Graco 308304C ELECTRIC,230 VAC ULTRA 500 AIRLESS PAINT SPRAYER Owner's Manual

INSTRUCTIONS-PARTS LIST
a
I
)
o
This manual contains important
warnings and information.
READ AND RETAINFOR REFERENCE
G 308-304
ORAC0
Rev. C
Supersedes Aand B,
never released
ELECTRIC, 230 VAC
ULTRAs 500
Airless Paint
195 bar Maximum Working Pressure
Model 231-315, Series A
Complete sprayer with io-boy cart, hose, gun,
RAC lV@,DripLess” Tip Guard and SwitchTip”.
Table of Contents
Setup
Operation
Troubleshooting
........................ 5
.................... 6
.............. 11
Repair ......................
19
Displacement Pump Repair .... 33
Displacement Pump Parts ..... 36
Accessories ................. 36
Parts - Loboy Sprayer ........ 40
Parts - Pressure Control ...... 40
Wiring Dia ram
......... 41
Technical 8ata .::::: ......... 44
Dimensions.. ................ 44
Warranty ....................
44
NOTE This is an exampleof the DANGER labelon your sprayer.
This labelis available in other languages, free
of charge.
See Daae36 to order.
~
into the body byhigh pressure airless spray 01
Spray painting, flushing or cleaning equipment with flammable liquidsLiquids can be injected
leaks - especially hose leaks.
in confined areas can resunin fire or explosion.
Use outdoors orin extremely weii ventilated areas. Ground equipment,Keepbodyclearofthenoule.Neverstopleakswithanypartofthebody
Drain all pressure before removing parls.Avoid accidental triggeringo
hoses, containers and objects being sprayed.
n d spraying.
Avoid all ignitionsources such as static electricity from plastic drop gun by always setting safety latch when
Never
spray
without
a
tip
guard.
cloths, open flames such
as pilot lights, hot objects such as cigarettes,
arcs h m connecting or disconnecting power cordsor turning light In case
of accidental skin injection. seek
switches on and off.
“Surgical Treatment”.
immediate
Failureto follow this warning can result in death or serious injury.Failure to follow this warning can result In amputation or serious
I injury.
I
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
GRACO INC. P.0.BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT1988. GRACO INC.
II
1
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS
INJURY.
FOR PROFESSIONAL USEONLY. OBSERVE ALL WARNINGS
Read and understand all instruction man.ualsbefore Operating equipment.
FLUID INJECTION HAZARD
Safety Latch
General Safety
Wheneveryoustopspraying,Bvenforamoment,alwayssetthe
This equipment generates very
high fluid pressure. Sprayfrom
gunsafetyiatchintheclosedor"safe"position,makingthegun
the gun, leaksor Nptured componentscaninject fluid through
inoperative.Failuretosetthesafetylatchcanresultinaccidenta1
yourskinandintoyourbodyandcauseextremelyseriousbodily
triggering of the gun.
injury, including the need for amputation.
Aim. fluid injected or
splashedintotheeyesorontheskincancauseseriousdamage.
Diffuser
Never point the spray gun at anyone or at any part of the body.megundiftuserbreaksupsprayandreducestheriskoffluidinNever put hand or fingers overthe spray tip.Nevertry to "blow
jection when thetip isnot installed. Check diffuser operation
back" paint; this is NOT an air spray system.
regularly. Followthe Pressure Rellef Procedure, below, then
remove the spraytip. Aim the gun into a metalpail,holdingthe
Alwayshavethetipguardinpiaceonthespraygunwhenspraying.
gunfirm~tothepail.Usingthelowestpossibiepressure,trigger
the
gun. If thefluid emitted is not dftused into an irregular
Always follow the Pressure Rellef Procedure, below, before
stream, replace thediffuser immediately.
cleaning or removing the spraytip or servicing any system
equipment.
Tip Guard
Never try to stop or deflect leaks with your hand
body.
or
ALWAYS have the tip guard in place on the spray gun while
Besureequipmentsafetydevicesareoperatingproperlybefore spraying. Thetip guard alerts youto the fluid injection hazard
and helps reduce,
but does not prevent, the risk of accidentally
each use.
placing yourfingers or any part of yourbody close to the spray
Medical Alert--Airless Spray Wounds
tip.
If any fluid appears to penetrate yourskin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS
A SIMPLE
Trigger Guard
CUT. Teiithe doctor exactly what
fluid was injected.
Alwayshavethetriggerguardinplaceonthegunwhenspraying
to reduce the risk of accidentally triggering thegun if it is
NotetoPhyslclan:lnjectionintheskinisatraumaticinjury.Itls
dropped or bumped.
Important to treat the Injury surglcslly
as soonaspossible.
Donotdeiaytreatmenttoresearchtoxicity.Toxicityisawncern
Spray Tip Safety
withsomeexoticcoatingsinjecteddirectlyintothebloodstream.
Useearemecautionwhencleaningorchangingspraytips.Ifthe
Consultation with a plastic surgeon or reconstructive hand surspray tip clogs while spraying, engage
the gun safety latch imgeon maybe advisable.
mediately. ALWAYSfollowthePressure Rellef Procedure and
Spray Gun Safety Devices
then removethe spraytip to clean
Be sure all gun safety devicesare'operating properly before
NEVER wipeoff build-up aroundthe spraytip until pressure is
this can
each use. Do not remove or modifyany part of the gun;
cause a malfunctionand result in serious bodily injury.
fully relievedand thegun safety latch is engaged.
it.
Pressure Relief Procedure
To reduce the risk of serious
bodily injury, including fluid injection,splashingfiuidorsolventintheeyesorontheskin,or
injuryfrommovingpartsorelectricshock,alwaysfoliowthis
procedurewheneveryoushutoffthesprayer,whenchecking
or servicing any part of
the spray system, when installing,
cleaning or changing spray tips, and whenever
you stop
spraying.
1. Engage thegun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug thesprayer.
2
308-304
.4. Disengage the gun safety latch.
Hold a metal art ofthe
gun firmly to the side of a grounded metal
pair and trig
ger the gun to relieve pressure.
5. Engage thegun safety latch.
6. Openthe pressuredrainvalve,
havingacontainerready
tocatchthedrainage.Leavethevalveopenuntilyouare
ready to spray again.
If you suspect that the spraytip or hose is completely
clogged, orthat pressure hasnot been fully relieved afterfollowingthestepsabove,VERYSLOWLYloosenthetipguard
retaining nut or hose end coupling and relieve pressure
gradually, then loosen completely.
Nowciearthetiporhose.
MOVING PARTSHAZARD
Movingp,arts canpinch or amputate yourfingers or other
body
parts.Keepclearofmovingpartswhenstartingoroperatingthe
sprayer. Followthe Pressure Rellef Procedure on page 2 be-
General Safety
fore checking or servicing any of
part
the sprayer, to prevent it
from starting accidentally.
EQUIPMENT MISUSEHAZARD
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemicalsandfluids,wusingwwnMdamagedparts,cancausethem
toruptureandresultinRuidinjection,splashingintheeyesoron
theskin,orotherseriousbodilyinjury,orfire,explosionorproperty damage.
NeverafterormodifyanYPartofthisequiPment;
doingsocould
cause it to malfunction.
System Pressure
Thissprayercandevelop195 barMaximumWorking
Pressure.
Besurethatallsprayequipmentandaccessoriesusedarerated
towithstandthispressure.Donotmceedthemaximumworking
pressure of any component or accessory used
in the system.
Fluid and Solvent Compatibility
Allchemicalsusedinthesprayermustbechemicallycompatible
with the wetted parts shown
inthe TECHNICALDATA on page
44,
your chemical supplier to
compatibility,
Donotuse 1.1.l-trichloroethane, methvlenechloride. otherhaCheckallsprayequipment regularlyandrepairorreplaceworn
logenated hydrocarbon solvents or fluids
containingsuchsolor damaged parts immediately. vents in this equipment, which contains aluminum and/or zinc
parts.Suchusecouldresuitinaseriouschemicalreaction,with
Alwayswearprotectiveeyewear,gloves,clothingandrespirator
the possibiltty of explosion, which
could cause death, serious
bodily injury and/or substantial
propelty damage.
as recommendedby the fluid and solvent manufacturer.
HOSE SAFETY
High pressure fluid
in the hoses canbe very dangerous.If the
hose develops a leak, split or rupturetodue
any kind of wear,
from it can
damage or misuse, the
high pressure spray emitted
cause a fluid injection injury or other serious
bodily injury or
property damage.
Handle and route hoses carefully.
Do not pull on hosestomove
equipment. Keep the hoses clear moving
of
partsand hot surfaces. Donotusefluidsorsolventswhicharenotcompatiblewith
theinnertubeandcoverofthe hose. DonotexposeGraw hose
to temperatures above02" C or below-No C.
~uidhosesatleasionceaweek.Ifyourhosedoesnothaveatag
Tighten a l l fluid connections Securely beforeeach use.High
pressurefiuidcandislodgealoosewuplingorallowhighpresonkwhichspecifiesthemaximumelectricalresistance,contact
sure sprayto be emitted from the coupling.
the hose supplier or manufacturer
forthe maximum resistance
Never usea damaged hose. Before each use, check the entire limits. Use a resistance meter
in the appropriate range for your
hose for cuts, leaks, abrasion,bulging cover, or damage or
hose to check the resistance.If the resistance exceeds the recmovementofthehosecouplings.Ifanyoftheseconditionsexist.
ommended limits, replaceit immediately. An ungrounded or
Do not try to recouplehigh pres- poorly grounded hose can make your system hazardous. Also
replace the hose immediately.
sure hose or mend it with tape or any other device.
A repaired read FIRE
OR EXPLOSION HAZARD.
hose cannot contain the
high pressure fluid.
FIRE OR EXPLOSION HAZARD
2:
9
Staticelectricityiscreatedbytheflowoffluidthroughthe pump
Fluid hoses:.use only rounded hoses with a maximum
of
150m combined hoseengthto ensuregroundingcontinuand hose.'If every part of the spray equipment not
is properly
ity. See Hose Grounding Contlnulty.
grounded, sparking may occur; and
the system may become
hazardous. Sparking may also occur when
plugging in or un:
3 Spraygun:obtaingroundingthroughwnnectiontoapropplugging a power supply cord or using a gasoline engine. erly grounded
fluid hose andsprayer.
