Graco 308073A LoPro 500 SPRAYER Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains IMPORTANT

INSTRUCTIONS and WARNINGS.

READ AND RETAIN FOR REFERENCE.

120 V AC, 15 AMP

ABATEMENT TECHNOLOGIES

LoPro 500 SPRAYER

2750 psi (190 bar) MAXIMUM WORKING PRESSURE

Model 231–123, Series A

U.S. Patent No. 4,323,741; 4,397,610

Patented 1983, Canada

And Other Patents Pending

TABLE OF CONTENTS

Warnings

Setup

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . .

Shutdown & Care . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Flushing

Troubleshooting

Repair

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer Parts . . . . . . . . . . . . . . . . . . . .

Pressure Control Parts

Pump Parts . . . . . . . . . . . . . . . . . . . . . .

Technical Data, Dimensions

Acccessories

Warranty

. . . . . . . . . . . .

. . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

13

14

20

34

2

8

10

12

36

38

39

39

40

308–073

Rev A

NOTE: This is an example of the DANGER label on your sprayer.

This label is available in other languages, free of charge.

See page 39 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

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1990, GRACO INC.

SAFETY WARNINGS

HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.

FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS

Read and understand all instruction manuals before operating equipment.

FLUID INJECTION HAZARD

General Safety

This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.

NEVER point the spray gun at anyone or at any part of the body.

NEVER put hand or fingers over the spray tip. NEVER try to

“blow back” material; this is NOT an air spray system.

ALWAYS have the tip guard in place on the spray gun when spraying.

ALWAYS follow the Pressure Relief Procedure, below, before cleaning or removing the spray tip or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body.

Be sure equipment safety devices are operating properly before each use.

Medical Alert––Airless Spray Wounds

If any fluid appears to penetrate your skin, get EMERGENCY

MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE

CUT. Tell the doctor exactly what fluid was injected.

Note to Physician: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible.

Do not delay treatment to research toxicity . Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

Spray Gun Safety Devices

Be sure all gun safety devices are operating properly before each use. Do not remove or modify any part of the gun; this can cause a malfunction and result in serious bodily injury.

Safety Latch

Whenever you stop spraying, even for a moment, always set the gun safety latch in the closed or “safe” position, making the gun inoperative. Failure to set the safety latch can result in accidental triggering of the gun.

Diffuser

The gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed. Check diffuser operation regularly. Follow the Pressure Relief Procedure, below, then remove the spray tip. Aim the gun into a metal pail, holding the gun firmly to the pail. Using the lowest possible pressure, trigger the gun. If the fluid emitted is not diffused into an irregular stream, replace the diffuser immediately.

Tip Guard

ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the fluid injection hazard and helps reduce, but does not prevent, the risk of accidentally placing your fingers or any part of your body close to the spray tip.

Trigger Guard

Always have the trigger guard in place on the gun when spraying to reduce the risk of accidentally triggering the gun if it is dropped or bumped.

Spray Tip Safety

Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately. ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it.

NEVER wipe off build–up around the spray tip until pressure is fully relieved and the gun safety latch is engaged.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electric shock, always follow this procedure whenever you shut of f the sprayer , when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying.

1.

Engage the gun safety latch.

2. Turn the ON/OFF switch to OFF.

3.

Unplug the sprayer.

1,5

3

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.

5. Engage the gun safety latch.

6.

Open the pressure drain valve, having a container ready to catch the drainage. Leave the valve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, wrap a rag around the tip guard retaining nut or hose end coupling and VERY SLOWLY loosen the part to relieve pressure gradually , then loosen completely. Now clear the tip or hose.

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MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers or other body parts. KEEP CLEAR of moving parts when starting or operating the sprayer. Follow the Pressure Relief Procedure on page 2 before checking or servicing any part of the sprayer, to prevent it from starting accidentally.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious bodily injury, or fire, explosion or property damage.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

System Pressure

This sprayer can develop 2750 psi (190 bar) MAXIMUM

WORKING PRESSURE. Be sure that all spray equipment and accessories used are rated to withstand this pressure. DO NOT exceed the maximum working pressure of any component or accessory used in the system.

Fluid and Solvent Compatibility

All chemicals used in the sprayer must be chemically compatible with the wetted parts shown in the TECHNICAL

DATA on page 39. Consult your chemical supplier to ensure compatibility.

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious bodily injury and/or substantial property damage.

FIRE OR EXPLOSION HAZARD

Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray equipment is not properly grounded, sparking may occur , and the system may become hazardous. Sparking may also occur when plugging in or unplugging a power supply cord or using a gasoline engine. Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying indoors or outdoors, and can cause a fire or explosion and serious bodily injury and property damage.

If you experience any static sparking or even a slight shock while using this equipment, STOP SPRAYING IMMEDIATELY. Check the entire system for proper grounding. Do not use the system again until the problem has been identified and corrected.

Grounding

To reduce the risk of static sparking, ground the sprayer and all other spray equipment used or located in the spray area.

CHECK your local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to ground all of this spray equipment:

1. Sprayer: plug the power supply cord, or extension cord, each equipped with an undamaged three-prong plug, into a properly grounded outlet. Do not use an adapter. All extension cords must have three wires and be rated for 15 amps.

HOSE SAFETY

High pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage.

ALL FLUID HOSES MUST HA VE SPRING GUARDS ON

BOTH ENDS! The spring guards help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture.

TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling.

NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot contain the high pressure fluid.

HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Keep hoses clear of moving parts and hot surfaces of the pump. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose. DO NOT expose Graco hose to temperatures above

180 _ F (82 _ C) or below –40 _ F (–40 _ C).

Hose Grounding Continuity

Proper hose grounding continuity is essential to maintaining a grounded spray system. Check the electrical resistance of your fluid hoses at least once a week. If your hose does not have a tag on it which specifies the maximum electrical resistance, contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it immediately ardous. Also read FIRE OR EXPLOSION HAZARD.

. An ungrounded or poorly grounded hose can make your system haz-

2.

Fluid hoses: use only grounded hoses with a maximum of

500 ft (150 m) combined hose length to ensure grounding continuity. See Hose Grounding Continuity.

3.

Spray gun: obtain grounding through connection to a properly grounded fluid hose and sprayer.

4.

Object being sprayed: according to local code.

5.

Fluid supply container: according to local code.

6.

All solvent pails used when flushing, according to local code. Use only metal pails, which are conductive. Do not place the pail on a non–conductive surface, such as paper or cardboard, which interrupts the grounding continuity.

7.

To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the gun firmly to the side of a grounded metal pail, then trigger the gun.

Flushing Safety

Reduce the risk of fluid injection injury , static sparking, or splashing by following the flushing procedure given on page 13 of this manual. Follow the Pressure Relief Procedure on page

2, and remove the spray tip before flushing. Hold a metal part of the gun firmly to the side of a grounded metal pail and use the lowest possible fluid pressure during flushing.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

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AVERTISSEMENT

La pulvérisation à haute pression peut causer des blessures très graves.

Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité.

Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel.

RISQUES D’INJECTION

Consignes generales de sécurité

Cet appareil produit un fluide à très haute pression. Le fluide pulvérisé par le pistolet ou le fluide sous pression provenant de fuites ou de ruptures peut pénétrer sous la peau ou à l’interieur du corps et entrainer des blessures très graves, voir même une amputation. Même sans être sous pression, le fluide éclaboussant ou entrant dans les yeux peut aussi entrainer des blessures graves.

NE JAMAIS pointer le pistolet vers quelqu’un ou vers une partie quelconque du corps. NE JAMAIS mettre la main ou les doigts sur l’ajutage du pulvérisateur. NE JAMAIS essayer de “refouler” la peinture.

TOUJOURS garder la protection de l’ajutage en place sur le pistolet pendant la pulvérisation.

TOUJOURS observer la March à Suivre pour Détendre la

Pression donnée plus loin, avant de nettoyer ou d’enlever l’ajutage du pulvérisateur, ou d’effectuer un travail quelconque sur une partie de l’appareil.

NE JAMAIS essayer d’arrêter ou de dévier les fuites avec la main ou le corps.

Avant chaque utilisation, bien s’assurer que les dispositifs de sécurité fonctionnent correctement.

Soins medicaux

En cas de pénétration de fluide sous la peau: DEMANDER IM-

MEDIATEMENT DES SOINS MEDICAUX D’URGENCE. NE

PAS SOIGNER CETTE BLESSURE COMME UNE SIMPLE

COUPURE.

Avis au medecin: La pénétration des fluides sous la peau est un traumatisme.

Il est important de traiter chirurgicale-

ment cette blessure immédiatement. Ne pas retarder le traitement pour effectuer des recherches sur la toxicité. Certains revêtements exotiques sont dangereusement toxiques quand ils sont injectés directement dans le sang. Il est souhaitable de consulter un chirurgien esthétique ou un chirurgien spécialisé dans la reconstruction des mains.

Dispositifs de sécurité du pistolet

Avant chaque utilisation, bien s’assure que tous les dispositifs de sécurité du pistolet fonctionnent correctement. Ne pas enlever ni modifier une partie quelconque du pistolet; ceci risquerait d’entraîner un mauvais fonctionnement et des blessures graves.

Verrou de sécurité

A chaque fois que l’on s’arrête de pulvérisér , même s’il s’agit d’un court instant, toujours mettre le verrou de sécurité du pistolet sur la position “fermée” ou “sécurité” (“safe”) pour empêcher le pistolet de fonctionner . Si le verrou de sécurité n’est pas mis, le pistolet peut se déclencher accidentellement.

Diffuser

Le diffuseur du pistolet sert à diviser le jet et à réduire les risques d’injection accidentelle quand l’ajutage n’est pas en place.

Vérifier le fonctionnement du dif fuseur régulièrement. Pour cette vérification, détendre la pression en observant la Marche

à Suivre pour Détendre la Pression donnée plus loin puis enlever l’ajutage du pulvérisateur. Pointer le pistolet dans un seau en métal, en le maintenant fermement contre le seau. Puis, en utilisant la pression la plus faible possible, appuyer sur la gachette du pistolet. Si le fluide projete n’est pas diffusé sous forme de jet irrégulier, remplacer immédiatement le diffuseur.

Protection de l’ajutage

TOUJOURS maintenir la protection de l’ajutage en place sur le pistolet du pulvérisateur pendant la pulvérisation. La protection de l’ajutage attire l’attention sur les risques d’injection et contribue à réduire, mais n’évite pas le risque, que les doigts ou une partie quelconque du corps ne passent accidentellement à proximité immédiate de l’ajutage du pulvérisateur.

