment. Use only genuine Graco parts.
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 31 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.
2
308799
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 7 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.
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.
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.
Use only with a grounded outlet that matches the grounded plug of this equipment.
MOVING PARTS HAZARD
Moving parts 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 7 to prevent the
equipment from starting unexpectedly.
NOTE: This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge. See page 31 to order.
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
4
308799
Component Identification and Function
V
T
S
A
R
B
U
03008
L
P N
M
K
J
H
C
G
D
F
E
7690A
Fig. 1
A
Motor
DC motor, permanent magnet, totally enclosed, fan cooled
B
Drive Assembly
Transfers power from DC motor to the displacement pump
C
Pail Hanger
Container for fluid to be sprayed may be hung here
D
Displacement Pump
Transfers fluid to be sprayed from source through spray gun
E
Primary Fluid Outlet
Single spray gun operation is connected here
F
Secondary Fluid Outlet
Second spray gun operation is connected here
G
Pressure Drain Valve
Relieves fluid outlet pressure when open
H
Fluid Filter
Final filter of fluid between source and spray gun
J
Pressure Adjusting Knob
Controls fluid outlet pressure
K
Pressure Control
Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
L
ON/OFF Switch
Power switch that controls 120 VAC main power to sprayer
M
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
N
50 ft (15 m) Main Hose
1/4 in. ID, grounded, nylon hose with spring guards on both ends
P
Contractor Gun
High pressure spray gun with gun safety latch
R
RAC IV Switch Tip
Uses high pressure fluid to clear tip clogs without removing tip from spray gun
S
RAC IV Tip Guard
Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
T
Spray Gun Safety Latch
Gun safety latch inhibits accidental triggering of spray gun
U
Power Cord Rack
Holds wrapped power cord for storage
V
Spray Hose Rack
Holds wrapped spray hose for storage
308799
5
Setup
2. Single gun hookup.
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Working Pressure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Connect gun and hose assembly to primary
fluid outlet (F). Do not use thread sealant.
c.
CAUTION
Do not install spray tip.
3. Two gun hookup.
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions:
Do not allow material to freeze in sprayer.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
Use nylon spray hose at least 50 ft (15 m) long.
Do not use wire braid hose.
Do not install shutoff device between sprayer and
gun. See Fig. 1.
b. Unscrew cap from 1/4 npsm(m) secondary
fluid outlet (E).
c.
Connect gun and hose assembly to secondary
fluid outlet.
WARNING
NOTE: See Fig. 1, except where noted.
1. Fill packing nut full with Graco Throat Seal Liquid
(TSL), supplied. Fig. 2.
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. Also read FIRE OR
EXPLOSION HAZARD on page 4 and
Grounding, page 7.
4. Turn ON/OFF (L) switch OFF. Plug sprayer power
cord into grounded electrical outlet at least 20 ft
(6 m) from spray area.
5. Flush pump to remove oil. See Flushing,
page 10.
Fig. 2
6
308799
6. Prepare paint according to manufacturer’s recommendations. Remove any paint skin. Stir paint
thoroughly. Strain paint through fine nylon mesh
bag (available at most paint dealers) to remove
particles that could clog filter or spray tip. This is
an important step for trouble-free paint spraying.
Setup
Grounding
Grounded
Outlets
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire or
explosion that could cause serious injury or death.
Fig. 3
Grounding Prong
2. Do not alter ground prong or use adapter.
1. This equipment requires a 120 VAC, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
Startup
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:
NOTE: See Fig. 4 except where noted.
1. Put suction tube (39) into paint container.
2. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
3. Plug in sprayer power cord.
CAUTION
Do not run pump without fluid in it for more than 30
seconds to avoid damaging pump packings.
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1.
2.
3.
4.
Engage gun safety latch.
Turn ON/OFF switch to OFF.
Unplug power supply cord.
Disengage gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Engage gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose obstruction.
Use this procedure each time you start sprayer to ensure sprayer is ready to operate safely.
Startup Procedure
NOTE: Flush sprayer if first-time startup.
See page 10.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce risk of static sparking and
splashing when priming or flushing
system, hold metal part of gun firmly to
side of grounded metal pail before triggering gun.
4. Prime pump.
a. Open (handle down) pressure drain valve (G).
If no secondary hose is installed, be sure secondary outlet cap is installed. Turn ON/OFF
(L) switch ON. Slowly turn pressure adjusting
knob clockwise until sprayer starts. When fluid
comes from drain hose, close pressure drain
valve (handle forward).
b. Fig. 5. Disengage gun safety latch. Following
warning, above, trigger gun until all air is
forced out of system and paint flows freely
from gun.
c.
Release trigger. Engage gun safety latch.
5. Check all fluid connections for leaks. Relieve fluid
pressure before tightening connections.
6. Fig. 5. Engage gun safety latch. Install spray tip.
Install tip guard. See manual 308644, supplied.
Startup
7. Adjust spray pattern.
RAC IV
HANDLE
RETAINING
NUT
GUN SAFETY
LATCH ENGAGED
a. Increase pressure just until spray from gun is
completely atomized. Use lowest pressure
necessary to get desired results. This reduces
overspray and fogging, decreases tip wear and
extends the life of the sprayer.
b. Use larger tip for more coverage rather than
increasing pressure.
c.