Sparks can ignite fumes from solvents and the fluid being
4. Object being sprayed: according to localcode.
to local code.
sprayed. dust Particles and other flammable substances. 5. Fluid supply container: according
whether youaresprayingindoorsoroutdoors,andcancausea
6. AII Solvent pails usedwhen flushing, accordingto local
fireorexplosionandseriousbodilyinjuryandpropertydamage.
code. Use onlv metal
Dails. which are conductive.
Do not
placethepaildnanon-conductivesurface,suchaspaperor
Ifyouexperienceanystaticsparkingorevenaslightshockwhile
cardboard, which Interrupts the grounding continuity.
using this equipment,
Stop Spraylng Immedlately. Check the
7.
To
maintain groundin continuitywhenflushingorrelieving
entiresystemforpropergrounding.Don0tusethesystemagain
p!essure,
always hol8 a metal partof the gun firmly
to the
until the problem has been
identifiedand corrected.
slde of a grounded metal pall. then triggergun.
the
Flushing Safety
Grounding
To reduce the risk
of static sparking, ground the sprayer all
and Reducetheriskoffluidinjectioninjury,staticsparking,orsplashothersprayequipmentusedorlocatedinthesprayarea.Check
ingbyfollowingtheflushingproceduregivenonpage9andlO
yourlocalelectricalcodefordetaiiedgroundinginstructionsfor
ofthis manual. FollowthePressure Rellef Procedureon page
your areaand typeof equipment. Be sure toground all of this 2,andremovethespraytipbeforeflushing.Holdametalpartof
the gunfirmly to the side of a grounded metal
pail and use the
spray equipment:
lowest possiblefluid pressure during flushing.
1. Sprayer: connect a ground
wire and clamp (supplied)to a
true earth ground.
IMPORTANT
-
United States Government safety standards have been
adopted under the Occupational Safety and Act.
Health
These standards
particularlythe General Standards, Part 1910, and the
Construction Standards, Part 1926
- should be consulted.
308-304
3
Setup
b. Have a licensed electrician altach an appropriate plugto the power supply cord.
NOTE When tightening fittingsat the pressure control, hold one wrench firmlv
on thehex of the Dressure
control fittingto keep It from rotating. Use another
wrench to tighten the mating fitting.
c. Use an extension cord which has
3 wires of a
minimum 1.5 mm size, and a maximum 45
of
m long. Longer lengths may affect sprayer
performance.
1. Connect the hoses
(62,63) and gun(61). See Fig.
1. Don’t use thread sealant on the hose and gun
connections. Don’t install the spray tip yet1
WARNING
If you supply your
own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has atip guard, and that each part
is rated for
at least195 bar Working Pressure. This is to r e
duce the risk of serious bodily injury caused by
static sparking,fluid injectionor over-pressurization and rupture
of the hose or gun.
CAUTION
To avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
4.
Be sure the ON/OFF switch(302) is OFF. Then
plug the cord into a grounded electrical outlet at
least 6 m away from the spray area.
WARNING
Proper electrical groundingis essential to reduce
the risk of fire or explosion which can result
in serious bodily injuryand properly damage. Refer to
the warning sectionFIRE OR EXPLOSION HAZARD on page3 for more detailed grounding instructions.
A
Do not Install any shutoff device here.
1. Always use nylon spray hose at least
15.2 m
long.
2. Never usea wire braid hoseas 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.
1.
;
4. Always use the main filter outlet for one gun
operation. Neverplug this outlet.
2. Fill the’.packing nut/wet-cup
(216) 1/3 fullwith
Graco Throat Seal Liquid
(TSL), supplied. See
Fig. 1.
3. Check the electrical service.
a. Be sure the electrical serviceIs properly rated
for your sprayer and that the outlet you use
is
properly grounded.
4
308-304
Fig. 1
ma
Setup
5. Flush the pump
to remove the lightweight
oil
6. Prepare thepaint accordingto the manufacturer's
which waslefl in to protect pumpparts after fac- recommendations.
tory testing.
a. Remove any skin that may have formed.
a. Before using water-base Daint, flushwith mineral spirits followed by soapy water, and then
b. Stir the paintto mix pigments.
a clean water flush.
b. Before using oil-base paint, flush with mineral c.
Strain the paint through a fine nylon mesh
e
bag (available at most paint dealers)
to r
move particles that could
clog thefilter or
c. See FWSHINQ on pages9 and 10 for the spray tip. This
is probably the most Important
flushing procedure. step toward trouble"ree
spray painting.
spirits only.
308-304
5
Operation
-
WARNING1 -
1
4. Disengagethe gun safely latch. See Fig.
4.
To reduce the risk of serious bodily injury, including fluid injectionor splashing in the eyes or on
the skin, or injury from moving parts, always follow 5. To prime the pump, open the pressure drain
valve. Turn the ON/OFF switch
to ON, and slowly
the Pressure Relief Procedure Warning on page
increase
the
pressure
setting
until the sprayer
2 before checking, adjusting, cleaning and shutstarts.
When
fluid
is
flowing
freely,
hold a metal
ting down the sprayer.
part of the gun firmly against and aimed into a
grounded metal waste container. See Fig.
3.
Trigger the gunto prime the hose
and gun. Keep
startup
the gun triggered until all isair
forced out of the
Use this procedure each time you
start the sprayerto
system and the paint flows freely from the gun.
help ensure the sprayer
is ready to operate and that
Release thetrigger and engage the gun safety
you startit safely.
latch.
NO= For the first time startup, be sure
to flush the
sprayer first. See pageg and 10 for FLUSHING.
1. Don't install the spray tip yet1
2. Put the suction tube into the paint container.
3. Lower the pressure setting by turning the pressure adjusting knob all the way counterclockwise.
See Fig. 2.
6. Check all fluid connections for leaks. if any leaks
are found, follow the
Pressure Relief Procedure
Warning on page
2 before tightening connections.
7. Install the spraytip andtip guard. You must use
a tip guard on the gun.
Be surethe gunsafety
latch is engaged. See Fig.4. Install the spray tip.
If you are using the RAC
iV tip guard, referto
manual 307-848, supplied with the gun, for installation instructions. If you are using some other
tip guard, refer to theinstructions supplied with
it.
A
Maintainfirm metal-tometal contact
when flushing
Fig. 3
6
308-304
0143
Operation
0. Adjust the spray pattern.
1. Clean the front of the
tip frequently during the
day's operation. First, follow the Pressure Relief
Procedure Warning on page2. Then use a
a. Increase the pressure settingby turning the
solvent-soaked brushto wipe awayfluid buildpressure adjusting knob clockwise. Increase
pressure lust until spray from the gun
is comup, which helps prevent
tip clogging.
pletely atomized.To avoid excessive over2. Ifthe spray tip does clog, release the gun trigger,
spray and fogging, and
to decrease tip wear
engage the gun safety latch, and rotateRAC
the
and extend the life of the sprayer, always use
IV handle 180". See Fig. 4.
the lowest possible pressure needed
to get
the desired results.
3. Disengage the gun safely latch and trigger the
gun into waste
a
container. Engage the gun
b. If more coverageis needed, use a larger
tip
safety latch again.
rather than increasing the pressure.
4.
c. Test the spray pattern.To adjust the direction
of the spray pattern, engage the gun safely
latch and loosen the retaining nut. Position
5.
the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern. Then
tighten the retaining nut.
Cleaning a Clogged Tip
Return the handleto the original position, disengage the gun safely latch, and resume spraying.
Is sflllclogged, engage the gun safety
latch, shutoff and unplug the sprayer, and open
the pressure drain valve
to relieve pressure. Clean
the spraytip as shown in manual 307-848, supplied with the
RAC IV.
/f the tlp
N handle shown
A RAC
in spraying position.
A Gun
safely latch
shown engaged.
..
0
0
0
I
NEVER operate the spray gun with the
tip
guard removed.
DO NOT hold your hand, body, or a in
rag
front
of the spraytip when cleaning or checking a
clogged tip.Always point the gun toward the
ground or into awaste container when checking tosee if the tipis clear.
DO NOT try to "blow back" paint; this
is NOT
an air spray sprayer.
Fig. 4
0137
Maintenance
WARNING
To reduce the risk of serious bodily injury, includ-
ing fluid injection
or splashingin the eyes oron
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure Warning
on page
2 before checking, adjusting, cleaning and shutting down the sprayer.
1. Check the packing nuthrvet-cup daily. First follow
the Pressure Relief Procedure Warning on page
2. Be sure the wet-cup
is 1/3 full of TSL atalltimes to help preventfluid buildup on the piston
rod and premature wear of packings.
The packing
nut should be tight enough
to stop leakage, but
no tighter. Over tightening may cause binding and
excessive packing wear. Usea round punch or
brass rod and light hammer to adjust the nut.See
Fig. 5.
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.
r-
WARNING
Refer to the warning sectionHOSE SAFETY on
page 3 for information on
the hazard of using
damaged hoses.
A
Turn packing nut in directionof arrow to tighten.
2. Clean thefluid filter often
and whenever the
sprayer is stored. First follow the Pressure Relief
Procedure Warningon page2. Refer to manual
307-273, supplied, for the cleaning procedure.
3. Lubricate4he bearing housing after every
100
hours of operation. Fill the connecting
rod cavity
with SAE No. 10 non-detergent oil. See Fig.
6.
4. Flush the sprayer at the end of each work day
and fill it with mineral spirits
to help prevent pump
corrosion and freezing. See
FLUSHING on page
10.
CAUTION 1-
To prevent pump corrosion, and
to reduce the
chance of fluid freezingin the pump or pressure
control in cold weather, never leave water or any
type of paintin the sprayer whenit is not in use.
Freezing can seriously damage the sprayer or result in a loss of pressure or stalling.
5. For very short shutoff periods, leave the suction
tube in the paint, follow the Pressure Relief Procedure Warning on page
2, and clean the spray
tip.
8
308-304
Fig. 5
Q
Fill withSAE No. 10
nondetergent oil
I
I
m1
NOTE: Several flushes are often required
to thoroughly clean the system and prepare
it for the next
fluid to be sprayed, orto store the sprayer. Use this
chart to determine the required flushes for the fluids
you are using, and then follow the procedure below
for flushing.
*Use this category for flushing a brand new sprayer
and flushing after storage.
Prepare to use the sprayer
Next fluid to be
System has
this fluid in it: sprayed.