Consignes de sécurité concernant l’ajutage du pulvérisateur

Faire extremement attention à l’occasion du nettoyage ou du remplacement des ajutages du pulvérisateur . Si l’ajutage se bouche pendant la pulvérisation, mettre immédiatement le verrou de sécurité du pistolet. T OUJOURS bien observer la

Marche à Suivre pour Détendre la Pression puis enlever l’ajutage du pulvérisateur pour le nettoyer.

NE JAMAIS essuyer ce qui s’est accumulé autour de l’ajutage du pulvérisateur avant que la pression ne soit completement tombée et que le verrou de sécurité du pistolet ne soit engagé.

Marche à Suivre pour Détendre la Pression

Pour réduire les risques de blessures graves, y compris les blessures par injection de fluide ou celles causées par des

éclaboussures dans les yeux ou sur la peau, des pièces en mouvement ou par électrocution, toujours bien observer cette marche à suivre à chaque fois que l’on arrête le pulvérisateur,

à l’occasion de la vérification, du reglage ou du nettoyage du systeme ou lors du changement des ajutages.

1. Engager le verrou de sécurité du pistolet.

2. Basculer l’interrupteur de commande de pression sur AR-

RET (OFF).

3. Debrancher le cordón d’alimentation.

1,5

3

4. Désengager le verrou de sécurité du pistolet. T out en maintenant une partie métallique du pistolet fermement appuyée contre le côté d’un seau en métal, actionner le pistolet pour libérer la pression.

5. Engager le verrou de sécurité du pistolet.

6. Ouvrir la soupape de sécurité et la laisser ouverte jusqu’a ce que l’on soit pret à se servir de nouveau du pulvérisateur. Débrancher le fil de la bougie.

Si l’on soupçonne que le tuyau ou l’ajutage du est complètement bouche, ou que la pression n’a pas été complètement libérée après avoir procede aux operations ci–dessus, desserrer très LENTEMENT un raccord du bout du tuyau ou l’écrou de retenue de la protection de l’ajutage et libérer progressivement la pression.

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RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIEL

Consignes générales de sécurité

Toute utilisation anormale de l’appareil de pulvérisation ou des accessoires comme, par exemple, la mise sous une pression excessive, les modifications de pièces, l’utilisation de produits chimiques et de matières incompatibles et l’utilisation de pièces usées ou abîmées peut causer des dégâts à l’appareil ou des ruptures de pièces et entraîner une injection de liquide ou d’autrès blessures sérieuses, un incendie, une explosión ou d’autrès dégâts.

Pression

Ce pulvérisateur peut produire une PRESSION MAXIMUM DE

TRAVAIL 190 bar (2750 lb/po2). S’assurer que tous les

éléments du pulvérisateur et ses accessoires sont conçus pour résister à la pression maximum de travail de ce pulvérisateur.

NE PAS depasser la pression maximum de travail d’aucun des

éléments ou accessoires utilisés avec cet appareil.

NE JAMAIS alterer ou modifier une piece de cet appareil; ceci risquerait d’entraîner son mauvais fonctionnement.

Vérifier régulièrement tout l’appareil de pulvérisation et ses equipements et réparer ou remplacer immédiatement les pièces usées ou abîmées.

Compatibilité chimique des corps

BIEN S’ASSURER que tous les corps des solvants utilisés sont chimiquement compatibles avec les parties mouillées indiquées dans les TECHNICAL DATA, a page 39. T oujours lire soigneusement les documents et brochures du fabricant des fluides et solvants utilisés avant de s’en servir dans ce pulvérisateur.

MESURES DE SÉCURITÉ CONCERNANT LES TUYAUX FLEXIBLES

Le fluide à haute pression circulant dans les tuyaux peut être très dangereux. En cas de fuite sur le tuyau, de fissure, déchirure ou rupture à la suite de l’usure, de dégâts ou d’une mauvaise utilisation, les projections de fluide haute pression qui en proviennent peuvent entraîner des blessures graves par pénétration sous la peau ou par contact, ainsi que des dégâts matériels.

TOUS LES TUYAUX FLEXIBLES DOIVENT AVOIR DES RES-

SORTS SPIRALE DE PROTECTION AUX BOUTS!

Les spirales de protection contribuent à eviter la formation de pliures, de boucles ou de nœuds sur les tuyaux qui pourraient entraîner la rupture du tuyau à l’endroit du raccord ou à son voisinagé.

SERRER FERMEMENT tous les raccords avant chaque utilisa– tion. Le fluide sous pression peut faire sauter un raccord desserre ou produire un jet à haute pression s’échappant par le raccord.

MANIPULER LES TUYAUX AVEC PRECAUTION ET CHOISIR

SOIGNEUSEMENT LEUR CHEMIN. Ne pas déplacer le fluide en tirant sur le tuyau. Ne pas utiliser de fluides ou de solvants qui ne sont pas compatibles avec l’enveloppe intérieure ou extérieure du tuyau. NE PAS exposer le tuyau à des températures supérieures à 82

(–40

) C (180 ) F) ou inférieures à –40 ) C

) F).

Continuité de la mise à la terre des tuyaux

Une bonne continuité de la mise à la terre des tuyaux est essentielle pour maintenir la mise à la terre de l’ensemble de vaporisation. Vérifiez la résistance électrique de vos tuyaux à fluides et

à air, au moins une fois par semaine. Si votre tuyau ne comporte pas d’étiquette qui précise la résistance électrique maximum, prenez contact avec le fournisseur de tuyaux ou la fabricant pour avoir les límites de résistance maximum. Utilisez un mètre de résistance de la gamme appropriée pour votre tuyau et vérifiez la résistance. Si celle–ci dépasse les límites recommandées, remplacez le tuyau immédiatement. Un tuyau sans mise à la terre ou avec une mise à la terre incorrecte peut entraîner des risques pour votre systeme. Lisez aussi LES

RISQUES D’INCENDIE OU D’EXPLOSIÓN ci–dessus.

NE JAMAIS utiliser un tuyau endommagé. NE PAS essayer de refaire le raccord d’un tuyau haute pression ni de réparer le tuyau avec du ruban adhesif ou par tout autre moyen. Un tuyau réparé ne peut pas résister au fluide sous pression.

RISQUES D’INCENDIE OU D’EXPLOSIÓN

De l’électricité statique est produite par le passage du fluide à grande vitesse dans la pompe et dans les tuyaux. Si toutes les pieeces de l’appareil de pulvérisation ne sont pas convenablement reliées à la masse ou à la terre, des étincelles peuvent se produire et l’appareil risque d’être dangereux. Des étincelles peuvent également se produire à l’occasion du branchement ou du débranchement du cordón d’alimentation. Les étincelles sont suffisantes pour allumer les vapeurs de solvants et le fluide pulvérisé, les fines particules de poussieère ainsi que d’autrès substances inflammables, quand on pulvérisé à l’intérieur ou à l’extérieur, et elles peuvent causer un incendie ou une explosión, ainsi que des blessures graves et des dégâts matériels.

Toujours brancher le pulvérisateur dans une prise se trouvant

à au moins 6 m (20 pieds) de l’appareil et de l’endroit où se fait la pulvérisation. Ne pas brancher ou débrancher un cordón d’alimenations quel qui’il soit dans la zone où se fait la pulvérisation quand il y à le moindre risque que des vapeurs encore présentes dans l’air prennent feu.

S’il se produit des étincelles d’électricité statique, ou si vous ressentez la moindre décharge, ARRÊTEZ IMMÉDIATEMENT LA

PULVÉRISATION. Vérifiez que le système entier est bien mis

à laterre. Ne vous servez pas du systeeme avant que le problème soit identifié et corrigé.

Mise à la terre ou à la masse

Pour réduire les risques de production d’étincelles d’électricité statique, le pulvérisateur et tous les équipements utilisés ou se trouvant dans la zone de pulvérisation doivent être reliés à la terre ou à la masse. Pour connaître le detail des instructions de mise à la terre dans la region et le type particulier d’équipement,

CONSULTER le code ou les réglementations électriques locales. S’ASSURER que tous les équipements de pulvérisation suivants sont bien reliés à la terre:

1. Pulvérisateur: Brancher le cordón d’alimentation ou la rallonge qui doivent être équipés d’une prise à 3 fiches en bon

état, dans une prise de courant convenablement mise à la terre. Ne pas utiliser d’adaptateur . Toutes les rallonges doivent avoir 3 fils et être prevues pour 15 ampères.

2. Tuyaux flexibles: Afin d’assurer la continuité de la mise à la terre, n’utiliser que des tuyaux comportant une mise à la terre et ayant une longueur maximum combinée de 150 m

(1500 pieds). Se reporter également au paragraphe Continuité du circuit de mise à la terre des tuyaux.

3. Pistolet: Réaliser la mise à la terre en le raccordant à un tuyau flexible et à un pulvérisateur dèjá convenablement reliés à la terre.

4.

Récipient d’alimentation: observer le code ou les réglementations locales.

5. Objets, matériel ou surfaces reçevant la pulvérisation: observer le code ou les réglementations locales.

6.

Tous les seaux de solvants utilisés pour le rinçage: observer le code ou les réglementations locales. N’utiliser que des saux métalliques conducteurs de l’électricité. Ne pas mettre le seau sur une surface non conductrice comme sur du papier ou du carton car cela interromprait la continuité de la mise à la terre.

7. Pour conserver la continuité de la mise à la terre quand on rince le matériel ou quand on libére la pression , toujours maintenir une partie métallique du pistolet fermement appuyée contre le côté d’un seau en métal puis appuyer sur la détente du pistolet.

Mesures de sécurité concernant le Rincage

Pour réduire les risques de blessures par pénétration de la peau et les risques dûs aux etincelles d’electricite statique ou aux éclaboussures, observer la marche à suivre pour le rincage donnée à la page 13 de ce manuel. Observer la “Marche à

Suivre pour Détendre la Pression” donnée à la page 4 en enlever l’ajutage du pulvérisateur avant le rincage. Maintenir une partie métallique du pistolet fermement appuyée contre le côté d’un seau en métal et utiliser la pression la plus faible possible pendant le rincage.

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ADVERTENCIA

EL ROCIADO a ALTA PRESIÓN PUEDE CAUSAR GRAVES LESIONES.

SOLO PARA USO PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.

Lea y entienda todo el manual de instrucciónes antes de manejar el equipo.