Test spray pattern. To adjust pattern, engage
gun safety latch, loosen retaining nut. Position
tip guard horizontally for horizontal pattern or
vertically for vertical pattern. Then tighten retaining nut. Fig. 5.
GUN SAFETY
LATCH DISENGAGED
Fig. 5
03008
Cleaning a Clogged Tip
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
1. Relieve pressure.
2. Clean front of tip frequently during operation.
3. If spray tip clogs, release gun trigger, engage gun
safety latch, and rotate RAC IV handle 180 .
See Fig. 5.
L
J
4. Disengage gun safety latch and trigger gun into
waste container. Engage gun safety latch again.
G
F
E
39
5. Rotate RAC IV handle 180 to original position,
disengage gun safety latch, and resume spraying.
6. If tip is still clogged, engage gun safety latch, shut
off and unplug the sprayer, and open pressure
drain valve to relieve pressure. Clean spray tip as
shown in manual 308644.
Fig. 4
7691A
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
6. Coil hose and hang it on hose rack when storing it,
even for overnight, to help protect hose from kinking, abrasion, coupling damage, etc.
1. Check packing nut (A) daily. First relieve pressure.
Keep packing nut full of TSL at all times to help
prevent fluid buildup on piston rod and premature
wear of packings.
A
228
If pump begins to leak, loosen packing nut and
remove throat nut spacer (228). Tighten packing
nut just snug. Over tightening causes binding and
excessive packing wear. Use a round punch or
brass rod and light hammer to adjust nut. Refer to
Fig. 6. When leakage occurs again, repack the
pump.
2. Clean fluid filter often and whenever sprayer is
stored. Follow Flushing Guidelines on page 10 for
cleaning procedure.
TIGHTEN
7692A
Fig. 6
B
3. Lubricate bearing housing after every 100 hours of
operation. First relieve pressure. Remove front
cover (49). Fill bearing housing cavity (B) with SAE
10 non-detergent oil. See Fig. 7.
49
4. For very short shutoff periods, leave suction tube
in paint, relieve pressure, and clean spray tip.
5. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 10.
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.
Fig. 7
7693A
Flushing
When to flush
Determine material to spray from column 1. Flush with
material in column 2. Then follow recommendations in
one of next three columns.
CAUTION
Do not leave water or water-based fluids in sprayer if
it could freeze. Push water out with mineral spirits.
Frozen fluid in sprayer prevents starting and may
cause serious damage.
If you are going to:
Flush with:
Prime with:
Clean with:
Store unit with:
Spray with new sprayer or
sprayer that has been
stored
Mineral spirits, then
compatible solvent
such as water or
mineral spirits
Compatible paint, Compatible solvent
such as latex or
such as water or
oil-base
mineral spirits
Mineral spirits
Spray latex paint
Warm, soapy water,
then clean water
Latex paint
Warm soapy water,
then clean water
Mineral spirits
Spray oil paint
Mineral spirits
Oil-base paint
Mineral spirits
Mineral spirits
Change latex to oil paint
Warm, soapy water,
then clean water
Mineral spirits
Mineral spirits
Mineral spirits
Change oil to latex paint
Mineral spirits, then
soapy water, and finally, clean water
Latex
Warm, soapy water,
then clean water
Mineral spirits
Change colors, same base Compatible solvent
such as water or
mineral spirits
How to flush
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing,
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 when
flushing.
1. Follow Pressure Relief Procedure on page 7.
Engage gun safety latch.
6. Do not run pump dry for more than 30 seconds to
avoid damaging pump packings!
7. Follow Pressure Relief Procedure on page 7.
Engage gun safety latch.
8. Unscrew filter bowl and reinstall clean screen.
Install bowl and hand tighten.
9. Remove suction tube and screen and clean them
separately.
FILTER
BOWL
2. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
J
3. Remove spray tip from gun. See Fig. 8. Remove
filter bowl, filter support and screen. Clean screen
separately and install bowl without screen or
support to flush it.
4. Put suction tube into a grounded metal pail with
1/2 gallon of compatible solvent. Close pressure
drain valve (G).
5. Start sprayer. See page 7. To save fluid still in
sprayer, trigger gun into another container until
next fluid appears, then trigger gun back into
compatible solvent container. Circulate flushing
fluid a few minutes to thoroughly clean system.
10
308799
SCREEN
FILTER
SUPPORT
G
7694A
Fig. 8
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
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 pressure control knob setting. The mo- 1. Slowly increase pressure setting to see if
tor will not run if it is at the minimum setting
motor starts.
(fully counterclockwise).
2. Check for a clogged spray tip or fluid filter
. Re- 2. Relieve pressure, refer to separate gun, tip,
fer to separate gun, tip, or fluid filter instruction or fluid filter instruction manual for cleaning.
manual.
Basic Mechanical Problems
1. Check for frozen or hardened paint in pump 1. Thaw. Plug in sprayer and turn on. Slowly
(64). Using a screwdriver,carefully try to rotate
increase pressure setting to see if motor
fan at back of motor by hand. See page 17.
starts. If it doesn’t, see NOTE 1, below.
2. Check displacement pump connecting rod pin 2. Push pin into place and secure with spring
(66). It must be completely pushed into conretainer.
necting rod (63) and retaining spring (68) must
be firmly in groove ofconnecting rod. See Fig.
25.
3. Check for motor damage. Remove drive
3. Replace motor (73) if fan won’t turn. See
housing assembly (67). See page 25. T ry to
page 27.
rotate fan by hand.