Flushing order:
Flush 1
Flush 2
Flush 3
sprayer:
I
Oil-based paint- Mineral spirits none
*Oil-based
solvent or paint new color
Water-based
Oil-based
Mineral spirits
water
paint solvent or paint
Water or water- Water-based
paint - new color water
based paint
Clean water Warm soapy
Water or water- Oil-based paint
based paint
Mineral spirits Clean water Warm soapy
water
none
Prime with oil-based paint
none Clean water
Warm
soapy
Prime
with
water
Prepare the sprayer for storage
Oil-based
Prepare for
solvent or paint storage
Water or water- Prepare for
based paint storage
Mineral spirits none
none
Warm soapy Clean water Mineral spirits
water
Relieve pressure,
Leave drain valve open
Relieve pressure,
Leave drain valve open
308-304
9
r
CAUTION
1
NEVER allow waterto freeze in the pressure
control. Doing so prevents the sprayer from being
started and causes serious damage
to the pressure control. Pump the water out with mineral
spir'k.
WARNING
b reduce the riskof static sparking and splashing
h e n flushing, always remove the spray
tip from
he gun andhold a metal part of the gun firmly
to
he side of a grounded metal pail.
4. Put the suction tube into a grounded metal pail
with 2 liters of compatible solvent.
5. Start the sprayer. See Steps1 to 5'on page 6. To
save thefluid 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
minutesto thoroughly clean the system.
6. Do not run the pump dry for more30than
seconds to avoid damaging the pum packingsl
7. Follow the illustratedPressure Relief Procedure
on page2. Engage the gun safety latch.
8. Unscrew the filter bowl and reinstall the clean
screen. Install thebowl and hand tighten.
I. Follow the illustratedPressure Relief Procedure
on page2. Engage the gun safety latch.
2. Turn the pressure adjusting knob fully counter-
clockwiseto the minimum pressure.
3. Remove the spray tip from thegun. Remove the
filter bowl(A) and screen(e); leave the filter
support (C) in place. Clean the screen separately
and install the bowl without the screen
to flush it.
See Fig7.
10 308-304
Fig. 7
mSB0
Troubleshooting
Check everythinginthe guide before disassembling
the sprayer.
WARNING
I
To reduce therisk of serious bodilyinjury, including fluid injectionor splashing in the eyesor on
the skin, or injury from movingparts, always follow
the PressureRelief ProcedureWarning on page
2 before checking,adjusting, cleaning and shutting down the sprayet
I
Motor Won’tOperate
Type of Problem
What to Check
If checkis OK, go to the next check
What to Do
If check is not OK, refer to this column
Basic fluid pressure
problems
1. Check the pressure control knob setting. 1. Slowly increase the pressure setting
to see
The,motorwillnotrunifitisattheminimum
ifthe motor starts.
Basic mechanicalproblems
1. Check for frozenor hardened paintitithe 1. Thaw’. Plug in sprayer and turn
on. Slowly
setting
-~(fully
. counterclockwse).
2. Checkforacloggedspraytip.kefertothe 2. Relievepressure,refertoyourssparategun
separate gun or
tip instruction manual.
or tiD instruction manual for
tio cleaning.
-
increase pressure settingto see if motor
starts.Ifitdoesn’t,replace~hedisplacsment
pump ackings (see page 33) andlor replace t e bare pressure control box
(300).
See page 25.
2. Checkdisplacement pump connectinrod 2. Push pin into place and secure with the repin (20).It must becompletelypushetinto
taining spring.
connectingrod(9)andretainingspring(21)
should be f i r m 1 In groove of connecting
rod. See page 5.
3. Check for motor damage. Remove drive 3. Replace motor(2)iffan won’t turn.
housing assembly (6).See page 28.Try to
See page 30.
rotate fan bv hand.
E
J
Basic electrical problems
1. Check electricalsupp wnhvolt meter Me
1.
ter should read190-kdvolts.
’
2. Check extensioncord for visible damage. 2.
Use a volt meter or test lamp at extenslon
cord outlet to check.
3. Check sprayer powersupply cord 31 1) for 3.
visibledamagesuchasbrokeninsulationor
wires.
4. Check motor brush leads, terminalsand 4.
brush length. Brush length shouldbe 10
mm minimum. See page 32.
7
Reset buildin circuit breaker: replace
building fuse. ry another electrical outlet.
Replace extension cord.
Replace power supply cord.
See page 20.
Tighten terminal screws: replace brushes.
See page 32.
Thaw the sprayerif water or water-based paint has frozene, due
In to exposure to low temperatures, by placing it in a warm area.
Do not try to start the sprayeruntil it has thawed completely.If the bourdon tube was not damaged by the freezing. the pump
should operate. If paint hardened (dried)in the sprayer, thepump packings and/or bare pressure control must
be replaced. See
page 33 or 25.
308-304
11
Type of Problem
What to Check
If
check is OK, go to the next check
I
1. Check leads from bridge
308)to motor to 1.
Dlagnoalng clrcult board
be sure they ere securey fastened and
Indlcatorlamps.The normal
properly mated.
condition is red lamp on,
clear lamp on when board is
2. CheckGlandG2connectionsbetweencir- 2.
telling pump to run.
cuitboard (72)and bridge (308)fordamage
or loose termlnals.
Follow pressure Relief pro- 3. Check forloose motor brush lead connec-3.
cedure Warnlng. Remove
tions and terminals.See page 32.
gun from hose. Remove
4.
4. CheckbrushlengthwhichshouldbalOmm
pressurecontrolcoverand
minimum. See page 32.
check for faultycondition of
NO= The brushes do not wear at the
circuit board lamps.
samerateonbothsidesofthemotor.Check
both brushes.
5.
Condltlon A
5. Check for broken or misali ned motor
Both lamps on:pump
brushsprin s Rolledpotlionoyspringmust
won't operateand motor
restsquare&ontopofbrush.Seepage32.
Is not running
6. Check motor brushes for
binding~inbrush 6.
holders. See page 32.
~
~
~
~~
~~~
What to Do
If check is not OK, refer to this column
Replace anyloose terminals and crimp
ta
leads. Be sure male terminal blades
are
straight and firmly connected to matlng
pan.
Cleancircuitboardmaleterminals.Replacs
loose or damaged terminals. Securely
re.
connect leads.
Tightenterminalsuews.Replacebrushesil
leads are damaged.See page 32.
Replace brushes.See page.32.
Replace spring It broken. Realign spring
with brush. See page 32.
a
Clean brush holders. Remove carbon with
smallcleanin brush.l\lignbrushleadswith
slot in brush older to assure free vetlical
brush movement.
7. Checkmotorarmaturecommutatorforbum 1. Removemotorand have motor shop resurspots,gougesandextremeroughness.Reface commutatorifpossible. See page30.
move motor cover and brush inspection
Dlates to check. See oaae 32.
3. Replace motor.See page 30.
8. Check motorm a t u r e for shorts using armaturetester(gmwler)orperiormspintest.
see page 17.
3. Replace bridge.See page 21.
9. Check bridge (308) by substituting with a
good bridgeorperiormingbridgetest. See
pagel8or21.
CAUTION: Do not perform this check
until armature is determinedto be good. A bad arout a good
mature will Immediately burn
bridge.
r-~"
.SWTCH
12 308-304
Qpe of Problem
Condition B (continued)
Both lamps off
REFER TO THE WRING DIAGRAM ON PAGE 12
TO IDENTIFY TP POINTS.
.
!.
What to Do
What to Check
If check is not OK, refer to this column
I check is OK, go to the next check
Checkeiectricalsuppl Connectvoltmeter I. Rese!circuilbreakerorrepiaceoutletfuse.H
urcult breaker orfuse continues to own,
to electrical outlet. k t e r should read
see "Electrical Short".. Mae
18.
190-250 Volts.
.
Check powersu ply to circuit board with ?. Unplug s rayer Check continuity of both
spra ertumedOR.MeasurevoltageatTP1
poles of 8NIOFF switch (302) from TP3to
TP4andTP5toTP6.Reolaceswitchiffaultv.
and#P2.Metershouldread190-250Volts.
See page 20.
-
~~
CheckcontinuityofRFIfiiter(310)fromTP7
lo TPB and TP9 to TP10. Replace filter ii
faulty. See page 22.
Checkpowersu iycord 3ll)forcontinufromTP11tof~2and7(P13toTP14.Re#ace cord if faulty. See page 20.
Check for any loose connections.
Checkalltermhaisandwiresfordamageor 1. Repiacedamagedterminaisandreconnect
loose fit.
securely.
I. Checkmotorthermalcutoutswitch.Unplug I. Replace ekctric motor ii switch does not
close when motor is cool. See page 30.
sprayer. Allow motor to cool. Disconnect
motor thermal switch leads at TP9 and
TP10. Use ohmmeter to check continuity.
Switch should be closed when motor IS
I.
C
o
o
.l
i. Replace the microswitch. See page 23.
pressure in the pressure control. disconnectwiresTPlBandTPl9.Checkcontinuilv
across switch terminals wlth
an ohmmetei.
Switch contact should
be closed. Depress
actuatorbutton.Anaudible"dick"indicates
the contacts have opened. Ohmmeter
should read infinity.
i. Checkcircuitboard(72)bysubsfiutingwith 5. Replace circuit board.See page 24.
a good board.
i. Check microswitch (306). Wnh no fluid
.
Check circuit board(72) by removing fr%
boxwithoutdisconnectingwires;swpage
.
Replace circuit board.See page 24.
24 tor removal procedure.
Plug in and turn on sprayer. Clear lamp
should be on now [emoving thecircuil
boardoverridestheoptIcaidetector.Tumoff
and unplug the sprayer.
-
WARNING: Removing the circuit board whilestill wired overrides the
to over-pressurize, if the
optical detector which could cause the sprayer
on ONLY long
microswitchdoes not function properly. Turn the sprayer
enough to check lamp conddion, then shut
off immediately.
I
WARNING: To reduce the risk of electric shock,
handle boardby edges
to come in contact with the board!
only1 Do not ailow any metal objects
I
!. Check bourdon tube flag (A) and detector 2. Adjust pressure controlto see if that corposition (6). Reinstali circuit board(see
rects problem.See page 26.
page 24). Turn pressure setting to maximum:flagshouldextend lessthanhalfway
If not, replace bare pressure control box
into optical detectorslot from the t o n
(300). See Daae 25.