PELIGRO DE INYECCIÓN DE FLUIDO

Seguridad general

Este equipo genera un fluido a una presión muy alta. El rociado de la pistola, los escapes de fluido o roturas de los componentes pueden inyectar fluido en la piel y el cuerpo y causar lesiones extremadamente graves, incluyendo a veces la necesidad de amputación. También, el fluido inyectado o salpicado en los ojos puede causar graves daños.

NUNCA apuntar la pistola hacia alguien o alguna parte del cuerpo. NUNCA colocar la mano o los dedos encima de la bo– quilla. NUNCA tratar de “hacer retornar la pintura”; este NO es un sistema de rociado de aire.

SIEMPRE tener colocado el protector de la boquilla en la pistolamientras se está pulverizando.

SIEMPRE seguir el procedimiento de descarga de presión, dado másabjo, antes de limpiar o sacar la boquilla o de dar servicioa cualiquier equipo del sistema.

NUNCA tratar de parar o desviar los escapes con la mano o el cuerpo.

Asegurar que todos los aparatos de seguridad del equipo están funciónando bien antes de cada uso.

Tratamiento médico

Si pareciera que un poco de fluido penetró la piel, conseguir

TRATAMIENTO MÉDICO DE URGENCIA DE INMEDIA TO.

NO TRATAR LA HERIDA COMO UN SIMPLE CORTE. Decir al médico exactamente cua fluido fue.

Aviso al médico: Si se llega a inyectar este fluido en la piel se causa una lesión traumática.

Es importante tratar quirúrgicamente la lesión a la brevedad posible.

No demorar el tratamiento para investigar la toxicidad. La toxicidad es algo de suma importancia en algunas pinturas exóticas cuando se inyectan directamente al torrente sanguineo. Sirá conveniente consultar a un especialista en cirugia plástica o reconstructiva de las manos.

Aparatos de seguridad de la pistola pulverizadora

Asegurar que todos los aparatos protectores de la pistola están funciónando bien antes de cada uso. No sacar ni modificar ningúna pieza de la pistola pues podria causar el malfunciónamiento de la misma con las consiguientes lesiones personales.

Pestillo de seguridad

Cada vez que se deje de pulverizar, aunque sea por un breve momento, siempre colocar el pestillo de seguridad en la posición “cerrada” lo que deja la pistola inoperante. El no hacerlo puede llevar al disparo imprevisto de la pistola.

Difusor

El difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyección cuando no está instalada la boquilla.

Revisar con regularidad el funciónamiento del difusor. Seguir el

procedimiento de descarga de presión, dado más abajo, y después sacar la boquilla. Apuntar la pistola a un balde metálico, sosteniéndola bien firme contra el. Utilizando la presión más bajo posible, disparar la pistola. Si el fluido emitido no sale disperso en un chorro irregular, reemplazar de inmediato el difusor.

Protector de la boquilla

SIEMPRE tener el protector de la boquilla colocado en la pistola mientras se está pulverizando. Este protector llama la atención contra el peligro de inyección y ayuda a reducir, pero no evita, la colocación accidental de los dedos o cualquier otra parte del cuerpo cerca de la boquilla.

Seguridad de la boquilla pulverizadora

Tener mucho cuidado al limpiar o cambiar las boquillas. Si llegara a obstruirse mientras está pulverizando, enganchar el pestillo de la pistola de inmediato. SIEMPRE seguir el pro–

cedimiento de descarga de presión y después sacar la bo– quilla para limpiarla.

NUNCA limpiar la acumulación de pintura alrededor de la bo– quilla antes de que se haya descargado por completo la presión y el pestillo este enganchado.

Procedimiento de descarga de presión

Para reducir el riesgo de sufrir graves lesiones corporales, incluyendo inyección o lesiones causadas por piezás en movimiento o choque eléctrico, siempre seguir este procedimiento al apagar la máquina pulverizadora, al revisar o dar servicio a cualquier parte del sistema de pulverización, al instalar, limpiar o cambiar las boquillas, y cada vez que se deja de pulverizar.

1. Enganchar el pestillo de la pistola.

2. Mover el interruptor eléctrico (ON/OFF) a la posición OFF

(apagado).

3. Desenchufar el cordón electrico.

4. Desenganchar el pestillo de la pistola. Sujetar una parte metálica de la pistola bien firme contra un balde de metal, y disparar la pistola para descargar la presión.

1,5

3

5. Enganchar el pestillo de la pistola.

6. Abrir la válvula de presión y tener listo un reclipiente para recibir la pintura. Dejar la válvula de alivio de presión abierta hasta que se este nuevamente listo para pulverizar.

Si se sospecha que la boquilla o la manguera está completamente obstruida, o que no se ha descargado por completo la presión después de haber seguido el procedimiento anterior, aflojar MUY LENTAMENTE la tuerca de retención del protector de la boquilla o acoplamiento de la punta de la manguera y descargar gradualmente la presión, después, aflojarlo por completo. Luego, despejar la boquilla o la manguera.

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PELIGRO POR MAL USO DEL EQUIPO

Seguridad general

Cualquier mal uso del equipo pulverizador o los accesorios, tal como sobrepresurización, modificación de piezás, uso de matériales y productos quimicos incompatibles, o utilización de piezás dañadas o desgastadas, puede hacen que se rompan y causen la inyección de fluido u otras lesiones corporales graves, incendio, explosión o dañon a la propiedad.

NUNCA alterar o modificar ningúna pieza de este equipo; el hacerlo podria causar una avería.

REVISAR con regularidad el equipo pulverizador y reparar o reemplazar de inmediato las piezás dañadas o desgastadas.

Presión del sistema está pulverizadora puede desarrollar 190 barías (2750 psi) de presión DE TRABAJO MÁXIMA. Asegurar que todo el equipo pulverizador y sus accesorios tienen la capacidad para aguantar la presión máxima de trabajo de está pulverizadora. NO exceder la presión máxima de trabajo de ningún componente o accesorio de este sistema.

Compatibilidad de fluido

Siempre leer las instrucciónes del fabricante del fluido y solvente antes de usarlos en está pulverizadora.

Siempre usar gafas, guantes, vestimetas protectora y un respiradero, tal como recomiendan los fabricantes del fluido y del solvente.

SEGURIDAD EN EL USO DE LAS MANGUERAS

El fluido que escapa a alta presión por las mangueras puede ser muy peligroso. Si en la manguera se desarrolla un escape, una rotura o rajadura debido a cualquier tipo de desgaste, daño o maltrato, el chorro a alta presión emitido por alli puede causar una lesion por inyección u otras lesiones corporales graves o daños a la propiedad.

!TODAS LAS MANGUERAS PARA FLUIDOS TIENEN QUE

TENER GUARDAS DE RESORTE EN AMBOS EXTREMOS!

Estas protegen las mangueras contra dobleces o retorceduras en los acoplamientos o cerca de ellos, los que podrian traducirse en roturas de la manguera.

Antes de usarlas, APRETAR bien firmes todas las conexiones.

El fluido a alta presión puede desalojar un acoplamiento suelto o dejar que por el escape un chorro a alta presión.

NUNCA usar una manguera que está dañada. Siempre, revisarla en busca de cortaduras, escapes, abrasion, cubierta abultada, o acoplamientos sueltos o dañados. Si llegara a encontrarse cualquiera de estás condiciónes, reemplazar de inmediato la manguera. NO intentar racoplar una manguera de alta presión o enmendarla con cinta adhesiva u otro matérial similar. Una manguera que ha sido remendada no aguante el fluido a alta presión.

MANEJAR Y PASAR CUIDADOSAMENTE LAS MAN-

GUERAS. No tirar de las mangueras para mover el equipo. No usar fluidos o solventes que sean incompatibles con el tubo interno y la cubierta dela manguera. NO exponer las mangueras a temperaturas sobre 82 ) C (180 ) F) o bajo –40 ) C (–40 ) F).

Continuidad del circuito de puestá a tierra de la manguera

La continuidad del circuito de puestá a tierra apropiado es esencial para mantener conectado a tierra el sistema pulverizador. Es indispensable revisar la resistencia eléctrica máxima de las mangueras de aire y de fluido por lo menos una vez a la semana. Si la manguera no tiene una etiqueta en la cual se especifica la resistencia eléctrica, ponerse en contacto con el proveedor o fabricante de la manguera para la información sobre los límites de resistencia. Usar un metro de resistencia en la gama apropiade para comprobar la resistencia; si excede los límites recomendados, reemplazarla de inmediato. Es muy arriesgado tener una manguera sin puestá a tierra o con la puestá a tierra en malas condiciónes. Leer también la información sobre RIESGO DE INCENDIO O EXPLOSIÓN, más arriba.

PELIGRO DE INCENDIO O EXPLOSIÓN

El flujo a alta velocidad del fluido al pasar por la bomba y manguera crea electricidad estática. Si todas las partes del equipo pulverizador no tienen buena tierra, pueden ocurrir chispas, convirtiendo al sistema en algo peligroso. T ambién, pueden producirse chispas a enchufar o desenchufar el cordón electrico o al usar un motor de gasolina. estás chispas pueden inflamar los vapores de los solventes y el chorro de fluido pulverizado, particulas de polvo y otras sustancias in flamables, sea al aire libre o bajo techo, lo que podria causar una explosión o incendio y graves lesiones corporales y daños al a propiedad.

Enchufar siempre la pulverizadora a un tomacorriente que se encuentre a por lo menos 6 m (20 pies) de la maquina y del area que se va a rociar. No enchufar o desenchufar ningún cordón electrico en el lugar donde se está rociando cuando todavia exista la posibilidad de que queden vapores inflamables en el aire.

Si ocurre una chispa de electricidad estática o incluso un ligero choque electrico mientras se usa el equipo, DEJAR DE PUL-

VERIZAR DE INMEDIATO. Revisar todo el sistema en busca de una tierra apropiada. No usar de nuevo el sistema hasta haber identificado y soluciónado el problema.

Peusta a tierra

Para reducir el reisgo de chispas estáticas, conectar a tierra la pulverisadora y todo el otro equipo de pulverisar que se use o se encuentre en el lugar que se va a rociar. Consultar el codigo electrico de la localidad para las instrucciónes sobre las conexiones a tierra exigidas para la zona y tipo de equipo. Asegurar de conectar a tierra todo este equipo pulverisador:

1.

Pulverizadora: enchufar el cordón electrico, o cable extensor, cada uno un enchuf de très patas en buen estádo, a un tomacorreinte con puesat a tierra aporpiado. No usar un adaptador. Totos los cables extensores tienen que tener très hilos y una capacidad de 15 amperios.