Basic Electrical Problems
1. Check pressure control safety circuit.
2. Turn pressure control ON/OFF switch to
OFF to RESET. If pressure control safety
continues to trip, see ELECTRICAL
SHORT on page 15.
2. Check electrical supply with volt meter. Meter 2. Reset building circuit breaker; replace
must read 105–125 VAC.
building fuse. Try another outlet.
3. Check extension cord for damage. Check ex- 3. Replace extension cord.
tension cord continuity with a volt meter.
4. Check sprayer power supply cord (79)
for 4. Replace power supply cord. See page 19.
damage such as broken insulation or wires.
NOTE 1: Thaw 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 sprayer until it has thawed completely
. If paint hardened (dried) in sprayer, pump packings must be replaced.
See page 29 (Displacement Pump Repair).
308799
11
Troubleshooting
MOTOR WON’T OPERATE (Continued)
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 Electrical Problems
(continued)
1. Check leads from motor to be sure they are
securely fastened and properly mated.
1. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Follow Pressure Relief Procedure on page 7. Remove
gun from hose. Remove pressure control cover.
Clean circuit board terminals. Securely reconnect leads.
2. Check for loose motor brush lead connections 2. Tighten terminal screws. Replace brushes
and terminals. See page 18.
if leads are damaged. See page 18.
3. Check brush length which must be 1/2” mini- 3. Replace brushes. See page 18.
mum. See page 18.
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 18.
4. Replace spring if broken. Realign spring
with brush. See page 18.
5. Check motor brushes for binding in brush
holders. See page 18.
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
spots, gouges and extreme roughness.
See page 18.
6. Remove motor and havemotor shop resurface commutator if possible. See page 27.
7. Check motor armature for shorts using arma- 7. Replace motor. See page 27.
ture tester (growler) or perform spin test. See
page 17.
8. Check motor control board (104) by perform- 8. Replace with new pressure control board
ing motor control board diagnostics on page
(104). See page 21.
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
Refer to wiring diagram on
1. Check power supply cord (79). Connect volt 1. Replace power supply cord. See page 19.
meter between TP1 (neutral) and TP2. Plugin
page 35 to identify test points
sprayer. Meter must read 105 to 125 AC.
V Un(TP).
plug sprayer.
2. Check ON/OFF switch (80). Connect volt me- 2. Replace ON/OFF switch. See page 19.
ter between TP1 and TP3 terminal on ON/
OFF switch. Plug in sprayer and turn ON.Meter must read 105 to 125 V
AC. Turn off and unplug sprayer. Reconnect TP3.
3. Check motor thermal cutof f switch. Turn 3. If thermal switch is open (no continuity), alsprayer OFF. Check for continuity between
low motor to cool. If switch remains open afTP4 and TP5 with ohmmeter.
ter motor cools, replace motor. If thermal
switch closes after motor cools, correct
cause of overheating.
4. Check all terminals for damage or loose fit.
12
308799
4. Replace damaged terminals and
nect securely.
recon-
Troubleshooting
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 page 29.
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, turnoff and unplug sprayer.
3. Check electrical supply with volt meter. Meter 3. Reset building circuit breaker; replace
must read 105–125 VAC.
building fuse. Repair electrical outlet or try
another outlet.
4. Check extension cord size and length; must 4. Replace with a correct, grounded extenbe at least 12 gauge wire and no longer than
sion cord.
300 ft.
5. Check leads from motor to pressure control 5. Be sure male terminal blades are centered
circuit board (104) for damaged or loosewires
and firmly connected to female terminals.
or connectors. Inspect wiring insulation and
Replace any loose terminal or damaged
terminals for signs of overheating.
wiring. Securely reconnect terminals.
6. Check for loose motor brush leads andtermi- 6. Tighten terminal screws. Replace brushes
nals. See page 18.
if leads are damaged. See page 18.
7. Check for worn motor brushes which must be 7. Replace brushes. See page 18.
1/2” minimum. See page 18.
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 18.
squarely on top of brush.
9. Check motor brushes for binding in brush
holders. See page 18.
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.
10.Replace with new pressure control board
(104). See page 21.
11. Check motor armature for shorts by using an 12.Replace motor. See page 27.
armature tester (growler) or perform spin test.
See page 17.
12.Check motor control board (104) by perform- 11. Replace with new pressure control board
ing motor control board diagnostics on page
(104). See page 21.
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
308799
13
Troubleshooting
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 sealingtape
on threads if necessary.
4. Check to see if intake valve ball and piston ball4. Remove intake valve and clean. Check
are seating properly. See page 29.
balls and seats for nicks; replace if necessary. See page 29. Strain paint before using to remove particles that could clog
pump.
5. Check for leaking around throat packing nut 5. Replace packings. See pages 29–30.Also
which may indicate worn or damaged packcheck piston valve seat for hardenedpaint
ings. See page 29.
or nicks and replace if necessary. Tighten
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
(66). See page 30.
spring (68) is fully in grooveall around constroke
necting rod. See page 30.
2. Check connecting rod assembly (63) 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 25.
and unplug sprayer. See page 25.
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 motor control board are firmly 1. Reconnect securely. See Fig. 29.
connected. Be sure all male terminals blades
are centered and firmly connected to female
terminals. See Fig. 29.