308-304
13
Low output
v p e of Problem
aw output
What to Check
If check is OK. go to the next check
1. Check forworn spray tip.
2. Check to see that pump does not continue
What to Do
ff check is not OK, refer to this column
I. Follow Pressure Rellet ProcedureWarn
lngthenreplacetip. See yourseparategun
or tip manual.
2. Service pump. See page 33.
tostrokewhenguntriggerisreleased.Plug
in and turn on sprayer. Prime with paint.
Trigger gun momentaril thenrelease and
engagesafety latch.Rekve pressure.tum
off and unplugsprayer.
3. Checkelectricalsupplywithvonmeter.Me- 3. Reset buildin circuit breaker; replace
buildingfuse. Wepair electrical outlet ortry
ter should read190-25OVotts.
another outlet.
4. Checkextensioncordsizeand1ength;must 8. ReplacewiIhacorrw3,groundedextension
cord.
be at least 1.5mm dia. wireand no longer
than 45 m.
5. CheckGlandG2leadsfrombridge(306)to 5. Cleancircuitboardmaleterminals.Replace
looseor defective lead terminals. Securely
circuitboard(72 fordamageorloosewires
reconnect lead terminals
to board.
or connectors. efer to page 24.
6. Check stall pressure. Rreif
to Pressure 3. Adjust pressure control.See page 26.
Control Adjustmenton page 26.
7. Check bridge(308) and- leads and ter- 7. Be sure male terminal blades are centered
to female terminals.
minals to motor. Inspect wiring insulation and firmly connected
Replace any loose terminal or dama ed
See
and terminals for signs of overheating.
wiring. Securely reconnect
wiresto bridlge.
page 21.
8. Checkforloosemotorbrushleadsandter- 3. Tightenterminalscrews.Replacebrushesif
leads are damaged.See page 32.
minals. See page 32.
9. Check for worn motor brushes which 3. Replace brushes.See page 32.
should be 10 mm minimum:See page 32.
10.Check for broken and misaligned motor IO. Replace springif broken. Realign spring
brushsprin s Rolledportionofspringmust
with brush.See page 32.
rest squareayon top of brush.
carbon dust
11. Check motor brushes for
binding in brush 11. Clean brush holders, remove
holders. See page 32.
withsmallcleaningbrush.Align brushlead
withslot in brush holderto assurefreevertical brush movement.
See page 24.
12. Checkcircuitboard(72 bysubstitutingwith 12.Replace circuit board.
a good circuit board. ee page 24.
13. Check motor armature for shorts byusing 13.Replace motor.See page 30.
anarmaturetester(grow1er)orperformspin
test. See Dam 17.
14. Check bridg;? (308)by substituting with a14. Replace bridge.See page 21.
good bridge or by performingthe bridge
test. See page 18 or 21.
A
+
B
~~
~~~
CAUTION
Do not perform this check until armature
is
determined to be good. Abad armature will
immediately bum out agood bridge.
14 308-304
No Output
Type of Problem
I
What to Do
What to Check
If check is OK, go to the nextcheck
1. Check paint supply.
2. Check forclogged intake strainer.
3. Check for loose suction
tube or fittings.
1.
2.
3.
4. Check to see if intakevalve ball and piston 4.
bail are seating properly. Seepage 33.
5. Checkforleakingaroundthroatpackingnut 5.
whichmayindicatewomordamagedpackings. See paQe33.
If check is not OK, refer to this column
Refilland reprime pump.
Remove and clean, then reinstall.
lighten; usethread sealant or sealingtape
on threads if necessary.
Removeintakevalveandclean.Checkballs
and seats for nicks; replaceif necessary.
See page 33.
Replacepackings.Seepage33.Alsocheck
pistonvalveseatforhardenedpaintornicks
and replace if necessary.
- ~ - ~
1. Checkdis lacementpumpconnectingrod 1. Redace Din if misslno. Be sure retainina I
pin (20). l e e page 35.
spiing(2i) isfullyingrooveallaroundCOG
necting rod. See page
35.
2. Check connecting rod (9) assembly for 2. Replace connecting rod assembly. See
Motor runsbut pump does
not stroke
~~
damage. Seepage 28.
~
~
I
I
page 28.
3. Checkdrive housingassemblyfordamage
and replaceif necessary. See page28.
Excessive Pressure Fluctuations
Type of Problem
Spray pattern variations
I
What to Check
I
1
What to Do
If
check is OK, go to the nextcheck .
If
check is not OK, refer to this coiumn
1. Be sureboth G1 and 6 2 leads frombrldge 1. Reconnect securely. See page
24.
(308)to circuit board(72)
. . are firmlv conI nected. See page24.
2. Check stall pressure. Refer to Pressure 2. Adjust pressure cuntrol.See page26.
Control Adjustmenton page 26.
3. Carefully bend flag(A) into alignment with
3. Check bourdon tube flag
(A) and detector
detector(B)slottoseeifthatcorrectsprobI
position. Turn ressure sening to maxilem. if not, replace bare pressure control
mum;flagshouPdnotdragorbindinopticai
assembly(300).Adjustpressurecontrolaf!
detector (B) slot of circult board.
ter reassembly.
"\
A
see Page 24.
4. Checkcircuitboard(72)bysubstitutingwith 4. Replace circuit board.
a good board. See page24.
5. Check LOW OUTPUT section on page 14.
308-304
15
Motor Is Hot and Runs Intermittently
What toDo
What to Check
If check is not OK, refer to this column
If check is OK, go to the next check
Checktosee if sprayer hasbeenoperatin 1. Decrease pressure setting or increase tip
size.
at high pressure with small tips, whic!
causeslowmotorRPMandresultsinexcessive heatbuild up.
. Checktoseeifambienttemperaturewhere 2. Movesprayertoshaded,coolerarealfpos
sible.
sprayer is located is more than 32- or
Cr
sprayer is locatedIn direct sun.
Check to see if sprayer has been leftin a 3. Turn off spra er whenever ou stop spraying for awhi e and relieve#uid pressure.
stalled condition (sprayer turnedon, pressurized, butnotoperatlng)forlong periods
of time.
Type of Problem
Y
Electrical Short
Type of Problem
as soon as sprayer switchis
turned on.
CAUTION
Any short in any part of the
motor power circuit, which
is
connected to the output side
of the bridge,will cause the
bridge to bum out immediataly. Correctlydiagnose and
repair all shwts before checking and replacing bridge.
~~
What to Check
What toDo
If check is OK, go to the naxtcheck
If check is not OK, refer to this column
I. Check all electrical wirin for damagedin- 1. Repair or replace any damaged wiring
or
sulation, and all termin& for loose fit or
terminals. Securely reconnect al wr
ies.
damage. Be sure to check wires between
pressure control and motor which are encased in conduit (41). See page 30.
?. Check for missing inspection plate gasket
2. Correct fauity conditions.
(see page 32). bent terminal forks or other
meta to metal mntact points whichcould
cause a short.
3. Check motor armature
for shorts by using 3. Replace motor.See page 30.
anarmaturetester(grow1ar)orperformspin
test. See page 17. Inspect windings for
burns.
Check bridge (308) by substituting with a 4. Replace bridge. See page
21.
ood bridge or by performingbridge test.
ee page18 or 21.
CAUTION
Do not perform this check until armature
is
jetermined to be good. A bad armature will
mmediately burnout a good bridge.
4.
8
Building circuit breaker opens I. Check 'BasicElectrical Problems'on page
11.
as soon as sprayer is pluggeo
2.
CheckON/OFFswfich
(302). See pa e20 2.Replace ON/OFF switch.See page 20.
into outlet and sprayerIs NOT
Be sure the sprayer is unplugged1
Dicon:
turned on.
nect wires from switch and checkswitch
with ohm meter. The ohm meter should
read Infinity with the ONlOFF switch
OFF,
and zero with the switch
ON.
CAUTION
4 short in the motor circuit
will burn the bridge
)ut Immediately, which in turn usually causes
,he ONIOFFswitch to fail in the closed mode.
16 308-304
Spin Test
WARNING
To reduce the risk of serious bodily injury, including fluid injectionor splashingin the eyes oron
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure
Warning on page
2 before checking. adjusting, cleaning
and shutting down the sprayer.
n
For checking armature, motor wlnding and brush
electrical continuity.
Setup
1. Remove the drive housing from'the sprayer
as
described in DRIVE HOUSING REPLACEMENT,
Steps 1-7, page 28.
2. Remove the pressure control cover
(48) and
screws (79). Remove the motor cover
(l),the fan
cover (F), and the Inspection covers
(J). See Fig.
8.
3.
Disconnect thetwo leads from the motor
to the
bridge (308). See Fig. 9.
Armature Short Clrcuit Test
1. Quickly turn the motor fan by hand.
If there are no
shorts, the motor will coast
two or three revolu-
Fig. 0
mJBI
tions before coming
to a complete stop.
2.
If the motor does not spin freely and resists rotation, the armatureis shorted and the motor must
be replaced. See page
30.
Armature, Brushes, and Motor Wiring
Open CircuitTest (Continuity)
1. Connect thetwo black motor leads together with
a test lead.
308
2. Turn the motor fan
by handat abouttwo revolu-
tions per second.
3.
If there is uneven or noturning resistance, check
the following and repair parts
as needed. See
page 32.
a.
b.
c.
d.
e.
f.
4.
broken brush springs
broken brush leads
loose brush terminal screws
worn brushes
broken motor leads
loose motor lead terminals
If there is still uneven or no turning resistance,
replace the motor. See page
34.
Fig. 9
w
308-304
17
Bridge Test
Remove thebridge from the pressure control box and
Check For
perform this test
to determine if the bridge
is functional. See BRIDGE RECTIFIER REPLACEMENT,
page 21. Use a continuity tester, such
as multi-meter
1. Linesholt
set on theX1 ohms scale.
Connect meter+ to bridge AC1
Connect meter- to bridoe AC2
All tests must be performed.
If the bridge fails
even
one test.it must be replaced.
2. Diode 1
Connect meter to bridge Fig. 10 shows theposition of the wireson the bridge.
Connect meter- to bridge
ACl
......................................... .
Using thecharl at the right, connect the meter wires
Connect meter to bridge AC1
as indicated and then check the continuity.
Connect meter- to bridge -
0
0
0
0
0
Fig. 10
0
+
+
~~~~~~
3. Diode 2
Connect meter+ to bridge Connect meter- to bridge AC2
+
...........