2.

Mangueras para fluidos: usar solamente mangueras con puestá a tierra de una longitud combinada de 150 m (500 pies), para asequrar buena continuidad a tierra. Referirse también al párrafo sobre continuidad a tierra de la manugeura.

3.

Pistola: hace la puestá a tierra conectándola a una manguera de fluido y pulverizadora bien conectadas a tierra.

4.

Suministrar un recipiente: de acuerdo al código de la localidad.

5.

Objeto que se está rociando: de conformidad con el codigo local.

6.

Todos los baldes de solvente usados durante el lavado, de conformidad con el código local. Usar solamente baldes de metal, que sean conductivos. No colocar el balde en una superficie no conductiva, como papel o cartón, que interumpe la continuidad a tierra.

7.

Para mantenar la continuidad a tierra durante el lavado o descarga de presión, siempre apoyar una parte metálica de la pistola bien firme contra el costado del balde de metal, después apretar el gatillo.

Seguridad durante el lavado

Para reducir el riesgo de que se inyecte o salpique fluido en la piel, o que ocurra una descarga de electricidad estática, siempre seguir las INSTRUCCIÓNES PARA EL LAVADO, dadas en la página 13. Seguir el procedimiento de descarga

de presión en la págna 6, y quita la boquilla rociadora antes de lavar. Apoyar una parte metalica de la pistola bien firme contra el costado de un balde de metal y usar le presión más baja posible de fluido durante el lavado.

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SETUP

1. Connect Hose and Gun. See Fig 8–1.

NOTE: When tightening fittings at the pressure control, hold one wrench firmly on the hex of the pressure control fitting to keep it from rotating. Use another wrench to tighten the mating fitting.

a. Remove the cap from the outlet nipple and screw the 50 ft. (15.2 m) main fluid hose on to the nipple.

CAUTION

To avoid damaging the pressure control, which may result in poor equipment performance and component damage, follow these precautions:

1. Always use nylon spray hose at least 50 ft

(15.2 m) long.

2. Never use a wire braid hose as it is too rigid to act as a pulsation dampener.

3. Never install any shutof f device between the pressure control and the main hose.

See Fig

8–1.

b. Connect the 6 ft. (1.8 m) hose to the main fluid hose with the nipple provided. Connect the short hose to the gun inlet connection.

c. Don’t use thread sealant, and don’t install the spray tip yet!

WARNING

If you are supplying 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 2750 psi (190 bar) Working Pressure .

This is to reduce the risk of serious bodily injury caused by static sparking, fluid injection or over– pressurization and rupture of the hose or gun.

3. Fill Packing Nut/Wet–Cup. See Fig 8–1.

Fill the packing nut/wet–cup 1/3 full with Graco

Throat Seal Liquid (TSL), supplied.

4. Check the Electrical Service.

a. Be sure the electrical service is 120 V, 60 HzAC,

15 Amp (minimum) and that the outlet you use is properly grounded.

b. Do not remove the third prong of the power supply cord, which is the grounding prong, and do not use an adapter.

c. Use an extension cord which has 3 wires of a minimum 12 gauge size, and a maximum of 200 ft. (61 m) long. Longer lengths may affect sprayer performance.

ON/OFF SWITCH

FILL THE

PACKING NUT/WET-CUP

1/3 FULL WITH TSL

PRESSURE DRAIN VALVE

1/4 npsm(m) OUTLET NIPPLE

CONNECT MAIN HOSE HERE

DO NOT INSTALL ANY SHUTOFF

DEVICE BETWEEN THE PRESSURE

CONTROL AND THE FIRST 50 FEET

(15 M) OF HOSE

Fig 8–1

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SETUP

5. Plug in the Sprayer. Be sure the ON/OFF switch is

OFF. Then plug the cord into a grounded electrical outlet at least 20 ft. (6 m) away from the spray area.

WARNING

Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious bodily injury and property damage. Refer to the warning section FIRE OR EXPLOSION HAZARD on page 3 for more detailed grounding instructions.

6. Flush the pump to remove the lightweight oil which was left in to protect pump parts after factory testing.

a. Before using water–base material, flush with mineral spirits followed by soapy water, and then a clean water flush.

b. Before using oil–base material, flush with mineral spirits only.

c. See FLUSHING GUIDELINES on page 13 for the flushing procedure.

7. Prepare the material according to the manufacturer’s recommendations.

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OPERATION

WARNING


To reduce the risk of serious bodily injury , including fluid injection, splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying.



3. Unplug the power supply cord.

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.


6. Open the pressure drain valve, having a container ready to catch the drainage. Leave the valve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, wrap a rag around the tip guard retaining nut or hose end coupling and VERY

SLOWLY loosen the part to relieve pressure gradually, then loosen completely. Now clear the tip or hose.

6. To prime the pump , hold a metal part of the gun firmly against and aimed into a metal waste container.

See Fig 10–1. Squeeze the trigger and hold it open, turn the ON/OFF switch to ON, and slowly increase the pressure until the sprayer starts. Keep the gun triggered until all air is forced out of the system and the material flows freely from the gun. Release the trigger and engage the gun safety latch.

CAUTION

If the pump runs without fluid in it for more than 30 seconds, the displacement pump packings will be damaged. If the pump does not prime easily, follow the NOTE below.

NOTE: If the pump is hard to prime, place a container under the pressure drain valve and open it.

When fluid comes from the valve, close it. Then disengage the gun safety latch and proceed as in Step 6, above.

MAINTAIN FIRM

METAL TO METAL

CONTACT WHEN

PRIMING

Startup

Use this procedure each time you start the sprayer to help ensure the sprayer is ready to operate and that you start it safely.

NOTE: For the first time startup, be sure to flush the sprayer first. See page 13 for FLUSHING

GUIDELINES.

1. Close the pressure drain valve.

2. Don’t install the spray tip yet!

3. Put the suction tube into the material container.

NOTE: To adjust the pressure, use the pressure adjusting knob on the pressure control. Turn the knob counterclockwise to decrease pressure and clockwise to increase pressure.

4. Lower the pressure setting by turning the pressure adjusting knob all the way counterclockwise. See Fig

11–1.

5. Disengage the gun safety latch.

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Fig 10–1

7. Check all fluid connections for leaks. If any leaks are found, follow the Pressure Relief Procedure

Warning, to the left, before tightening the connections.

8. Install the spray tip and tip guard. Refer to the instructions supplied with your tip guard and/or spray gun. First be sure the fluid pressure is relieved and the gun safety latch is engaged.

9. Adjust the spray pattern.

a. Increase the pressure just until spray from the gun is completely atomized. To avoid excessive overspray and fogging, and to decrease tip wear and extend the life of the sprayer, always use the lowest possible pressure needed to get the proper atomization of the material you are spraying.

b. Follow your material manufacturer’s spray pressure recommendations.

b. If more coverage is needed, use a larger tip rather than increasing the pressure.

c. Test the spray pattern. To adjust the direction of the spray pattern, engage the gun safety latch and loosen the retaining nut. Position the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern. Then tighten the retaining nut.

OPERATION

PRESSURE ADJUSTING KNOB

ROTATE CLOCKWISE TO

INCREASE PRESSURE

ON/OFF SWITCH

SUCTION TUBE

PRESSURE

DRAIN VALVE

Fig 11–1

Cleaning a Clogged Tip

WARNING

To reduce the risk of serious bodily injury from fluid injection;

NEVER operate the spray gun with the tip guard removed.

DO NOT hold your hand, body, or a rag in front of the spray tip when cleaning or checking a clogged tip. Always point the gun toward the ground or into a waste container when checking to see if the tip is clear.

DO NOT try to “blow back” material; this is NOT an air spray system.

1.

Clean the front of the tip frequently during the day’s operation. First, follow the Pressure Relief Proce-

dure Warning on page 10.

2. If the spray tip clogs, release the gun trigger and engage the gun safety latch.

If your gun has a self–clearing tip, rotate the tip.

Disengage the gun safety latch and trigger the gun into a waste container. Engage the gun safety latch again. Return the handle to the original position, disengage the gun safety latch, and resume spraying.

If your gun does not have a self–clearing tip, or

if the tip is still clogged , engage the gun safety latch, shut off and unplug the sprayer, and open the pressure drain valve to relieve pressure. Clean the spray tip as instructed in your separate tip guard and/ or spray gun instruction manual.

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SHUTDOWN AND CARE

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 Pres-

sure Relief Procedure Warning on page 10 before checking, adjusting, cleaning and shutting down the sprayer.

1.

Check the packing nut/wet–cup daily . Relieve pressure. See page 10. Be sure the wet–cup is 1/3 full of TSL at all times to help prevent material 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. Use a round punch or brass rod and light hammer to adjust the nut. See

Fig 12–1.

2.

Lubricate the bearing housing after every 100 hours of operation. Remove the cover of the bearing housing. Fill the bearing housing cavity with SAE non–detergent oil. See Fig 12–1.

3.

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 GUIDELINES on page 13.

CAUTION

To prevent pump corrosion, and to reduce the chance of fluid freezing in the pump or pressure control in cold weather, never leave water or any type of material in the sprayer when it is not in use. Freezing can seriously damage the sprayer or result in a loss of pressure or stalling.

4.

For very short shutoff periods, leave the suction tube in the material, relieve pressure, and clean the spray tip.

5.

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.

WARNING

Refer to the warning section, HOSE SAFETY, on page 3, for information on the hazard of using damaged hoses.

LUBRICATE BEARING

HOUSING AFTER

EVERY 100 HOURS OF

OPERATION. USE SAE

NON–DETERGENT OIL.

Fig 12–1

PACKING NUT/

WET–CUP

TO TIGHTEN, TURN

CLOCKWISE, AS

SHOWN

BY ARROW

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When to Flush

FLUSHING GUIDELINES

1.

New Sprayer. Your new sprayer was factory tested in lightweight oil which was left in to protect pump parts.

Before using water–base material, flush with mineral spirits followed by soapy water , and then a clean water flush.

Before using oil–base material, flush with mineral spirits.

2.

Changing Colors. Flush with a compatible solvent.

3.

Changing from water–base to oil–base material.

Flush with warm, soapy water, then mineral spirits.

4.

Changing from oil–base to water–base material.

Flush with mineral spirits, followed by warm, soapy water, then a clean water flush.

5.

Storage.

Water–base material: flush with water, then mineral spirits. Relieve pressure.

Oil–base material: flush with mineral spirits. Relieve pressure.