2. Check maximum working pressure.
WHAT TO DO
When check is not OK refer to this column
2. Replace pressure control board (104).
See page 21.
3. Check motor control board (104) by perform- 3. Replace with a newpressure control board
ing motor control board diagnostics on page
(104). See page 21.
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
4. Check LOW OUTPUT section, page 13.
14
308799
Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Motor is hot and runs intermittently.
1. Determine if sprayer was operated at high 1. Decrease pressure setting or increase tip
pressure with small tips, which causes low
size.
motor RPM and excessive heat build up.
WHAT TO DO
When check is not OK refer to this column
2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible.
is located is no more than 90 F 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
WHAT TO DO
When check is not OK refer to this column
Building circuit breaker opens 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.
as soon as sprayer switch is
Also check wires between pressure control
turned on.
and motor. See page 27.
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
2. Correct faulty conditions.
(see page 27), bent terminal forks or other
metal to metal contact points which could
cause a short.
3. Check motor armature for shorts. Use an ar- 3. Replace motor. See page 27.
mature tester (growler) or perform spin test.
See page 17. Inspect windings for burns.
4. Check motor control board (104) by perform- 4. Replace with a newpressure control board
ing motor control board diagnostics on page
(104). See page 21.
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
Building circuit breaker opens 1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
as soon as sprayer is plugged
into outlet and sprayeris NOT 2. Check ON/OFF switch (80) See page 19. Be 2. Replace ON/OFF switch. See page 19.
sure sprayer is unplugged! Disconnect wires
turned on.
from switch. Check switch with ohmmeter .
The reading must be infinitywith the ON/OFF
switch OFF, and zero with the switch ON.
3. Check for damaged or pinched wires in the
pressure control. See page 21.
3. Replace damaged parts. See page 21.
Sprayer quits after sprayer op- 1. Check Basic Electrical Problems on page 11. 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
must read 105 to 125 VAC.
sprayer until corrected.
3. Check tightness of pump packing nut. Over 3. Loosen packing nut. Check for
leaking
tightening tightens packings on rod, restricts
around throat. Replace pump packings, if
pump action, and damages packings.
necessary. See page 29.
.
308799
15
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 flat blade
of insulated male connector is centered in wraparound blade of female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Be sure
wires are not pinched between cover and control
box.
Tool List
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. adjustable wrench
Adjustable, open-end
wrench
Torque wrench
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
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 repair before regular operation of sprayer
to be sure problem is corrected.
16
308799
WARNING
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 sprayer does not operate properly, review
repair procedure again to verify that everything
was done correctly. If necessary, see Troubleshooting Guide, pages 11 – 15, to help identify
other possible problems and solutions.
WARNING
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.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
4. Reinstall motor shield before regular operation
of sprayer and replace if 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 preceding WARNING.
Spin Test
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
WARNING
ELECTRIC SHOCK HAZARD
Do not touch brushes, leads, springs or
brush holders while the sprayer is
plugged in to reduce risk of electric
shock and serious bodily injury.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
1. Relieve pressure. Connect red and black motor
leads together with a test lead. Turn motor fan by
hand at about two revolutions per second.
2. If there is uneven or no turning resistance, check
following: broken brush springs, brush leads,
motor leads; loose brush terminal screws, motor
lead terminals; worn brushes. Repair parts as
needed. See page 18.
3. If there is still uneven or no turning resistance,
replace motor. See page 27.
F
For checking armature, motor winding and brush electrical continuity.
Setup
1. Relieve pressure. Remove drive housing. See
page 25.
2. Remove motor shield (54), fan cover (A) and
inspection covers (82). See Fig. 9.
3. Remove pressure control cover (B). Disconnect
motor leads (F) and (G). See Fig. 10.
Armature Short Circuit Test
Relieve pressure. Quickly turn motor fan by hand. If
there are no shorts, the motor will coast two or three
revolutions 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 27.
82
Fig. 10
G
7695A
54
A
Fig. 9
B
7703B
308799
17
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in. Note
that brushes wear differently on each side ofmotor, so check both. Brush Repair Kit 220853 is
available. A new spring clip, 1 10816, may be
purchased separately.
5. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes seem to wear too fast.
CAUTION
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
When installing the brushes, follow all steps carefully
to avoid damaging the parts.
6. Install new brush so lead is in long slot of holder.
See Fig. 13.
BRUSH HOLDER
NOTE: Read General Repair Information on page 16
before doing this procedure.
SHORT SLOT
LONG SLOT
1. Relieve pressure.
BRUSH
SPRING
CLIP
2. Remove motor shield (54). Remove inspection
covers (B) and gaskets on each side of motor.
See Fig. 11.
54
Fig. 13
NOTE: SPRING MUST COIL
IN THIS DIRECTION
01227
7. Slide terminal under terminal screw washer and
tighten screw. Be sure motor lead is still connected
at screw. See Fig. 14.
Fig. 11
B
7703B
SPRING
SPRING CLIP
3. Push in spring clip to release hooks from brush
holder. Pull out spring clip. See Fig. 12.
SPRING
HOOK
BRUSH
BRUSH LEAD
BRUSH
TERMINAL SCREW
SPRING CLIP
110816
Fig. 12
01227
4. Loosen brush lead terminal screw. Pull brush lead
away, leaving motor lead terminal in place. Remove brush and spring. See Fig. 14.