Connect meter to bridgeAC2
Connect meter- to bridge -
0
%. Gate 1
+
+
Connect meter to bridge
Connect meter- to bridge AC1
Ohmmeter
Reading
No continuity
Continuity
..................
No continuity
Continuity
..................
No continuity
No continuity
5. Gate2
Connect meter+ to bridge
Connect meter- to bridge AC2 No continuity
3.
Diode 3
Connect meter to bridge Connect meter- to bridge +
+
.........................................
+
Connect meter to bridge +
Connect meter- to bridge -
18
308-304
Continuity
..................
No continuity
r
General Repair Information
4. Test your repair before regular operation
of the
WARNING
To reduce the risk of serious bodily injury, including fluid injection or splashing
in the eyes or on
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure Warning
on page
2 before checking, adjusting, cleaning and shutting down the
sprayer.
~~
~~
sprayer to be sure the problemIs corrected.
If the sprayer does not operate properly, review
the repair procedure again
to verify thate v e y
thing was done correctly.If necessary, referto the
Troubleshooting Guide, pages11-18, to help
identify other possible problems and solutions.
WARNING
1. When disconnecting wires
in the pressure control
assembly, use needle nose pliersto separate
mating connectors.
When reconnecting the wires, be sure the flat
blade of the insulated male connector.is centered
in the wrap-around bladeof the female connec-
tor.
To reduce the riskof serious bodily injury, including electtic 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.
CAUTION
To reduce the risk of a pressure control malfunction, be sureto properly mate connectors, and
never puli on wire
a
to disconnect Pulling on a
wire could loosen
the connector fromthe wire.
it.
CAUTION
2. Route wiresin the pressure control assembly
carefully through the legs of the U-shaped bour- 5. Reinstall the motor cover before regular operation
don tube. Thisis to avoid interfering with the
of the sprayer and replace
it if it is damaged. The
bourdon tube, which movesas the pressure setcover directs cooling air around the motor to help
ting changes, andto avoid pinching the wires beprevent overheating.It can also help reduce the
tween the pressure control box and cover.
risk of bums, fire or explosion; see the WARNING, below.
CAUTION
3. Keep all screws, nuts, washers, gaskets,and
electrical fittings removed during repair procedures. These parts are
not normally provided
with
replacement assemblies.
- r
WARNING
During operation, the motor becomes very hot
and could bum your skin
if touched. Flammable
materials spilled on the hot, bare motor could
cause a fire or explosion. Always have the motor
cover in place during regular operation
to reduce
the risk of bums, fire
or explosion.
308-304
19
Power Supply Cord
-
WARNING
Before doing this procedure, follow
the Pressure
Relief Procedure Warning
on page2 to reduce
the risk ofserious bodily injury, including fluid
injection or splashingin the eyes oron the skin, or
injury from moving part.
I
>
NOTE Refer to Fig. 11 and 12.
1. Remove the nut(337) from the filter stud
(310).
2. Remove the three screws(4) holding the pressure
control tothe frame.
3. Remove the pressure control mounting bracket
(50) and screws(51).
4. Disconnect the power supply cord wires from the
control box terminal strip(336)using a screwdriver.
336
337
338
5. Install the new power supply cord
(311) in the reverse order of disassembly.
6. Have a licensed electrician install a new plug on
the other end of the cord. Be sure
to follow alllocal codes regarding the type plug
of to use.
Fig. 12
00382
On/Off Switch
WARNING
Before doing this procedure, follow the
Pressure
Relief Procedure Warning
on page2 to reduce
the riskof serious bodily injury, Including fluid injection or splashingin the eyes oron theskin, or
injury from moving part.
6. Reconnect the wires.
7. Reinstall the pressure control cover and screws.
NOTE: Refer to Fig. 13.
1. Remove the pressure control cover and screws.
302
2. Disconnect the wires from the ON/OFF switch
(302).
3. Pry off the retaining clip(303).
303
4. Remove the ONlOFF switch.
5. Install the new switch as shown
in Fig. 13.
20
308-304
Fig. 13
DpBl
Bridge/Rectifier
WARNING1-
Before doing this procedure, follow the Pressure
Relief Procedure Warnlng
on page2 to reduce
the risk of serious bodily injury, including
fluid Injection or splashingin the eyes or on the skin, or
injury from moving part.
NOTE Refer to Fig. 14.
The lockwashers(333)must bein front of the
bridge to avoid overheating which will result
in
bridge failure. Refer to the Detailin Fig. 14.
6. Make surethe bridgeis flush with the side
of the
box and tighten the screws securely.
1. Remove the pressure control cover and screws.
7. Connect all wires. Carefully route the wires.
2. Disconnect all wires from the bridge
(308)at the
appropriate terminals.
7
CAUTION
Be surethe flat blade of the insulated male connector
is centered in the wrap-around blade of
3. Outside the pressure control box on the right side
the
female
connector when
the connections are
are two screws (331).Loosen, but don’t remove
made.
Improper
connections
may cause the
the screw near the back mounting plate
(50).
sprayer
to
malfunction.
Route
all
wires carefully
to
Then loosen and remove the front screw. Slide
avoid
interference
with
the
movement
of
the
bourthe bridgeout.
don tube, circuit board, or control box cover which
could cause a malfunction.
4. Slide the new bridge
(308)Into thebox being sure
the lockwasher(333)on the rear screw
(331)is IN
FRONT of the bridge.
8. Reinstall the pressure control cover and screws.
5. Install the front screw
(331),lockwasher (333)and
nut (332).
A
Lwsen but do not remove
A Lockwasher must be in front of bridge
Fig. 14
308-304
21
Choke Replacement
WARNING
Before doing this procedure, follow the Pressure
Relief Procedure Warningon page2 to reduce
the risk of serious bodily injury, including
fluid injection or splashingin the eyes or on the skin, or
WARNING
Before doing this procedure, follow the Pressure
Relief Procedure Warnlngon page2 to reduce
the risk of serious bodily injuiy, including fluid injection or splashingin the eyes oron theskin, or
Injury from moving part.
NOTE Refer to Fig. 15 and 16.
NOTE Refer to Fig. 15 and 16.
1. Remove the pressure control cover and screws.
1. Remove the pressure control cover and screws.
2. Remove the screws(4), lockwashers (64)and
nuts (65) from the mounting bracket
( 5 0 ) and
gently pull the pressure control away from the
cart. Support the pressure control.
2. Remove the screws(4), lockwashers (61)and
nuts (65) from the mounting bracket
(50)and
gently pull the pressure control away from the
cart. Suppolt the pressure control.
3. Remove the screws(51) and the mounting bracket (50) from the back of the pressure control.
3. Remove the screws(51) and the mounting bracket (50) from the back of the pressure control.
4. Remove the grounding screw(312) and the lead.
4. Use a needle nose pliers
to remove the four wires
Loosen the appropriate screw
on the terminal
strip (336) and disconnect the yellow/green choke
lead.
5. Remove the upper nut and lockwasher
(337,338)
on the outsideof the pressure control box.
6. Remove the old choke (309) and install n
aew one
in the reverse order of disassembly.
..
from the filter(310).
5. Remove the lower nut and lockwashers
(337.338)
on the outside
of the pressure control box.
6. Remove theold filter and install a new one
in the
reverse order of disassembly.
Fig. 16
22
308-304
Microswitch
WARNING
Before doing this procedure,
Reiiei Procedure Warning on
the riskof serious bodily injuly,
jection or splashingin the eyes
injury from moving part.
foilow Pressure
the
page
2 to reduce
including fluid inor on the skin, or
5. Perform the PRESSURE CONTROL ADJUSTMEN1on page26 before regular operation ofthe
sprayer.
6. Reinstall the cover and screws.
306
NOTE Referto Fig. 17.
1. Remove the pressure control cover and screws.
2. Disconnect both wires from the microswitch(306).
to remove the nuts from
3. Use the socket wrench
the microswitch.
4.
Check to see if the flag(X) has been loosened.If
it has. be sure the
fluid pressure is 0, then loosen
the two hex nuts behind the.microswitch. Adjust
the distancefrom the top ofthe flag to the top
inside of the pressure control box
to 40.79 +/0.254 mm. lighten the screws and recheck the
dimension.
Fig. 17
308-304
23
Circuit Board
WARNING
Before doing this procedure, follow Pressure
the
Relief Procedure Warning on page
2 to reduce
the risk of serious bodily injury, including
fluid injection or splashingin the eyes or onthe skin, or
injury from moving part.
NOTE: Refer to Fig. 18.
1. Remove the pressurecontrol cover and screws.
CAUTION
Be sure theflat bladeof the insulated male
connector is centeredin the wrap-around bladeof
the female connector when the connections are
made.
Route all wires carefully
to avoid interference with
the circuit board, bourdon tube, or pressure
control cover.
These precautions are essential
to reduce therisk
of a malfunction.
1
Step 2 is essentialto reduce therisk of damaging
the
I C circuit
A board
U T while
' Oremoving
N or installing
it.
2. Turn the pressure control knob all the way coun-
'terclockwise to the minimum setting
to release
spring tension on the board.
Also check to be
sure only three or four threads of the pressure
control knobshaft are exposed below the pressure adjustment nutOrsack down the nut, if
necessary. See Fig.18.
6. Reconnect all wires. Refer
to the wiring diagram
in
Fig. 19.
7. Perform the PRESSURE CONTROL ADJUSTMENT starting on page
26, if you installed a new
board.
3. Disconnect all the circuit board wires, including
the two heavy black wires. Pay close attention
to
where connections are made. See Fig.
19.
4. To remove the board from the
box, pull out the
black plastic-tipped pin(330). Push the bottom
of the circuit board toward
the wall of the box and
carefully slide the board out.
5. Install the boardin the box at the same angle itas
was removed.
Fig.
24 308-304
Fig. 18
Pressure Control
WARNING
Before doing this procedure, follow the Pressure
Relief ProcedureWarning on page2 to reduce
the risk of serious bodily injury, including
fluid injection or splashingin the eyes oron theskin, or
injury from moving part.
4. Remove the pressure control cover and screws,
and disconnect the four motor leads
et the appropriate terminals. See Fig.19.
5. Refer to CIRCUIT BOARD REPIACEMENT on
page 24, remove the circuit board and retain.
NOTE Refer to Fig. 20.