CAUTION

NEVER leave water in the sprayer if there is the slightest chance it could freeze. Push the water out with mineral spirits. Water left to freeze in the pressure control tube prevents the sprayer from being started and causes serious damage to the pressure control.

WARNING

To reduce the risk of 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 and aimed into a grounded metal pail when flushing.

6. Lower the pressure setting by turning the pressure adjusting knob all the way counterclockwise.

MAINTAIN FIRM

METAL TO METAL

CONTACT WHEN

FLUSHING

Fig 13–1

6.

Startup after storage.

Before using water–base material, flush out the mineral spirits with soapy water and then a clean water flush. When using oil–base material, flush out the mineral spirits with the material to be sprayed.

How To Flush

1. Follow the Pressure Relief Procedure Warning on page 10.

3. Close the pressure drain valve.

4. Put the suction tube in a grounded metal pail of compatible solvent.

5. Remove the spray tip from the gun, if it is installed.

7. Hold a metal part of the gun firmly against and aimed into a metal waste container.

See Fig 13–1. Squeeze the trigger and hold it open, turn the ON/OFF switch to ON, and slowly increase the pressure setting until the sprayer starts. Keep the gun triggered until all air is forced out of the system and the solvent flows freely from the gun. Release the trigger and engage the gun safety latch. This procedure helps reduce the risk of static sparking and splashing.

NOTE: If the pump is hard to prime, place a container under the pressure drain valve and open it.

When fluid comes from the valve, close it.

8. Remove the suction tube from the pail. Disengage the gun safety latch and trigger the gun to force solvent from the hose. Do not let the pump run dry for more than 30 seconds to avoid damaging the pump packings! Relieve pressure.

9. Leave the pressure drain valve open until you are ready to use the sprayer again. Clean the fluid filter, if used.

10. If you flushed with mineral spirits and are going to use a water–base material, flush with soapy water followed by a clean water flush. Relieve pressure.

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TROUBLESHOOTING GUIDE


To reduce the risk of serious bodily injury , including fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying.



3. Unplug the power supply cord.

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

WARNING


6. Open the pressure drain valve, having a container ready to catch the drainage. Leave the pressure drain valve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, wrap a rag around the tip guard retaining nut or hose end coupling and VER Y

SLOWLY loosen the part to relieve pressure gradually, then loosen completely . Now clear the tip or hose obstruction.

Check everything in the guide before disassembling the sprayer.

PUMP WON’T OPERATE

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

Basic Fluid Pressure Problems 1. Check the pressure control knob setting. The motor will not run if it is at the minimum setting

(fully counterclockwise).

2. Check for a clogged spray tip. Refer to the separate gun or tip instruction manual.

Basic Mechanical Problems 1. Check for frozen or hardened paint in the pump (39) and/or pressure control tube. Using a screwdriver, carefully try to rotate fan at back of motor by hand.

2. Check displacement pump connecting rod pin (45). It must be completely pushed into connecting rod (68) and retaining spring (44) must be firmly in groove of connecting rod.

See page 32.

3. Check for motor damage. Remove drive housing assembly (71). See page 28. Try to rotate fan by hand.

Basic Electrical Problems 1. Check sprayer circuit breaker (309) button to be sure it has not popped up.

WHAT TO DO

When check is not OK refer to this column

1. Slowly increase the pressure setting to see if the motor starts.

2. Relieve pressure, refer to the separate gun or tip instruction manual for tip cleaning.

1. Thaw. Plug in sprayer and turn on. Slowly increase pressure setting to see if motor starts. If it doesn’t, see NOTE 1, below.

2. Push pin into place and secure with the spring retainer.

3. Replace motor (12) if fan won’t turn. See page 30.

2. Check electrical supply with volt meter. Meter should read 105–125 VAC.

3. Check extension cord for visible damage.

Use a volt meter or test lamp at extension cord outlet to check.

4. Check sprayer power supply cord (31 1) for visible damage such as broken insulation or wires.

5. Check motor brush leads, terminals and brush length. Brush length should be 1/2” minimum. See page 21.

1. Depress button to reset. If circuit breaker continues to open, see ‘Electrical Short’ on page 19.

2. Reset building circuit breaker; replace building fuse. Try another outlet.

3. Replace extension cord.

4. Replace power supply cord. See page 22.

5. Tighten terminal screws; replace brushes.

See page 21.

NOTE 1: Thaw the sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm area. Do not try to start the sprayer until it has thawed completely. If the bourdon tube was not damaged by the freezing, the pump should operate. If paint hardened (dried) in the sprayer, the pump packings and/or bare pressure control must be replaced. See page 32 (pump) or 25 (pressure control).

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PUMP WON’T OPERATE

TYPE OF PROBLEM

Diagnosing circuit board

indicator lamps. The normal condition is red lamp on, clear lamp on when board is telling pump to run.

Follow Pressure Relief Pro-

cedure W arning. Remove gun from hose. Remove pressure control cover. Check for faulty condition of circuit board lamps.

Condition A

Both lamps on; pump won’t operate and motor is not running

WHAT TO CHECK


1 . Check leads from bridge (308) to motor to be sure they are securely fastened and properly mated.

2. Check G1 and G2 connections between circuit board (70) and bridge (308) for damage or loose terminals. See the Wiring Diagram on page 16.

3. Check for loose motor brush lead connections and terminals. See page 21.

4. Check brush length which should be 1/2” minimum. See page 21.

NOTE: The brushes do not wear at the same rate on both sides of the motor. Check both brushes.

5. Check for broken or misaligned motor brush springs. See page 21.

6. Check motor brushes for binding in brush holders. See page 21.

WHAT TO DO


1. Replace loose terminals; crimp to leads.

Be sure male terminal blades are straight and firmly connected to mating part.

2. Clean circuit board male terminals. Replace loose or damaged terminals. Securely reconnect leads.

3. Tighten terminal screws. Replace brushes if leads are damaged. See page 21.

4. Replace brushes. See page 21.

Condition B (continued)

Both lamps off

5. Replace spring if broken. Realign spring with brush. See page 21.

6. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.

7. Remove motor and have motor shop resurface commutator if possible. See page 30.

7. Check motor armature commutator for burn spots, gouges and extreme roughness. Remove motor cover and brush inspection plates to check. See page 21.

8. Check motor armature for shorts using armature tester (growler) or perform spin test. See page 20.

9. Check bridge (308) by substituting with a good bridge or performing bridge test. See page 20.

CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature will immediately burn out a good bridge.

1. Check circuit breaker (309) button to be sure it has not popped up.

8. Replace motor. See page 30.

9. Replace bridge. See page 23.

1. Depress button to reset. If circuit breaker or fuse continues to open, see “Electrical

Short”, page 19.

2. Replace power supply cord. See page 22.

REFER TO THE WIRING

DIAGRAM ON PAGE 16

TO IDENTIFY TEST POINTS

(TP).

NOTE: Connect the volt meter to the terminal not the wire which you disconnect from the terminal.

2. Check power supply cord (31 1). Disconnect

TP6 female (neutral) and TP1 female and connect volt meter to these leads. Plug in sprayer. Meter should read 105 to 125 VAC.

Unplug sprayer. Reconnect TP1.

3. Check ON/OFF switch (303). Disconnect TP2 and connect volt meter to TP6 female and

TP2 male. Plug in sprayer and turn ON. Meter should read 105 to 125 VAC. Turn off and unplug sprayer. Reconnect TP2.

4. Check jumper wire (306). Disconnect TP3 and connect volt meter to TP6 female and

TP3 female. Plug in sprayer and turn on. Meter should read 105 to 125 VAC. Turn off and unplug sprayer. Reconnect TP3.

5. Check circuit breaker (309). Connect volt meter to TP6 female and TP4. Plug in sprayer and turn ON. Meter should read 105 to 125

VAC. Turn off and unplug sprayer.

3. Replace ON/OFF switch. See page 22.

4. Replace jumper wire.

5. Replace circuit breaker. See page 23.

308–073

MOTOR WON’T OPERATE

TYPE OF PROBLEM

Condition B (continued)

Both lamps off

REFER TO THE WIRING DIA-

GRAM BELOW TO IDENTIFY

TEST POINTS (TP).

WHAT TO CHECK


6. Check motor thermal cutout switch. Disconnect TP9.Connect volt meter to TP6 female and TP9 female. Plug in sprayer and turn on.

Meter should read 105 to 125 V AC. Turn off and unplug sprayer. Reconnect TP9.

7. Check microswitch (302).Reconnect TP6 connectors. Connect volt meter to TP15 male and TP4. Meter should read 50–125 VAC.

WHAT TO DO


6. Allow motor to cool. Correct cause of overheating. If switch remains open after motor cools, disconnect TP9 and TP10, check continuity between TP9 female and TP10 with ohmmeter. If open, replace motor. Reconnect TP9 and TP10.

7. Clean microswitch male terminals. Replace loose or damaged terminals. Securely reconnect leads.

8. Visually inspect microswitch (302) button. Adjustment stud should not depress button when fluid pressure is zero. Depress button with small screwdriver; audible click indicates microswitch is in normal position.

9. Check microswitch (302) continuity with ohm meter. Be sure sprayer is unplugged! Meter should read zero ohms.

8. Microswitch is faulty. Return sprayer for repair.

9. Microswitch is faulty. Return sprayer for repair.

10.Check all terminals for damage or loose fit.

10.Replace damaged terminals and reconnect securely.

11. Check circuit board (70) by substituting with a good board. See page 24.

11. Replace circuit board. See page 24.

WIRING DIAGRAM

Condition C

Red lamp on,

Clear lamp off

Unplug sprayer!

BLUE

WHITE

BLACK

YELLOW

RED

AC1 G1

AC2G2 +

_

MOTOR

LEADS

BLACK WHITE

NOTE:

TP9

TP13

TP15

TP10

TP14

TP16

GREEN

GROUND

WIRE

POWER SUPPLY CORD

1. Check circuit board (70) by removing from box without disconnecting wires; see page 24 for removal procedure.

WARNING: Removing circuit board while still wired over–rides optical detector which may cause sprayer to over–pressurize, if microswitch does not function properly . T urn sprayer on

ONLY long enough to check lamp condition, then shut off immediately.

WARNING: To reduce risk of electric shock, handle board by edges only! Do not allow any metal objects to come in contact with board!

Plug in and turn on sprayer. Clear lamp should be on now. Turn off and unplug sprayer.

MOTOR

THERMAL SWITCH

1. If clear lamp is not on, replace circuit board.

See page 28.