18
308799
Fig. 14
MOTOR LEAD
TERMINAL
01227
8. Place spring on brush as shown in Fig. 13.
9. Install spring clip and push it down to hook short
slots in housing. See Fig. 13.
10. Repeat for other side.
Motor Brush Replacement
11. Test brushes.
a. Remove pump connecting rod pin.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c.
Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
d. Inspect brush and commutator contact area for
excessive arcing. Arcs must not trail or circle
around commutator surface.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch brushes, leads, springs or
brush holders when sprayer is plugged
in to reduce risk of electric shock and
serious bodily injury.
Power Supply Cord
Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 15.
1. Relieve pressure.
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 brush inspection covers and gaskets.
13. Break in brushes.
a. Operate sprayer for one hour with no load.
b. Install connecting rod pin.
On/Off Switch
Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 15.
1. Relieve pressure.
2. Remove pressure control cover (82).
3. Disconnect power supply cord black (J) lead from
ON/OFF switch (80),the white wire (D) going to
circuit board, and green wire (E) to grounding
screw (107).
2. Remove pressure control cover (82).
3. Disconnect two wires (B) and (J) from ON/OFF
switch (80).
4. Loosen strain relief bushing (G) and remove power
supply cord (79).
4. Press in on two retaining tabs on each side of
ON/OFF switch (80) and remove.
5. Install power supply cord (79) and tighten strain
relief bushing (G).
5. Install new ON/OFF switch (80) so tabs of switch
snap into place on inside of pressure control
housing.
6. Connect power supply cord black (J) lead to
ON/OFF switch (80), white wire to circuit board
(D), and green wire (E) to grounding screw (107).
7. Install pressure control cover (82).
6. Connect two wires (B) and (J) to ON/OFF switch.
7. Install pressure control cover (82).
308799
19
Power Supply Cord and On/Off Switch
Replacement
80 B
J
79 G 107 E
D
82
Fig. 15
20
308799
Pressure Control Repair
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
Motor Control Board Removal
Motor Control Board Installation
1. Relieve pressure.
2. Fig. 16. Install motor control board (104) with four
screws (102) and washers (103).
3. Connect to motor control board:
1. Relieve pressure.
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect from motor control board:
Lead (E) to transducer.
Lead (D) to potentiometer.
Six motor leads (B).
Lead (111) to ON/OFF switch.
Lead (C) from power cord.
Lead (111) from ON/OFF switch.
Lead (C) to power cord.
Lead (D) from potentiometer.
Six motor leads (B).
Lead (E) from transducer.
4. Remove four screws (102), washers (103) and
circuit board (104).
4. Install cover (82) with five screws (28).
Motor control board diagnostics
1. Relieve pressure.
3. Turn ON/OFF switch ON.
2. Remove five screws (28) and cover (82).
See Fig. 16.
4. Observe LED operation and reference following
table:
LED
BLINKS
SPRAYER OPERATION
INDICATES
WHAT TO DO
Once
Sprayer runs
Normal operation
Do nothing
Twice
Sprayer runs
Normal operation
Do nothing
Twice
repeatedly
Sprayer shuts down and LED continues
to blink twice repeatedly
Line voltage is too
high
Lower line voltage to 120 VAC
Three times
repeatedly
Sprayer shuts down and LED continues
to blink three times repeatedly
Pressure transducer
is faulty or missing
Replace pressure transducer
Four times
repeatedly
Sprayer shuts down and LED continues
to blink four times repeatedly
Run away pressure.
Pressure greater than
4500 psi.
Replace motor control board.
See preceding Motor control
board removal procedure.
Five times
repeatedly
Sprayer shuts down and LED continues
to blink five times repeatedly
Locked rotor. Motor
can not turn because
of some mechanical
condition.
Clear obstruction and replace
broken parts preventing motor
from turning
308799
21
Pressure Control Repair
Pressure Control Transducer Removal
Pressure Adjust Potentiometer Removal
1. Relieve pressure.
1. Relieve pressure.
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect lead (E) from motor control
board (104).
4. Remove strain relief bushing (116).
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect lead (D) from motor control
board (104).
5. Remove pressure control transducer (31) and
packing o-ring (59) from control housing plate (89).
4. Remove potentiometer knob (81), sealing shaft nut
(106) and pressure adjust potentiometer (105).
Pressure Control Transducer Installation
Pressure Adjust Potentiometer Installation
1. Relieve pressure.
2. Fig. 16. Install packing o-ring (59) and pressure
control transducer (31) in control housing
plate (89). Torque to 30–35 ft-lb.
3. Install strain relief bushing (116).
4. Connect lead (E) to motor control board (104).
5. Install cover (82) with five screws (28).
22
308799
1. Relieve pressure.
2. Fig. 16. Install pressure adjust potentiometer
(105), sealing shaft nut (106) and potentiometer
knob (81).
3. Connect lead (D) to motor control board (104).
4. Install cover (82) with five screws (28).
Pressure Control Repair
59
31
97
89
81
99
116
112
98
28
91
104
86
102
120
82
87
50
B
107 A
111
E
D
C
Fig. 16
7697B
7697C
308799
23
Bearing Housing and Connecting Rod
Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 17.
NOTE: Stop sprayer at bottom of its stroke to get crank
(E) in its lowest position.T o lower crank manually, carefully rotate blades of fan with a screwdriver.