6. Remove the conduit(41).
1. Disconnect the main
fluid hose (63) from the
7. Remove the three pressure control mounting
screws (4) and lockwashers(64)and nuts(65)
located below the pressure control box. Remove
the box.
sprayer.
CAUTION
1 - '
Do not allow the adapter
(A) to turn while installing
the new pressure control
assembly. Turning it can
damage the sensitive bourdon tube. Hold the
adapter (A) firmly with a wrench while screwing on
the swivel union (78).
2. Disconnect the fluid hose
(23) from between the
displacement pump outlet nipple
(22) and pressure control inlet elbow(342).
(A)
3. Hold the hex of the pressure control adapter
firmly with a19 mm open end wrench. Use an
adjustable wrenchto loosen the swivel union
(78),
and remove the filter
(53).
Fig. 20
8. Remove the mounting bracket
(50) and screws
(51).
in the
9. Install the new pressure control assembly
reverse orderof disassembly. Reinstall the conduit seal(31) around the wires in the conduit connector (345) to prevent motor contaminationfrom
entering the pressure control. See the
DETAIL
below.
10. Perform the PRESSURE CONTROLADJUSTMENT, page 26, before regular operation of the
sprayer.
78
308-304
25
Pressure Control Adjustment
.". ....."
Improper adjustment can cause the sprayer
to overUSE UCTREME CAUTION WHEN PERFORMING
pressurize and result
in component rupture, fire or
THIS ADJUSTMENT PROCEDUREto reduce the
obrisk of a fluid Injection injury or other serious bodily explosion. It may also prevent the sprayer from
taining the maximum working pressure, resulting
in
injury which can result from component rupture,
poor sprayer performance.
electric shock, fire, explosion, or moving parts.
NEVER try to increase the sprayer's maximum working pressure of195 bar by performing these adjustments In any other way. Normal operation
of the
This procedure sets the sprayer
195 bar MAXIMUM
sprayer at higher pressures may result
in compoWORKING PRESSUREand sets the overpressurizanent rupture, fire or explosion.
To perform this adtion switch (microswitch)to approximately 3600 psi
justment, however, the sprayer pressure must be
(242 bar).
temporad/yincreased above the normal worklno
pressure.
Perform this procedure whenever the pressure control assembly is removed and reinstalled or replaced, or a newcircuit board is installed.
NOTE The following tools and equipment are required for this procedure.
195
Use a new15.2 m spray hose rated for at least
bar MAXIMUM WORKING PRESSURE.A used, under-rated hose could develop a high pressure leak
or rupture.
5. Be sure the gun safety
latch is engaged.
3/8in. nut driver or3/8in. socket wrench
1/4 in. open end wrench
7/16 in. open end wrench
0 - 350 psi, oil-filled test gauge, Part No.102-814
Pail of clean water
Mineral spirits
NEW high pressure spray hose, PartNo. 214-915
1. Follow thePressure Relief Procedure Warning
on page2.
2. Refer to the above listof tools and equipment
needed. Remove theplug from the
top of thefluid
filter and install the fluid-filled pressure gauge
(A)
Refer to Fig. 21. Connect the gunto the new test
hose and connect the hose
to the sprayer outlet.
3. Remove the pressure control cover.
4. Place the pump suction tube
in a pail of
clean
water.
26
308-304
Fig.
Pressure Control Adjustment
NOTE For Steps5 through 18, refer to Fig. 22.
15. With the pressure control
knob at the mlnimum
setting, turn the sprayer
ON.
6. Plug in the sprayer.
7. Tum the pressure control knob
(E) to the minimum setting (fully counterclockwise), and
tum the
sprayer ON. THE DISPLACEMENT PUMP
SHOULD NOTCYCLE
If It does cycle, remove the plug(74) t o m
the bottom of the pressure control. Insert a
3/8 in. nut driver through the opening, and
unscrew the pressure adjustment 0
nutjust
until thesprayer stops running.
Adjust the Overpressurization Switch
8. With the spray gdn triggered,
s/ow/ytum the
pressure control knob clockwise just until the
sprayer starts. Prime the pump and hose.
9. Slowly tum the pressure control knob
to the maximum setting. While watching the red light on the
circuit board and the pressure gauge,
tum the nut
s/ow/y to increase pressure until the red light
goes out and the gauge reads between
238
266 bar.
o
-
If the red lightdoes not go out by 266 bar,
loosen the nut
(P) and adjust the stud
(a)until the lightgoes out.
If the red lightgoes outbefore 238 bar,
(Q) unloosen the nut
(P) and adjust the stud
til the light goesout between 238 - 266 bar.
16. S/ow/yturn the pressure control knob
(B) clockwise to the maximum setting and
hold it there.
Use a 3/8 in. nut driver or socket wrench
to slowly
turn the pressure adjustment nutclockwise
until thegauge readsEXACTLY 195 bar.
o
17. Turn the pressure control knob
to the minimum
setting. Release the gun safety latch and trigger
the gun into a grounded
waste container until
pressure is relieved. Engage the gun safety latch.
Slowly increase the pressure
to verify that the
maximum working pressureis set at 195 bar.
I
CAUTION
To prevent pump cornsion, flush water
the out of
the pump, hose and gun with mineral spirits.
Be
sure to close the drain valve, first. Use the lowest
pressure necessalyto flush. Follow the Pressure
Relief Procedure Warning on
page 2. Leave the
mineral spiritsin the pumpto protect it until you
are readyto spray again.
18. Install the plug
(74) in the bottomof the pressure
control. Removethe gauge assembly and reinstall
the plug. Flush out
the water with mineral spirits.
A
Insert wrench to adust nut 0
10. Tighten the nut (P)If it was loosened in Step 9.
11. Trigger the gunto relieve pressure. Release the
trigger and engage the safety latch. Repeat Step
9 to verify your results.
12. Install the pressure control cover.
Maximum Working Pressure Adjustment
13.
Turn the
sprayerOFF. Disengage the gunsafety
latch. Trigger the guninto agrounded waste container until pressure
is relieved. Engage the gun
safety latch.
14. Use the3/8 in. nut driver to
turn the pressure adjustment nut counterclockwise one full turn.
o
A-
74 ”
Fig. 22
308-304
27
Drive Housing, ConnectingRod,
and Crankshaft.
WARNING
Before doing this procedure, follow the Pressure
Relief Procedure Warning on page
2 to reduce
the riskof serious bodily injury, including fluid injection or splashing In the eyesonor theskin, or
injury from moving part.
NOTE See Fig. 24 for Steps 1 to 15 unless othennrise
noted.
5. Remove the screws(12),spacers (15),screws
(16)and the motor cover(1).
6. Remove thetwo screws (58)and lockwashers(7)
holding the motor
to the drive housing.
7. Lightly tap the lower rear of the drive housing
(6)
with a plastic mallet
to loosen it from the front of
the motor. Thenpull the drive housing straight
off.
8. Inspect the drive housing
(6)for excessive wear
and replace partsas needed.
NOTE Stop the sprayer at the bottomR
.of
s stroke to
get the crank(57) in its lowest position. If the crank
9. Pull the crankshaft
(57)out. Inspectit for wear or
must be lowered manually, carefully rotate the blades
damage and replace
it, if necessary. Be sure the
of the fan with a screwdriver.
thrust bearings (57a and 57b) are
in the proper
place oncrankshaft.
1. Remove the displacement pump. See page
33.
10. Evenly lubricate the inside of the bronze bearing
in the drive housing with
high quality motor oil.
2. Remove the connecting rod
(9). Inspect it for wear
Liberally
pack
the
roller
bearing and gears with
or damage. Replace the rod,if necessary.
bearing grease.
3. Turn the displacementrod so the pin hole faces
11. Carefully align the drive housing and front of the
straight back. Insert a hex key wrench through
motor with the locating pins. Push the drive housthe hole and unscrew the screw
(8) located in the
ing onto the motor, or tap
it into place witha plasback of the drive housing. See Fig.
23.
tic mallet.
12. Reinstall the motor cover
(l), screws (16)and
screws (12)and spacers(15).
CAUTION
DO NOT use the drive housing screws
(8) to tryto
align or seat the housing
to the motor; doingso
will notensure proper alignment, but will cause
premature bearing wear.
Fig. 23
13. Install the screws(8) and lockwashers(7) on the
bearing housing and tighten evenly.
01578
4. Remove the other
two screws (8) and lockwashers (7) from thetop front of the drive housing
(6).
28
308-304
14. See Installing the Pump on page
35.
15. Reinstalltheiront cover and screws(11,13).Reconnect the suction tube
(14)and pump outlet
hose (23).
308-304
29
Motor
WARNING
Before dolng this procedure, follow the Pressure
. Relief Procedure Warning
on page2 to reduce
the risk of serious bodily injury. including fluid injection or splashingin the eyes or on the skin, or
injury from moving part.
CAUTION
Always pull the motor leads one at a time
to avoid
loosening the terminals.
NOTE See Fig.26 except where noted.
6. Loosen the conduit connector
(39) at the motor
and pull the conduit
(41) away from the motor,
then pullthe leads through the conduit, one at a
time.
1. Disconnect the pump outlet hose
(23) from the
.displacement pump outlet nipple
(22)..
7. Unscrew the conduit connector
(39)from the
motor.
2. Remove the pressure control cover and screws. 8.
Disconnect the four motor leads. See the WIRING
DIAGRAM below. Remove the
conduit seal(31)
9.
from the conduit connector
(345) coming into the
controlbox.
IO.
3. Use an adjustable wrench
to loosen the conduit
connector (345) at the pressure control assembly
(4).
11.
4. Swing the conduit(41) away from the conduit
connector.
Pull the wires through the elbow, one at a time.
Remove the front cover, screws, and washers
(11,13,3).
Remove the motor cover
(Iand
) screws(16,12)
and spacers(15).
m
Remove the three screws
(8) and washers
from of the drive housing
(two screws are
recessed and one
is behind the pump
displacement rod- see Fig.23 on page28).
5. Pull the motor leads through the elbow, one at a 12. Remove thetwo screws (58) and washers(7)
time.
from thetop of the motor.
FILER
13. Use a plastic mallet
to gently tap the displacement pump(19) from the rear
to loosen the drive
housing from the front
of the motor. Then
pull the
drive housingaway from the of the motor.
CAUTIONI -*
DO NOTallow the gear cluster
(26) to fall when
removing the drive housing
(6). It is easily damaged if dropped. The cluster may stay engaged
in
either the front end bell or the drive housing.