FLAG

OPTICAL

DETECTOR

CIRCUIT

BOARD

2. Check bourdon tube flag and detector position. Reinstall circuit board (see page 24).

Turn pressure setting to maximum; flag should extend less than half way into optical detector slot from the bottom.

2. Perform pressure control adjustment to see if that corrects problem. See page 26.

If not, replace bare pressure control box

(301). See page 25.

.

16 308–073

LOW OUTPUT

TYPE OF PROBLEM

Low Output

WHAT TO CHECK


1. Check for worn spray tip.

2. Check to see that pump does not continue to stroke when gun trigger is released. Plug in and turn on sprayer. Prime with paint. Trigger gun momentarily, then release and engage safety latch. Relieve pressure, turn off and unplug sprayer.

3. Check electrical supply with volt meter. Meter should read 105–125 VAC.

WHAT TO DO


1. Follow Pressure Relief Procedure Warn-

ing then replace tip. See your separate gun or tip manual.

2. Service pump. See pages 32–33.

3. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.

4. Replace with a correct, grounded extension cord.

4. Check extension cord size and length; must be at least 12 gauge wire and no longer than

200 ft.

5. Check G1 and G2 leads from bridge (308) to circuit board (70) for damaged or loose wires or connectors.

6. Check stall pressure. Refer to Pressure Control Adjustment on page 26.

7. Check bridge (308) + and – leads and terminals to motor . Inspect wiring insulation and terminals for signs of overheating. See page

23.

8. Check for loose motor brush leads and terminals. See page 21.

9. Check for worn motor brushes which should be 1/2” minimum. See page 21.

10.Check for broken and misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.

11. Check motor brushes for binding in brush holders. See page 21.

12.Check circuit board (70) by substituting with a good circuit board. See page 24.

13.Check motor armature for shorts by using an armature tester (growler) or perform spin test.

See page 20.

14. Check bridge (308) by substituting with a good bridge or by performing the bridge test.

See page 23 or 20.

CAUTION: Do not perform this check until armature is determined to be good. A bad armature will immediately burn out a good bridge.

5. Clean circuit board male terminals. Replace loose or defective lead terminals. Securely reconnect lead terminals to board.

6. Perform pressure control adjustment. See page 26.

7. Be sure male terminal blades are centered and firmly connected to female terminals.

Replace any loose terminal or damaged wiring. Securely reconnect wires to bridge.

8. Tighten terminal screws. Replace brushes if leads are damaged. See page 21.

9. Replace brushes. See page 21.

10.Replace spring if broken. Realign spring with brush. See page 21.

11. Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.

12.Replace circuit board. See page 24.

13.Replace motor. See page 30.

14.Replace bridge. See page 23.

308–073

NO OUTPUT

TYPE OF PROBLEM

Motor runs but pump does not stroke

WHAT TO CHECK


Motor runs and pump strokes 1. Check paint supply.

2. Check for clogged intake strainer.

3. Check for loose suction tube or fittings.

4. Check to see if intake valve ball and piston ball are seating properly.

5. Check for leaking around throat packing nut which may indicate worn or damaged packings. See page 32.

1. Check displacement pump connecting rod pin (45). See page 32.

2. Check connecting rod assembly (68) for damage. See page 28.

3. Be sure crank in drive housing rotates; plug in sprayer and turn on briefly to check. Turn off and unplug sprayer. See page 28.

WHAT TO DO


1. Refill and reprime pump.

2. Remove and clean, then reinstall.

3. Tighten; use thread sealant or sealing tape on threads if necessary.

4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary. See page 32. Strain paint before using to remove particles that could clog the pump.

5. Replace packings. See pages 32–33. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten the packing nut/wet-cup.

1. Replace pin if missing. Be sure retaining spring (44) is fully in groove all around connecting rod. See page 32.

2. Replace connecting rod assembly . See page 28.

3. Check drive housing assembly for damage and replace if necessary. See page 28.

EXCESSIVE PRESSURE FLUCTUATIONS

TYPE OF PROBLEM

Spray pattern variations.

WHAT TO CHECK


1. Be sure both G1 and G2 leads from bridge

(308) to circuit board (70) are firmly connected. See page 23.

2. Check maximum working pressure adjustment. Refer to Pressure Control Adjustment on page 26.

3. Check bourdon tube flag and detector position. Turn pressure setting to maximum; flag should not drag or bind in optical detector slot of circuit board.

CIRCUIT BOARD

WHAT TO DO


1. Reconnect securely.


3. Carefully bend flag into alignment with detector slot to see if that corrects problem.

If not, replace bare pressure control assembly (301). Perform pressure control adjustment after reassembly.

OPTICAL

DETECTOR

FLAG

4. Check circuit board (70) by substituting with a good board. See page 24.

5. Check LOW OUTPUT section, page 17.

4. Replace circuit board. See page 24.

308–073

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF PROBLEM WHAT TO CHECK


1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up.

WHAT TO DO


1. Decrease pressure setting or increase tip size.

2. Be sure ambient temperature where sprayer is located is no more than 90 is not located in direct sun.

_ F and sprayer

2. Move sprayer to shaded, cooler area if possible.

3. Determine if was sprayer turned on, pressurized, but not operating for long periods of time.

3 Turn off sprayer whenever you stop spraying for a while and relieve fluid pressure.

4. Check if bourdon tube is bent or out of shape. 4. Replace pressure control.

ELECTRICAL SHORT

TYPE OF PROBLEM

Building circuit breaker opens as soon as sprayer switch is 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 burn out immediately. Correctly diagnose and repair all shorts before checking and replacing bridge.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

Sprayer circuit breaker opens after sprayer operates for 5 to

10 minutes.

WHAT TO CHECK


1. Check all electrical wiring for damaged insulation, and all terminals for loose fit or damage.

Also check wires between pressure control and motor which are encased in conduit (1).

See page 25.

2. Check for missing inspection plate gasket

(see page 21), bent terminal forks or other metal to metal contact points which could cause a short.

3. Check motor armature for shorts. Use an armature tester (growler) or perform spin test.

See page 20. Inspect windings for burns.

4. Check bridge (308) by substituting with a good bridge or by performing bridge test. See page 23 or 20.

CAUTION: Do not replace bridge until armature is determined to be good. A bad armature will immediately burn out a good bridge.

1. Check ‘Basic Electrical Problems’ on page

14.

2. Check ON/OFF switch (302). Be sure the sprayer is unplugged! Disconnect wires from switch. Check switch with ohmmeter . The reading should be infinity with the ON/OFF switch OFF, and zero with the switch ON.

CAUTION: A short in the motor circuit burns the bridge out immediately , which usually causes the ON/OFF switch to fail in the closed mode.

1. Check electrical supply with volt meter. Meter should read 105 to 125 VAC.

WHAT TO DO


1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.

2. Correct faulty conditions.

3. Replace motor. See page 30.

4. Replace bridge. See page 23.

2. Replace ON/OFF switch. See page 22.

1. If voltage is too high, do not operate sprayer until corrected.

2. Check tightness of pump packing nut. Overtightening tightens packings on rod, restricts pump action, and damages packings.

3. Check maximum working pressure adjustment.

4. After determining that there is no short in system, reset circuit breaker button.

2. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary. See page 32.


4. If circuit breaker continues to open (button pops up), replace the circuit breaker. See page 23.

.

308–073

SPIN TEST

WARNING

Before doing this procedure, follow the Pressure

Relief Procedure Warning on page 2 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts, or electric shock. Unplug the sprayer!

Setup

Remove the drive housing. See page 28.

Remove the pressure control cover. Remove the motor shield (64). Remove the fan cover (B) and the inspection covers (A). See Fig 20–1.

Disconnect the + and – leads from the motor to the bridge

(308). See Fig 20–2.

Armature Short Circuit Test

Quickly turn the 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 30.

Armature, Brushes, and Motor Wiring Open

Circuit Test (Continuity)

Connect the two black motor leads together with a test lead. Turn the motor fan by hand at about two revolutions per second.

If there is uneven or no turning resistance, check for worn brushes or any loose or broken brush parts and repair as needed. See page 21.

If there is still uneven or no turning resistance, replace the motor. See page 30.

Fig 20-1

Fig 20-2

Fig 20–3

64

AC1 G1 –

AC2 G2 +

B

A

308

MOTOR LEADS

BRIDGE TEST

Remove the bridge from the pressure control (see page

23) and perform this test to determine if the bridge is functional. Use a continuity tester, such as multi–meter set on the X1 ohms scale.

Perform all tests in the chart. If the bridge fails even one test, it must be replaced.

Fig 20–3 shows the wire positions on the bridge. Using the chart in Fig 20–4, connect the meter wires as indicated by the black dots for each test, and then check the continuity.

In Tests 1, 2 and 3, there should be NO continuity.

In Tests 4, 5 and 6, connect meter wires as indicated, check continuity, then switch the meter wire connections and check continuity again. You should get NO continuity one way and YES continuity the other way.

In Tests 7 and 8, connect the meter wires as indicated by the black dots. Touch the indicated “G” wire to one meter wire, and then to the other. You should get NO continuity one way and YES continuity the other way.

20 308–073

CONTINUITY?

NO

NO

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

BRIDGE WIRES

G2 G1 –

D

D

D

+ AC1 AC2

D D

D

D

D

D

D

D

D

D

D

D

D

D

D

TEST 1

TEST 2

TEST 3

TEST 4

TEST 5

TEST 6 d d D

D D

D TEST 7

TEST 8

Fig 20–4

MOTOR BRUSH REPLACEMENT

SPRING NOTE: Replace the brushes when they have worn to less than 1/2 in. See Fig 21–3. Note that the brushes wear differently on each side of the motor, so check them both. Brush Repair Kit

220–853 and Spring Clip 110–816 are available.

WARNING



Fig 21–2

SPRING

1. Remove the motor shield (64). Remove the inspection covers (A) and gaskets on each side of the motor. See Fig 21–1.

BRUSH

64

1/2 in.

HOOK

BRUSH

SPRING CLIP

SPRING CLIP

A

Fig 21–1

2. Push in the spring clip to release its hooks from the brush holder. Pull out the spring clip . See Fig 21–2.

3.

Loosen the brush lead terminal screw. Pull the brush lead away, leaving the motor lead terminal in place.

Remove the brush and spring. See Fig 21–3.

4. Inspect the commutator for excessive pitting, burning or gouging. A black color on the commutator is normal. Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to wear too fast.

CAUTION

When installing the brushes, follow all steps carefully to avoid damaging the parts.