1. Relieve pressure.
11. Align connecting rod (63) with crank (E) and drive
housing locating pins (G) with bearing housing (22)
holes. Push bearing housing onto drive housing or
tap it into place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screws (25) to try
to align or seat the bearing housing; the bearing and
drive housing will not align properly and will result in
premature bearing wear.
12. Install screws and lockwashers (25,23). Tighten
screws evenly to 175 in-lb (19 N.m).
13. Install pump. See page 30.
14. Install remaining parts. See Fig. 17.
2. Remove front cover (49). Unclip drain hose (36)
from pump. Hold a wrench on pump intake valve
(213) and unscrew pump suction tube (39). Disconnect pump hose (70).
3. Push up retaining spring (68). Push pin (66) out
rear.
OIL B
67
PACK WITH
BEARING GREASE
63
25,23
E
TORQUE TO
175 in-lb (19 N.m)
49
4. Loosen locknut (47). Unscrew displacement
pump (64).
G
22
5. Remove four screws and lockwashers (25,23).
6. Lightly tap lower rear of bearing housing (22) with
a plastic mallet to loosen it from drive housing (67).
Pull bearing housing and connecting rod assembly
(63) straight off drive housing.
C
68
47
66
70
7. Remove pail bracket assembly (F) and install it on
new bearing housing.
40
64
F
213
39
8. Inspect crank (E) for excessive wear and replace
parts as needed. Evenly lubricate inside of bronze
bearing (B) with high quality motor oil. Liberally
pack roller bearing (C) with bearing grease.
36
85
9. Assemble connecting rod (63) and bearing housing
(22).
10. Clean mating surfaces of bearing and drive housings (22,67).
24
308799
Fig. 17
7698A
Drive Housing Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
CAUTION
DO NOT drop gear cluster (51) when removing drive
housing (67). Gear cluster may stay engaged in the
motor front end bell or the drive housing.
DO NOT lose thrust balls (90) located at each end of
gear cluster (51) 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 drive housing. If the balls are not
in place, the bearings will wear prematurely.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 18.
1. Relieve pressure.
2. Remove front cover (49) and motor shield (54).
Unclip drain hose (85) from pump.
4. Lightly tap lower rear of bearing housing (22) with
a plastic mallet to loosen it from drive housing (67).
Pull assembled bearing housing and connecting
rod straight off drive housing.
5. Remove two drive housing screws (26) and
lockwashers (20).
6. Remove two lower screws (16) and lockwashers
(20) and then two upper screws (16) and lockwashers (20) from front of motor (73).
7. Tap drive housing (67) with a plastic mallet to
loosen it from front of motor (73), and then pull
drive housing straight off.
8. Liberally apply approximately 4 ounces of bearing
grease to gear cluster (51). Grease is supplied
with drive housing replacement kit. Be sure thrust
balls (90) are in place.
9. Place bronze-colored washer (67b) then silver-colored washer (67a) on shaft protruding from big
gear in drive housing (67).
10. Align gears and push new drive housing straight
onto front of motor and locating pins.
11. Continue reassembling sprayer.
3. Remove four bearing housing screws (25) and
lockwashers (23).
308799
25
Drive Housing Replacement
34
2
16
20
54
90
67a
51
3
67b
67
22
25, 23
2
16
20
49
90
2
Torque to 175 in-lb (19 N.m)
2
Torque to 90–100 in-lb (10.2–11.3 N.m)
3
Liberally apply grease
Fig. 18
26
308799
1
20
26
85
Motor Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 16 and 19.
1. Relieve pressure.
CAUTION
DO NOT drop gear cluster (51) when removing drive
housing (67). The gear cluster may stay engaged in
the motor front end bell or the drive housing.
DO NOT lose thrust balls (90) located at each end of
gear cluster (51) 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.
2. Remove motor shield (54).
3. Remove pressure control cover (82). Disconnect
six motor leads (B). See figure 16.
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.
4. Remove strain relief (99) by pushing from behind
and into the control box. Pull motor wires bundle
through pressure control opening. See figure 16.
5. Remove front cover (49).
6. Remove two drive housing screws (26).
7. Remove two lower screws (16) and lockwashers
(20) and then two upper screws (16) and lockwashers (20) from front of motor (73).
8. Tap drive housing (67) with a plastic mallet to
loosen it from front of motor (73), and then pull
drive housing straight off.
9. While supporting motor (73) to keep sprayer from
tipping, remove four motor mounting screws (30).
Lift off motor.
10. Install new motor (73).
11. Liberally apply approximately 4 ounces of bearing
grease to gear cluster (51). Grease is supplied
with drive housing replacement kit. Be sure thrust
balls (90) are in place.
12. Place bronze-colored washer (67b) and then
silver-colored washer (67a) on shaft protruding
from big gear in drive housing (67).
13. Align gears and push drive housing (67) straight
onto front of motor (73) and locating pins.
14. Continue reassembling sprayer. Feed motor wires
through opening in pressure control. Connect six
motor leads to pressure control printed circuit
board. Install pressure control cover (A).
See Fig. 16.
308799
27
Motor Replacement
34
54
16
1
20
73
90
67a
51
2
67b
67
22
30
20
26
49
90
79 98
10
70
A
40
1
1
Torque to 90–100 in-lb (10.2–11.3 N.m)
2
Liberally apply grease
Fig. 19
28
308799
16
20
85
Displacement Pump Repair
Removing pump
1. Flush pump. Relieve pressure. Fig. 20. Cycle
pump with piston rod (222) in its lowest position.