DO NOT lose the thrust balls(24) located at each
end of the gear cluster(26) or allow themto fall
between gears. The balls, which are heavily covered with grease, usually stay
in the gear recesses, but could be dislodged.
If caught between
gears and not removed, the balls will seriously
damage the drive housing. If the balls areinnot
place, the bearings will wear prematurely.
14. Remove the four screws
(4) from the motor
bracket (A). Be sureto support the motor
to keep
the sprayer from tipping.
15. Lift the motor assembly
off the frame.
16. Align the new motor assembly with the frame
mounting holes. Install the screws (4)and related
hardware.
17. Liberally grease the gear cluster
(26) and pinlon
gear (B) and pack all bearings
in the motor front
end bell. Check
to be sure the thrust balls
(24)
are in place.
18. Place the bronze-colored washer (57a) and
THEN thesilver-colored washer (57b) on the
crankshaft (57).
19. Align the gears and push the drive housing
(6)
straight onto the front
of the motor and the locating pins.
20. Starting at Step 13 and working backwards, continue to reassemble the sprayer.
NOTE Use a turning motion on the conduit
(41)
when feeding wires through it. Be sure
to install the
conduit seal (31) around the wires the conduit connector (345)to prevent motor contamination from entering the pressure control. See the DETAIL below.
21. Reinstall the motor cover and pressure control
cover.
DETAIL
m315
Fig. 26
308-304 31
Motor Brushes
NOTE Replace the brushes when worn
to about 10
mm. Always checkboth brushes. Brush RepairKit
222-157, and Spring Clip (C),110-816, are available.
NOTE Replacement brushes may last only half as
long as the original ones.To maximum brush life,
break in new brushesby operating the sprayer with
no load (remove the pump connecting
rod pin) for at
least one hour.
WARNING
9. Test the brushes. With the sprayer
OFF and the
pump connecting rod removed, turn the pressure
control knobto the minimum pressure. Plug
in the
sprayer. Turn the sprayer
ON. Slowly increase the
pressure just until the motor comesto up
full
speed. Inspect the brush and commutator contact area for excessive arclng. Arcs should not
"trail" or circle around the commutator surface.
I O . Install the brush inspection covers and gaskets.
Install thefan cover and motor shield.
Before doing this procedure, follow the Pressure
Relief ProcedureWarning on page2 to reduce
the risk of serious bodily injury, including fluid injection or splashing
in the eyes or on the skin, or
injury from moving part.
1. Remove the motor cover
(I) and both inspection
covers and gaskets(H).See Fig. 27.
Fig. 27
2. Push in the spring
clip (C) to unhook it and then
pull it out. See Fig.28. Do not to let the spring(A)
fall into the motor.
3.
opa5
A
\I,
I
B
Loosen the screw(E). Pull
the brush lead
(D)
away, leaving the motor lead terminal
(F) in place.
Remove the brush (B)and spring(A). See Fig.29.
4. Inspect the commutator for excessive
pitting,
the commuburning or gouging. A black color on
tator is normal. Have the cornmutator resurfaced
by a qualified motor repair shop if the brushes
seem to wear too fast.
4
Fig. 28
1'
5. Install the new brush (B)
so its lead isin the long
slot (G) of the brush holder. Slide the terminal under the terminal screw
(E) washer and tighten the
screw. Be sure the motor lead
is still connected at
the screw. See Fig.30.
(8) as shown in
6. Place the spring (A) on the brush
Fig. 30.
7. Install the spring clip (C). Push
in and hook the
spring clip.
8. Repeat for the other side.
WARNING
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.
32
\
308-304
A
Spring must coil in
this direction
.
C
orm
Displacement Pump
WARNING
Before doing thisprocedure, followthe Pressure
Relief Procedure Warning
on page2 to reduce
the riskof serious bodily injury, including fluid injection or splashing
in the eyesor on theskin, or
injury from moving part.
Disassemblingthe pump.
1. Unscrew the intake valve
(223) and remove all
parts. See Fig.33.
*204
$p*
L o
‘202 \
223
Fig. 33
m38(1
2. Remove theplug (205). Unscrew the packing
nut
(216). See Fig.34.
(224) down and pull
ilout the
3. Tap the piston rod
bottom of the cylinder(219). See Fig.34.
02741
4. Remove the throat packings. See Fig.
34.
20
21
Fig. 32
224
01579
Removing the pump.
W
1. Flush the pump. Relieve pressure.
Fig. 34
2. Remove the front cover
(1 1). See Fig. 31.
5. Clamp the pistonrod (224) in a vise. Loosen the
nut (211). Unscrew the piston valve
(222). Remove the piston packings.
See Fig 35.
3. Unscrew the suction tube
(14) from the pump,
holding a wrench on the pump intake (223)
valve
to keep the pump from loosening. See Fig.
31.
4.
-7
Disconnect the pump outlet hose
(23). See Fig.
31.
5. Use a screwdriverto push aside the retaining
spring (21) at the top of the pump. Push the pin
(20) out the rear. See Fig.
32.
6. Push the retaining spring(21) up. Push the pin
(20) out the rear. Flg.
224
222
35
m388
308-304 33
-
Displacement Pump
A io
To reduce the risk of serious bodily injury from
pump rupture, useonly tool 222-585 to remove
the sleeve. If the sleeveis 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. 222-585
only. Screw thenut (H) into the cylinder
(219).
Screw down therod (J) to push the sleeve out.
See Fig. 36.
224
Apply one drop of
sealant these
4. Note the alignment of the piston(222) to the piston nut(21 1)and maintain this alignment through
Steps 5 , 6 and 7.
5. Apply ONEdrop 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
(21 1)contacts the
rod. See Fig.37. Place the flats of the
rod in a
vise.
6. Tighten the nut(21 1)onto the rod
(224) to 25
Fig. 36
Assembling the pump.
NOTE For the best results, use repair
kit 222-587,
and use all the
kt parts. Parts includedin the kt are
marked with an asterisk,(202*), in the text and drawings.
rod and
NOTE Soak the packingsin oil, and coat the
inside of the cylinder with oil.
NOTE Alternate leather and plastic packings as
shown in Fig. 39. Be sure thelips of the v-packinQs
face the direction shown. lncohect installation damages the packings and results
in pump leakage.
N.m. Use two wrenches to maintain the alignment
as mentioned in Step 4.
7. Stack the throat packings into the
top of the cylinder (219). install the packing nut
(216) loosely.
See Fig.39.
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 thetapered endof the sleeve is the bottom. See Fig.
38.
A
Tapered and
219
1. Check the pistonrod (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. 39.
3. Tighten the piston nut
(211) onto the piston
to 0.7
N.m.
34
308-304
Fig. 38
m30
9. Assemble and install the intake valve. a
Usem
packing (202*). Tighten the valve to
64 N.m. See
Fig. 39.
A ups
A of
A
A
A
Displacement Pump
of throat v-pacHngs must face up
Ups
piston v-packings must lace down
Ups of U-cup packing muit taco down
Leather
Installing thepump
A
A
Torque to 95 N.m
Face of bearing housing
Torque to 64 N.m
21
'
22
Fig. 40
oism
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 connectingrod (9) and continue screwing
in
the pump until the
pin slides easilyinto thehole.
See Fig.40.
2. Align thetop threads of the pump cylinder flush
with the face of the bearing housing
and so the
outlet nipple(22) is straight back.See Fig. 40.
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.40.
-
WARNING
Be sure the retaining spring
(21) is firmlyin the
groove, all the way around,
to prevent the pin(20)
from workingloose due to vibration.
If the pin worksloose, it or other parts could break
off due to the forceof the pump action.
These
parts could be projected through
the air and result
in serious bodily injury or properly damage, including damage to the pump connecting rod and
bearing housing.
Fig.
4. Assemble the remaining parts.
308-304 35
Parts - Displacement Pump
Model 222-584, Series A
Includes items 202 to 225
Rei.
No.
Part No.
202.
108-954
203* 105-522
204' 105-445
205 180-656
206*
176-749
207' 176-755
208.
176-754
209' 176-757
210* 176-750
211 176-751
212'
176-882
213* 176-997
214.
180-161
215' 180-073
216
176-758
218 183-571
219 183-562
220
183-559
221* 183-555
222 218-197
223
221-098
224 183-563
225* 105-444
Descrlptlon
PACKING, O-ring, PTFE
SEAL, U-CUP. polyurethane
BALL,sst
PLUG
V-PACKING. leather
V-PACKING, leather
GLAND, male
GLAND, female
GLAND. male
NUT, hex, retaining
V-PACKING, plastic
V-PACKING, PlaStlC
WASHER, backup
GLAND, female
NUT,packing
:
SLEEVE. cylinder
CYLINDER
GUIDE, ball
PIN, ballStop
VALVE. piston
VALVE, intake
ROD,piston
BALL
These pa& am also included in Repair
Kit
222-587, which may be purchasedsepamtely.
36 308-304
Accessories
Danger Labels
The English language DANGER label shown
on
page 1 is also on your sprayer.If you have painters who do not read English, order one
of the
following labelsto apply to your sprayer. The
drawing below shows the best placement
of
these labeis for good visibility.
Order the labels directly from
Gram, free of
charge.
1-800-423-8594
Toll Free:
In Minnesota: 1 -612-623-6921
French
Spanish
German
Greek
Korean
Displacement Pump Repair 222-587
See park on page38.
Repair instructions included with
kit.
Sleeve RemovalTool 222-585
Required for removing the displacement pump
sleeve.
Motor Brush Kit 222-157
Repair Instructions included with kit.
Spring Clip 110-816
Holds in motor brushes(not included with brush kit).
185-956
185-961
186-041
186-045
186-049
308-304
37
Parts
38
308-304
- Loboy Sprayer
Parts - Loboy Sprayer
Model 231 -315,Series A
Ultra 500, 230 Volt
includes items1 to 91
Ref.
No.
Part No.
Descrlptlon
1
181-612
53
w.