5. Install a new brush so the lead is in the long slot of the holder.

See Fig 21–4. Slide the terminal under the terminal screw washer and tighten the screw . Be sure the motor lead is still connected at the screw .

See Fig 21–4.

6. Place the spring on the brush as shown in Fig 21–4.

7. Install the spring clip and push it down to hook it in the housing. See Fig 21–2 and 21–4.

8. Repeat for the other side.

Fig 21–3

BRUSH LEAD

TERMINAL SCREW

MOTOR LEAD

TERMINAL

BRUSH HOLDER

SHORT SLOT

LONG SLOT

BRUSH

SPRING CLIP

110–816

NOTE: SPRING MUST COIL

IN THIS DIRECTION

Fig 21–4

WARNING

To reduce the risk of electric shock and serious injury, do not touch the brushes, leads, springs or brush holders while the sprayer is plugged.

CAUTION

Do not run the sprayer dry for more than 30 seconds while checking the brushes to avoid damaging the displacement pump packings.

9.

Test the brushes. With the sprayer OFF , turn the pressure control knob to minimum pressure. Plug in the sprayer. Turn the sprayer ON. Slowly increase the pressure until the motor comes up to full speed.

Inspect the brush and commutator contact area for excessive arcing. Arcs should not “trail” or circle around the commutator surface.

10. Install the remaining parts.

308–073

POWER SUPPLY CORD REPLACEMENT

WARNING



5. Reinstall the cover.

302

See Fig 22–1.

1. Remove the pressure control cover.

2. Disconnect the power supply cord lead from the ON/

OFF switch (303), the white wire going to the bridge

(308), and the green wire to the grounding screw

(343) and lockwasher (327).

3. Loosen the strain relief bushing (328). Remove the power supply cord (311).

4. Install the new cord (311) in the reverse order of disassembly.

Fig 22–1

343,327

328

311

303

308

ON/OFF SWITCH REPLACEMENT

WARNING



7. Install the switch guard (305), aligning the internal tab with the groove in the threads.

8. Powder the inside of the rubber boot (304) with talcum, then shake excess out of boot.

9. Install the nut and rubber boot and tighten.

See Fig 22–2 except where noted.


10. Reconnect the wires to the ON/OFF switch (303) and reconnect the wire to the microswitch (302).

11. Reinstall the pressure control cover.

2. Use a needle nose pliers to disconnect the upper terminal wire from the microswitch (302) for ease in removing the ON/OFF switch (303). See Fig 22–1.

304

3. Use pliers to disconnect the two black wires from the

ON/OFF switch (303). See Fig 22–1.

4. Use a 5/8 in. socket wrench to loosen and remove the nut and rubber boot (304) from the top of the pressure control box. Remove the switch guard

(305).

5. Remove the ON/OFF switch.

6. Install the new switch so the internal tab of the anti– rotation ring (A) engages with the vertical groove in the threads of the switch, and the external tab engages with the blind hole (B) of the pressure control box.

Fig 22–2

B

A

305

303

308–073

BRIDGE RECTIFIER REPLACEMENT

WARNING



5. Install the front screw (331), lockwasher (333) and nut (332). Make sure the bridge is flush with the side of the box and tighten the screws securely.

CAUTION

The lockwashers (333) must be in front of the bridge to avoid overheating which will result in bridge failure. See the DETAIL in Fig 23–1.

NOTE: The most common cause of bridge failure is

a faulty motor. Check the motor before replacing the bridge to prevent damaging the new bridge.

6. Connect all wires. Carefully route the wires.


2. Disconnect all wires from the bridge (308) at the appropriate terminals, using needle nose pliers.

3. Outside the pressure control box are two screws

(331).

Loosen, but don’t remove the screw nearest the motor. Then loosen and remove the front screw.

Slide the bridge out.

CAUTION

Be sure the flat blade of the insulated male connector is centered in the wrap–around blade of the female connector when the connections are made. Improper connections may cause the sprayer to malfunction.

Route all wires carefully to avoid interference with the movement of the bourdon tube, circuit board, or control box cover which could cause a malfunction.

4. Slide the slotted end of the new bridge (308) into the box so the lockwasher (333) on the rear screw (331) is IN FRONT of the bridge. See the DETAIL below.


303

310

306

309

308

BRIDGE INSTALLATION DETAIL

LOOSEN THIS SCREW

BUT DO NOT REMOVE

331

LOOSEN AND

REMOVE

SLOTTED

END 308

333

332

Fig 23–1

CIRCUIT BREAKER REPLACEMENT

WARNING



See Fig 23–1.


2. Use a small screwdriver to slide the terminal adapter off the circuit breaker terminal.

3. Disconnect the single black wire (306) from the circuit breaker (309) to the ON/OFF switch (303).

4. Use a 5/8 in. socket wrench to loosen the nut and boot (310) on the circuit breaker button.

5. Push down on the top of the circuit breaker and pull it out of the box.

6. Install the new circuit breaker in the reverse order.


CAUTION

Do not allow the circuit breaker contacts to touch the bourdon tube, which will cause a short. Tighten the circuit breaker nut firmly to prevent the circuit breaker from turning.

308–073

CIRCUIT BOARD REPLACEMENT

WARNING



6. Reconnect all wires. See the wiring diagram in Fig

24–2. Ease the pin (52) into the retainer.

A

70

See Fig 24–1 and 24–2 for this procedure.

52


B

2. Turn the pressure control knob (A) to the minimum setting to release spring tension on the board. Check to be sure only three or four threads of the pressure control knob shaft are exposed below the pressure adjustment nut (B). Loosen the nut, if necessary. See

Fig 24–1.

Fig 24–1

CAUTION

Step 2 is essential to reduce the risk of damaging the circuit board while removing or installing it.

3. Disconnect ALL wires from the board, including the two heavy black wires. Pay close attention to where connections are made. See Fig 24–2.

4. Pull out the black plastic–tipped pin (52). Push the bottom of the circuit board toward the wall of the control and carefully slide the board out.

CAUTION

Be sure the flat blade of the insulated male connector is centered in the wrap–around blade of 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 the risk of a malfunction.

5. Reinstall the new board in the box at the same angle as it was removed.

7. Perform the PRESSURE CONTROL ADJUST-

MENT, page 26, if you installed a new board.

Fig 24–2

24 308–073

70

BLUE

WHITE

BLACK

YELLOW

RED

52

BLACK

WHITE

GREEN

GROUND

WIRE

POWER SUPPLY CORD

AC1

AC2

G1

G2

_

+

MOTOR LEADS

MOTOR

THERMAL SWITCH

PRESSURE CONTROL REPLACEMENT

WARNING



4. Loosen the conduit connector (345). Pull the motor leads in the conduit (1) out of the pressure control.

5. Remove the circuit board and retain it. See page 24.

6. Remove the three screws (8) and nuts (10) located below the pressure control. Remove the pressure control.

See Fig 25–1 except where noted.

NOTE: If you are using the replacement pressure control, part no. 220–455, remove and discard the pressure control adapter (341). Hold the nut (B) firmly when removing the adapter.

1. Disconnect the main fluid hose from the pressure control outlet (A). Disconnect the fluid hose (72) at the pressure control nipple (344). Remove the drain hose (61) by pushing back on the sleeve of the drain valve connector (34).

2. Hold the hex of the pressure control nut (B) firmly with a wrench. Remove the drain valve (32) and then the tee (84).

3. Remove the pressure control cover (63). Disconnect the four motor leads. See Fig 24–2.

7. Remove the screws (23) holding the back mounting bracket (78) to the pressure control.

8. Install the new pressure control assembly in the reverse order of disassembly . Reinstall the conduit seal (28) around the wires in the conduit connector

(345) to prevent motor contamination from entering the control. See the DETAIL below.

9. Perform the PRESSURE CONTROL ADJUST-

MENT, page 26, before regular operation of the sprayer.

CAUTION

Do not allow the pressure control nut (B) to turn while installing the new pressure control assembly

Turning it can damage the sensitive bourdon tube.

.

Hold the nut firmly with a 1” open end wrench while screwing in the tee (84).

Fig 25–1

10

11

61

84

A

34

32

DETAIL

Shows position of conduit seal (28) in conduit connector (345)

B

344

72

345

23

78

8

36,63

1

28

345

CAUTION

Do not allow the pressure control nut (B) to turn at any time.

308–073

PRESSURE CONTROL ADJUSTMENT

WARNING

USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from component rupture, electric shock, fire, explosion, or moving parts.

This procedure sets the sprayer to 2750 psi (190 bar)

MAXIMUM WORKING PRESSURE and sets the overpressurization switch (microswitch) to approximately 3600 psi (248 bar).

Perform this procedure whenever the pressure control assembly is removed and reinstalled or replaced, or a new circuit board is installed.

NEVER try to increase the sprayer’s maximum working pressure of 2750 psi (190 bar ) by performing these adjustments in any other way. Normal operation of the sprayer at higher pressures may result in component rupture, fire or explosion. To perform this adjustment, however, the sprayer pressure must be temporarily increased above the normal working pressure.

Improper adjustment can cause the sprayer to overpressurize and result in component rupture, fire or explosion. It may also prevent the sprayer from obtaining the maximum working pressure, resulting in poor sprayer performance.

Use a new 52 ft (15.2 m) spray hose rated for at least

3000 psi (207 bar) MAXIMUM WORKING PRES-

SURE. A used, under–rated hose could develop a high pressure leak or rupture.

PRESSURE CONTROL

EXISTING TEE

EXISTING

NIPPLE

FLUID FILLED PRESSURE GAUGE,

102–814

NIPPLE, 162–453

CONNECT NEW HOSE

HERE.

CONNECT GUN ON END

OF HOSE.

SWIVEL,

156–823

TEE, 104–984

EXISTING PRESSURE

DRAIN VALVE

Fig 26-1

Service Tools Required:

D 3/8 in. nut driver or 3/8 in. socket wrench

D 1/4 in. open end wrench

D 7/16 in. open end wrench

D 0 – 5000 psi, oil–filled test gauge, Part No. 102–814

D Tee, 1/4 npt(m), p/n 104–984

D Nipple, 1/4 npt x 1/4 npsm, p/n 162–453

D Swivel, 1/4 npt(m) x 1/4 npsm swivel, p/n 156–823

D Pail of clean water

D Mineral spirits

D NEW spray hose, 1/4 in. ID x 52 ft., p/n 210–541


4. Place the pump suction tube in a pail of clean water.

5. Be sure the gun safety latch is engaged.

6. Plug in the sprayer.

NOTE: For Steps 7 through 18, refer to Fig 27–1.