4. Fig. 22. Push out pin.
2. Fig. 20. Unscrew suction tube and hose from
pump.
222
7675A
Fig. 22
5. Fig. 23. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 20
7672A
3. Fig. 21. Use screwdriver to push retaining spring
up.
Fig. 23
7673A
Repairing Pump
Fig. 21
7674A
See manual 308798 for pump repair instructions.
308799
29
Displacement Pump Repair
Installing pump
3. Fig. 26. Push retaining spring into groove all the
way around connecting rod.
WARNING
If the pin works loose, it or other 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 or property damage, including damage to the pump, connecting rod or bearing
housing.
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
1. Fig. 24. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
Fig. 26
7674A
Fig. 27. Screw jam nut down onto pump until stops.
Screw pump up into bearing housing until it is stopped
by jam nut. Back off pump and jam nut to align pump
outlet to back. Tighten jam nut by hand, then tap 1/8 to
1/4 turn with a 20 oz (maximum) hammer to approximately 75" 5 ft–lb (102 Nm).
7676A
Fig. 24
Fig. 27
2. Fig. 25. Push pin (21) into holes.
7673A
Fig. 28. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.
21
Fig. 25
7675A
Fig. 28
7677A
Accessories
DANGER LABELS
The English language DANGER label shown on
page 4 is also on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing shows the best placement of these labels for
good visibility.
Order the labels directly from Graco, free of
charge. Toll Free:
1–800–328–0211
Apply other
language here
French
Spanish
German
Greek
Korean
185955
185962
186042
186046
186050
Technical Data
Power Requirements . . . . . . . . . . . . . . . . . . .120
. VAC, 60 Hz,
1 phase, 15A minimum or 4000W generator
Motor 1.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP
(with latex at 2000 psi (138 bar, 13.8 MPa)
Working Pressure Range 0–3000 psi (0–210 bar, 0–21 MPa)
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . 193
. . (51)
Maximum Delivery Rating . . . . . . . . . . . . . . 1.1
. gpm (4.1 lpm)
Tip Size . . . . . . . . . . . . . . one
.
gun – 0.032; two guns – 0.021
(with latex at 2000 psi (138 bar, 13.8 MPa)
Power Cord . . . . . . . . . . . . . . . . 14
. AWG, 3 wire, 15 ft (4.5 m)
Inlet Paint Strainer . . . . . . . . . . . . . . . . 16
. mesh (975 micron)
stainless steel screen, reusable
Outlet Paint Filter . . . . . . . . . . . . . . . . . 60
. mesh (238 micron)
stainless steel screen, reusable
Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/4
. npt(m)
Fluid Outlet Size
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/8
. . npt(f)
Filter with standard 3/8 npt(f) to 1/4 npsm adapter 1/4 npsm
Basic Sprayer Wetted Parts: . . . . . . zinc-plated carbon steel,
polyurethane, polyethylene, stainless steel,
Delrin , chrome plating, leather,
V-Max UHMWPE, aluminum,
stainless steel, tungsten carbide
NOTE: Delrin is a registered trademark of the DuPont Co.
Dimensions
Weight (dry w/o packaging) . . . . . . . . . . . . . . . .107 lb (49 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28.5
. . in. (724 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.5
. . in. (648 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.5
. . in. (521 mm)
308799
31
Parts Drawing – Sprayer
Ultra MAX 1095 Sprayers
Model 232150, Series A
41*
77
Includes items 1 – 112, 123, 126
Basic Sprayer
84
Model 232151, Series A
54
34 73a*
41*
16
20
Includes items 1 – 126
Complete Sprayer
73
90
67a
51
67b
90
67
63
REF
77
22
62
48
52
37
35
16
REF
20
30
78
23
25
49
30
10
20
26
61
32
68
47
66
70
14
19
21
64
40
78
126
123
24
38
33
Ref 85
39
Ref 70
53
65
Ref 120
122
SEE PARTS ON PAGE 34
Ref 85
32
308799
120
121
7689B
Parts List – Sprayer
Ultra MAX 1095 Sprayers
Model 232150 Series A
Model 232151, Series A
Includes items 1 – 112, 123, 126
Basic Sprayer
REF
NO.
PART NO.
DESCRIPTION
Includes items 1 – 126
Complete Sprayer
QTY
10
110996
14
101242
16
100644
19
104811
20
105510
21
106062
22 240523
4
2
4
2
6
2
1
23
24
25
26
30
4
4
4
2
7
32
33
34
35
37
38
39
40
41
47
48
49
51
52
53
54
61
62
63
64
NUT, 5/16–18 unc–2a
RING, retaining
SCREW, socket head, 1/4–20 x 0.75”
HUBCAP
LOCKWASHER, spring, 1/4”
WHEEL, semi–pneumatic
BEARING HOUSING
includes 32 and 61
106115
LOCKWASHER, spring, 3/8”
114406
SCREW, filh, no. 8–32 x1”
107210
CAPSCREW, sch, 3/8–16 x 1–1/2”
107218
CAPSCREW, sch, 1/4–20 x 2.75”
111801
SCREW, serrated flange, hex hd,
5/16–18 x 1/2”
112746
NUT, hex
108691
PLUG, tubing
108865
SCREW, pan head, no. 8 x 3/8”
109032
SCREW, pnhd, 10–32 x 1/4”
110243
RING, retaining
192691
CLIP, spring
192641
TUBE, intake
162453
NIPPLE, 1/4 npt(m) x 1/4 npsm
187791
LABEL, DANGER, English
192723
NUT, hex
112827
BUTTON, snap
179899 COVER,
housing
179961
GEAR REDUCER
183350
WASHER
181072
STRAINER
240313
SHIELD, motor
includes labels 41 & 73a
192719
HANGER, pail
192027
SLEEVE
218034 CONNECTING
ROD
239923 DISPLACEMENT
PUMP
see manual 308798 for parts
2
2
6
4
2
1
1
2
2
1
2
1
1
2
1
1
1
2
1
1
REF
NO.