SHIELD, MOTOR,
includes one of item 24 1
2
222-052
MOTOR, ELECTRIC, 112 HP
1
includes items 2s. 24, 49 and 52
2a
1 10-293 . GREASE
1
3
154-636 WASHER, 5/8" ID
2
4
110-963 SCREW, hex head, no.5/16-18 x .25" 9
156-823 UNION, 114 npsm swivel x 1/4
5
npt
1
6
223-100
DRIVE HOUSING 1
105-510 LOCKWASHER, spring, 114"
7
5
8
107-445
3
CAPSCREW, Sch. 1/4-20 X 1.5"
218-359
9
1
CONNECTING ROD
10
100-040 PLUG, pipe, 1/4" 1
11
181-611 COVER, drive housing 1
12
108-709 SCREW, pnh, TypeI,
2
8-32 unc-3a x 1"
107-209 SCREW, filh, no. 6-32 X 1"
13
4
14
170-113 TUBE, suction
1
15
2
108-663 SPACER
16
108-865 SCREW, Dan head, no.8 x 318"
6
109-014 SPACER.
17
2
19
222-584
DISPLACEMENT PUMP
1
see page 36 for parts
20
1
176-816
PIN, straight, hdls
21
176-817
SPRING, retaining 1
22
162-453 NIPPLE, hex,1/4 npsm x 1/4 npt,
1-311 6"
2
23
235-575
HOSE, grounded, nylon, 1/4"ID, 21 3/4'
(738 m) long, spring guardboth ends 1
24
1
100-069
BALL, stainless steel, 1/4" dia.
25
1
181-608 LABEL, IDENTIFICATION
26
218-364
GEAR REDUCER
1
LABEL, DANGER
1
2 7 ~ 165-952
28
2
105-521
PLUG, plastic
29
206-994
THROAT SEALLIQUID,
8 02. (0.27 liter) not shown 1
LABEL, identification
30
1
181-609
31
107-447 SEAL, conduit see page40
2
33
220-678
CART KIT
1
Includes items3, 44, 90.
1
38A 185-954* LABEL, DANGER
1
39
108-460
CONNECTOR, conduit, 45'
40
222-176
PRESSURE CONTROL
1
see parts list on page 40
41
CONDUIT, electrical,
065-099
specify length when ordering 0.79 f l
42
2
106-062 WHEEL, semi-pneumatic
44
2
101 -242 RING, retaining
45
2
104-811 HUBCAP
48
1
183-995 COVER, pressure control
49
107-264 TERMlNALseepage 41
2
50
183-573
BRACKET, mounting
1
51
106-076 SCREW, flathd. thd frmg,
no. 10-24 x 316", type "C" 4
52
107-267 TERMINAL, female see page 41
2
214-570
54
55
56
57
57a
57b
58
59A
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75A
76
78
79
8OA
85
86
90
91
A
FILTER, fluid
Includes one of 10 and 22. see manual
1
307-273 for additionalparts
221 -077
PRESSURE DRAIN VALVE
1
161-610
LABEL. identification 1
176-762
NUT, hex. 1-1/2-18 1
218-242
CRANKSHAFT ASSEMBLY.
includes items 57a and 57b 1
180-131
. BEARING
1
107-434
BEARING
1
101 -682 SCREW, socket head, 1/4-20 x 0.62 " 2
178-034 TAG, WARNING
1
100-509
PLUG. square head, 114npt(m)
1
220-955
SPRAY GUN, airless
see 307-614 forparts
1
214-701
HOSE, grounded, nylon, 3/16" ID, ft3
both ends 1
(0.9 m) long. spring guards
223-541
HOSE, grounded, nylon, 1/4"ID, 50ft
(15 m) long, springguard both ends 1
100-214
LOCKWASHER, spring, 5/16" 9
100-188
NUT, heavy hex, 5/16-18unc-2a
9
103-473
TIE, wire strap 3
163-275
SPACER
2
221 -020 ELBOW, W ,112 npsm swivel x
1
314 npt(t)
103-927
CLhMP, hose
2
187-146 STRAINER
1
161 -607 LABEL, identification 1
218-355
1
ClRCUrr BOARD see page 40
178-920
HOSE, suction
1
101 -754 PLUG, pipe, soc hd. 316 npt
1
see page 40
185-955
LABEL, DANGER, French
1
185-470
BRACKET, shield 1
109-046 UNION, adapter, swivel 318
x npt(m) 1
110-037
SCREW, pnh. 10-24, Type 'C",
X ,625.
4
177-762
1
LABEL, WARNING
185-499
BRACKET, shield mounting
2
110-240 NUT, retaining, Type U
2
178-342 CLIP: large 2
183-261
DRAIN TUBE
1
.
Replacement Dangerand Warning labels, tags and
cards are available at no cost.
308-304
39
Parts - Pressure Control
Pressure Control Assembly 222-176
Ref.
No. Part
No.
300 223-419
302 109-191
303
109-192
306 109-074
308 218-400
309
218-366
310 107-427
311 185-314
312 100-035
315 222-099
317 222-577
318 222-386
319 222-367
320 222-578
321 222-579
322 222-353
323 222-354
324 107-438
40 308-304
Descrlptlon
otv.
PRESSURE CONTROL
1
includes 302 to 306
. ONIOFF SWITCH
1
. CLIP, retaining
1
. MICROSWITCH
1
RECTIFIER, bridge
1
CHOKE
1
FILTER
1
CORD SET power supply, no plug 1
SCREW, slotted pan hd,no. 8 x 5/16" 1
JUMPER, wire
1
HARNESS, wire
1
HARNESS, wire
1
HARNESS, wire
1
HARNESS, wire
1
HARNESS, wire
1
HARNESS, wire
1
HARNESS, wire
1
SCREW, flat head, no.
5-40 x 518" 2
325
326
327
328
329
330
331
332
100-975
101-792
157-021
105-746
107-258
180-041
101-273
100-179
333
100-718
334A 153-466
338
107-436
337 105-329
338 100-109
339 221-197
340 176-906
341
105-772
342 100-840
343
109-047
344
162-453
345 108-460
A
NUT, hex 110.5
LOCKWASHER, ext.no. 5
LOCKWASHER, no.8 internal
BUSHING, strain relief
TIP, pin, black plastic
PIN
SCREW, flat hd, no.10-24 x 5/8"
NUT, hex, no.10-24
LOCKWASHER, internal, no.10
LABEL, warning
TERMINAL, strip
NUT, hex,M8 x 1.25
LOCKWASHER, external.5/16"
BOURDON TUBE
NUT
WASHER
ELBOW
ADAPTER
NIPPLE
CONNECTOR, conduit.45"
2
2
1
1
1
1
2
2
2
1
1
2
2
1
2
2
1
1
1
1
Replacement Danger and Warning labels, tags and
cards are available at no cost.
Wiring Diagram
A ~eepageaor41
THERMAL SWITCH
308-304
41
NOTES
42
308-304
NOTES
308-304
43
Technical Data
Power Requirements
..............230 VAC, 50 Hz,
1 phase, 7 amp minimum
Working Pressure Range................ 0 - 195 bar
Cycles/liier
124
Maximum Delivery..
1.8 liter/min
No. 14AWG, 3 wire, 2.6 m
Power Cord
Inlet Paint Strainer
1190 micron
Stainless steel screen, reusable
Outlet Paint Filter
250 micron
Stainless Steel screen, reusable
314 npt(m) with 20" ID chamfer
Pump Inlet Size
Fluid Outlet Size
114 npsm from fluid filter
Wetted Parts:
Displacement Pump
Carbon steel, Polyurethane,
UHMW polyethylene, DelrinB, Leather
Filter ...... Aluminum, Carbon steel. Stainless steel,
..................................
...................
.............
....................
.......................
......
...........
...
Dimensi
........
..................................
...................................
Weight (dryw/o packaging)
. 3 6 K g(approx.)
Height ..................................
457 mm
Length
686 mm
Width
457mm
N O T E Delrinm is a registered trademarkof the
Company.
The Graco Warrantyand Disclaimers
WARRANTY
Graco warrants all equipment manufactured itby
and bearingits name to befree from defectsin material and workmanship on the
date of sale by an authorized Graco distributor
to the original purchaser for
use. As purchaser's sole remedy for breach
of this warranty, Gracowill, for aperiod of twelve months from the date of sale, repair
or replace any part
of the Ultra equipment proven de.fective. with the exception
of defects in parts
on the drive trainlgear box, which will
be repaired or replaced
for forty-eight months
sale and the electric motor (excluding brush replacement, which is routine maintenance) or pressure control
from the date of
assembly whichwill be repaired or replaced for twenty-four months from the date
sale. of
This warranty applies only when the
equipment is installed, operated and maintained
in accordance with Graco's wriaen recommendations.
This warrantydoes not cover, and Graco shall
not be liable for, any malfunction, damage
or wear causedby faulty installation, misapplication, abrasion, corrosion, Inadequate or improper maintenance, negligence, accident, tampering, or substitution of nonGraco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused
by the incompatibility with Graco
equipment of structures, accessories, equipment or materials
not supplied byGraco, orthe improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials
not supplied by Graco.
This warrantyis conditionedupon the prepaid return of the equipment claimed
to be defective to an authorized Graco distributor
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
If inspection of the equipment does not disclose any
equipment willbe returned to the original purchaser transporlation prepaid.
defect in material
or workmanship, repairs willbe made at a reasonable charge, which charges may
include the costs of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms ofthis warranty constitute purchaser's sole and exclusive remedy and areofinany
lieuother warranties (express or
implied), lncludlng wananty of merchantablllty or warranty of fltness for a particular purpose, and of any non-contractual
liabilities, including product liabilities, based on negligence or strict liability. Every
of liability
formfor direct, special or consequential
damages orloss is expressly excluded and denied.
In no case shall Graco's liability exceed the amount
the purchase
of
price. Any
action for breach of warranty must
be brought withintwo (2) years of the date of sale.
EQUIPMENT NOT COVEREDBY GRACO WARRANTY
Graco makesno warranty, and disclaimsal implied warrantles of merchantablllty and fltness for a partlcular purpose, with
respect to accessories, equipment, materials, or components sold
but not manufactured by Graco. These items sold,
but not
to the warranty, it any, of theirmanufacturer.
manufactured by Graco (such as electric motor, switches, hose, etc.) are subject
of these warranties.
Graco will provide purchaser with reasonable assistance
in making any claim for breach
Sales Offlces: Atlanta, Chicago, Dallas, Detroit,Los Angeles, Mt. Arlington (N.J.)
Forelgn Offlcas: Canada, England, Korea, Switzerland, France, Germany,
Hong Kong, Japan
GRACO INC. RO. BOX 1441 MINNEAPOLIS. MN 55440-1441
44
308-304
PRINTED IN USA. 308-304 10-93