PART NO.
65
66
206994
176818
67
67a
67b
68
70
73
73a
77
78
84
90
97
120
121
122
123
126
DESCRIPTION
QTY
THROAT SEAL LIQUID, 8 OZ
PIN, straight, hdls,
0.3125” dia x 1.023”
239929
DRIVE HOUSING
includes 67a and 67b
178967
.WASHER, silver–colored
107089
.WASHER, bronze–colored
176817
SPRING, retaining
239984
HOSE, grounded, nylon,1/4” ID
cpld 1/4 npsm (f), 25” (635 mm),
spring guards both ends
240034* MOT
OR, ELECTRIC
includes 41 & 73a
187784
.LABEL, DANGER, French
239998
HANDLE, cart
239980
FRAME, sprayer
114271
STRAP, velcro
100069
BALL, steel, 1/4” dia.
192694
HOUSING, control, box
238361
HOSE, grounded, nylon, 1/4” ID,
cpld 1/4 npsm(f), 50 ft (15 m)
spring guards both ends
238358
HOSE, grounded, nylon, 3/16” ID,
cpld 1/4 npsm(f), 3 ft (.9 m),
spring guards both ends
220955
SPRAY GUN
see manual 307614 for parts
192838
LABEL, WARNING, French
187975
LABEL, WARNING, English
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available.
Order separately.
Parts Drawing – Sprayer
69
70
72
40
76
89
79
81
12
9
31
59
106
80
127
101
99
98
75
116
112
28
97
107
82
105
102
91
92
86
104
115
71
7
100
74
4
6
50
5
87
55
85
34
308799
Parts List – Sprayer
Ultra MAX 1095 Sprayers
Model 232150, Series A
Model 232151, Series A
Includes items 1 – 112, 123, 127
Basic Sprayer
REF
NO.
PART NO.
Includes items 1 – 127
Complete Sprayer
DESCRIPTION
REF
QTY
4
5
6
7
9
12
28
31
224807
ASSEMBLY, cam, drain valve
111600 PIN,
grooved
187625
HANDLE, valve, drain
111699
GASKET, seat, valve
104361 O-RING,
packing
167025
STRAINER, mesh, 60
114392
SCREW, mach, panhd
240314
TRANSDUCER, pressure control
includes item 59
50
100020
WASHER, lock spring
55
112538
ELBOW, 90, street, reducing
59
111457
O-RING, packing
69 240315
BOWL, filter
includes item 72
71
187615
VALVE, seat
72
171941
SPRING, compression
74
235014
ASSEMBLY, drain valve
includes items 7 and 71
75
100721 PLUG,
pipe
76
186075 SUPPOR
T, filter
79
239995
CORD SET, power
80
114277
SWITCH, rocker, (spst)
81
114273
KNOB, potentiometer
82
193012
COVER, painted
85
240144
HOSE, drain
1
1
1
1
1
1
5
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
NO.
PART NO.
DESCRIPTION
QTY
86
240316
87
89
91
92
98
99
100
101
102
104
105
106
107
111
112
115
116
127
111832
192726
107505
164672
114284
114285
240131
192831
114420
240168
236352
112382
114391
240495
114393
193051
114409
193497
HOUSING, filter
includes item 9
CAPSCREW
PLATE, housing, control
PACKING, o-ring
ADAPTER
BUSHING, strain relief
BUSHING, strain relief
CAP, for secondary outlet
PLATE, instruction
SCREW, mach, pnhd
BOARD, PC
POTENTIOMETER, pressure adjust
NUT, shaft, sealing
SCREW, ground
WIRE, jumper
SCREW 3
LABEL, warning
BUSHING, strain relief
GASKET
1
4
1
1
2
1
1
1
1
4
1
1
1
1
1
1
1
2
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available.
Order separately.
Wiring Diagram
PRESSURE CONTROL BOARD 240168
TP3
111
BLACK
Pressure
Transducer
ON/OFF
Switch
YELLOW
104
TP4
TP2
Ground
VIOLET
TP5
BLACK
107
Potentiometer
Power Supply
Cord
TP1
GREEN
from Motor
WHITE
RED (+)
BLACK(–)
Fig. 29
308799
35
Graco Standard Warranty
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 theipment
equ
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 incompatibilit
y 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 distributo
r for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defecti
ve 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 ANYOTHER 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 no
thatother
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person operty,
or pr or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two ears
(2) yof the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED W
ARRANTIES 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 assistan
ce 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 abreach 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 proceedi
ngs
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parti
es reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciai
res
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty
Program”.
Graco Phone Number
TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to
you: 1–800–690–2894 Toll Free.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
www.graco.com
36
308799
PRINTED IN USA 308799 November 1997, Revised May 1999
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