7. Turn the pressure control knob (A) to the minimum setting (fully counterclockwise), and turn the sprayer

ON. THE DISPLACEMENT PUMP SHOULD NOT

CYCLE

1. Follow the Pressure Relief Procedure Warning on page 2.

2. See the above list of tools and equipment needed. Install the new parts shown in Fig 26–1. Connect the gun to the new test hose

If it does cycle, remove the plug (16) from the bottom of the pressure control. Insert a 3/8 in. nut driver through the opening, and unscrew the pressure adjustment nut (B) just until the sprayer stops running.

26 308–073

PRESSURE CONTROL ADJUSTMENT

Adjust the Overpressurization Switch

8. With the spray gun triggered, slowly turn the pressure control knob clockwise just until the sprayer starts. Prime the pump and hose.

14. Use the 3/8 in. nut driver to turn the pressure adjustment nut (B) counterclockwise one full turn.

15. With the pressure control knob at the minimum setting, turn the sprayer ON.

9. Slowly turn the pressure control knob to the maximum setting. While watching the red light on the circuit board and the pressure gauge, turn the nut (B)

slowly to increase pressure until the red light goes out and the gauge reads between 3400 –3800 psi

(234 – 262 bar).

16.

Slowly turn 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 nut (B) clockwise until the gauge reads EXACTLY 2750 psi (190 bar).

If the red light does not go out by 3800 psi

(262 bar), loosen the nut (C) and adjust the stud

(D) until the light goes out.

If the red light goes out before 3400 psi (234

bar), tighten the nut (C) and adjust the stud (D) until the light goes out between 3400 – 3800 psi

(234– 262 bar).

10. Tighten the nut (C) if it was loosened in Step 9.

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 pressure is set at 2750 psi (190 bar).

11. Trigger the gun to 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 sprayer OFF . Disengage the gun safety latch. Trigger the gun into a grounded waste container until pressure is relieved. Engage the gun safety latch.

CAUTION

To prevent pump corrosion, flush the water out of the pump, hose and gun with mineral spirits. Be sure to close the drain valve, first. Use the lowest pressure necessary to flush. Follow the Pressure

Relief Procedure W arning on page 2. Leave the mineral spirits in the pump to protect it until you are ready to spray again.

18. Install the plug (16) in the bottom of the pressure control. Remove the gauge assembly. Flush out the water with mineral spirits.

C

D

70

B

A

Fig 27–1

INSERT WRENCH HERE

TO ADJUST NUT (B)

16

308–073

DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT

WARNING


Relief Procedure W arning on page 2 to reduce the risk of a fluid injection injury , splashing in the eyes or in the skin, injury from moving parts or electric shock.

Be sure to unplug the sprayer!

5. Loosen the jam nut (41) with an adjustable wrench.

Unscrew and remove the displacement pump.

6. Turn the displacement rod so the pin hole faces straight back. Insert a hex key wrench through the hole to remove the screw (27). See Fig 28–2. Remove the other two screws (27) and lockwashers

(20) from the front of the drive housing (71). See Fig

29–1.

Refer to Fig 29–1 for Steps 1 to 18 unless otherwise noted.

7. Remove the motor shield (64).

NOTE: Stop the sprayer at the bottom of its stroke to get the crank (67) in its lowest position. If the crank must be lowered manually , carefully rotate the blades of the fan with a screwdriver.

8. Remove the two screws (15) and lockwashers (20) holding the motor to the drive housing.

1. Remove the front cover (59).

9. Lightly tap the lower rear of the drive housing (71) with a plastic mallet to loosen it from the front of the motor. Then pull the drive housing straight off.

2. Unscrew the swivel union (76) from the pump, holding a wrench on the pump intake valve to keep the pump from loosening.

3. Disconnect the pump outlet hose (72) from the displacement pump outlet nipple (40).

CAUTION

Do not allow the gear (69) to fall. It may stay attached to the drive housing or to the motor.

4. Use a screwdriver to push up the retaining spring

(44). Push the pin (45) out. See Fig 28–1.

45

Do not lose the thrust balls (9) located at each end of the gear (69). The balls, which are heavily covered with grease, usually stay in the shaft recesses, but could be dislodged. If caught between the gears and not removed, the balls will seriously damage the drive housing. If the balls are not in place, the bearings will wear prematurely.

68

Fig 28–1

27,20

44

41

71

10. Inspect the drive housing (71) for excessive wear and replace parts as needed.

11. Pull the crankshaft (67) out. Inspect it for wear or damage and replace it, if necessary. Place the bronze–colored washer (67a) and then the silver–colored washer (67b) on the crankshaft, when reinstalling it.

12. Remove the connecting rod (68). Inspect it for wear or damage. Replace the rod, if necessary.

13. Evenly lubricate the inside of the bronze bearing in the drive housing with high quality motor oil. Liberally pack the roller bearing and gears with bearing grease.

14. Carefully align the drive housing and front of the motor with the locating pins. Push the drive housing onto the motor, or tap it into place with a plastic mallet. Install the screws and lockwashers (15,20).

Turn the displacement rod so the pin hole faces straight back. Insert a hex key wrench through the hole to unscrew the screw (27).

CAUTION

DO NOT use the drive housing screws (27) to try to align or seat the housing to the motor; doing so will not ensure proper alignment, but will cause premature bearing wear.

Fig 28–2

308–073

15. Reinstall the motor shield (64).

16. Install the screws (27) and lockwashers (20) on the bearing housing and tighten evenly . Follow Step 6, above, for installing the screw located behind the displacement rod.

DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT

45

17. Screw the displacement pump about 3/4 of the way into the drive housing (71). Hold the pin (45) up to the pin hole in the connecting rod assembly (68) and continue screwing in the pump until the pin slides easily into the hole. Back of f the pump until the top threads of the pump cylinder are flush with the face of the drive housing and the outlet nipple (40) is facing back. Push the retaining spring (44) into the groove all the way around the connecting rod. T ighten the locknut (41) very tight – about 70 ft –lb (95 N.m) – with a 2 in. open end wrench and a light hammer. See

Fig 29–1 and 29–2.

WARNING

Be sure the retaining spring (44) is firmly in the groove all the way around, to prevent the pin (45) from working loose due to vibration.

See Fig 29–2.

68

FACE OF

BEARING

HOUSING

44

71

41

TORQUE TO

75 ft–lb (95 N.M)

Fig 29–2 If the pin works loose, it or other parts could break off due to the force of the pump action. These parts could be projected through the air and result in serious bodily injury or property damage, including damage to the pump connecting rod or bearing housing.

18. Reinstall the front cover (59). Reconnect the suction assembly and pump outlet hose (72).

64

33

FILL CAVITY WITH

SAE 10

NON–DETERGENT

MOTOR OIL

68

27

20

71

67a

67

67b

12

20

15

9

69

9

Fig 29–1

59

24

45

44

41

41

40

39

76

72

308–073

MOTOR REPLACEMENT

WARNING


Relief Procedure W arning on page 2 to reduce the risk of a fluid injection injury , splashing in the eyes or in the skin, injury from moving parts or electric shock. Be sure to unplug the sprayer!

13. Turn the displacement rod so the pin hole faces straight back. Insert a hex key wrench through the hole to remove the screw (27). Remove the other two screws (27) and lockwashers (20) from the front of the drive housing (71). See Fig 28–2.

14. Remove the motor shield (64).

NOTE: See Fig 31–1 except where noted.

1. Remove the pressure control cover and screws and disconnect the four motor leads. See the WIRING

DIAGRAM. Remove the conduit seal (28) from the conduit elbow (345) coming into the control box.

2. Use an adjustable wrench to loosen the conduit connector nut (345) at the pressure control assembly

(31).

3. Swing the conduit (1) away from the pressure control

.

4. Pull the motor leads through the connector, one at a time.

CAUTION

Always pull the motor leads one at a time to avoid loosening the terminals.

15. Remove the two screws (15) and lockwashers (20) from the top of the motor.

16. Use a plastic mallet to gently tap the displacement pump (39) from the rear to loosen the drive housing from the front of the motor. Then pull the drive housing away from the of the motor.

CAUTION

DO NOT allow the gear reducer (69) to fall when removing the drive housing (71). It is easily damaged if dropped. The reducer may stay engaged in either the front end bell or the drive housing.

DO NOT lose the thrust balls (9) located at each end of the gear reducer (69) or allow them to 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 are not in place, the bearings will wear prematurely.

5. Loosen the connector nut (30) at the motor and pull the conduit (1) away from the motor . Then pull the leads through the conduit, one at a time.

6. Unscrew the connector (30) from the motor.

7. Pull the motor leads through the connector, one at a time.

8. Remove the front cover (59).

9. Unscrew the swivel union (76) from the pump, holding a wrench on the pump intake valve to keep the pump from loosening.

10. Disconnect the pump outlet hose (72) from the displacement pump outlet nipple (40).

11. Use a screwdriver to push up the retaining spring

(44) at the top of the pump. Push the pin (45) out the rear. See Fig 28–1.

12. Loosen the jam nut (41) with an adjustable wrench.

Unscrew and remove the displacement pump.

17. Remove the motor mounting hardware: screws (8), lockwashers (1 1) and nuts (10) from the motor bracket (A).

18. Lift the motor off the frame.

19. Align the new motor with the frame mounting holes.

Install the motor mounting hardware.

20. Liberally grease the gear reducer (69) and pinion gear (B) and pack all bearings in the motor front end bell. Check to be sure the thrust balls (9) are in place.

21. Align the gears and push the drive housing (71) straight onto the front of the motor and the locating pins.

22. Starting at Step 15 and working backwards, continue to reassemble the sprayer.

NOTE: Use a turning motion on the conduit (1) when feeding wires through it.

308–073

MOTOR REPLACEMENT

WIRING DIAGRAM

303

302

BLUE

WHITE

YELLOW

BLACK

RED

309

AC1 G1

AC2 G2

_

+

59

24

27

20

71

BLACK WHITE

GREEN

GROUND

WIRE


MOTOR

LEADS

MOTOR

THERMAL SWITCH

64

15

20

12

67

69

67b

67a

9

A

11

10

40

72

76

345

1

DETAIL


28

345

8

30

31

33

8

Fig 31–1

308–073 31

DISPLACEMENT PUMP REPAIR

WARNING


Relief Procedure W arning on page 2 to reduce the risk of a fluid injection injury , splashing in the eyes or skin, injury from moving parts or electric shock. Unplug the sprayer!

NOTE: Packing Repair Kit 222–687 is available. For the best results use all the parts in the kit. Parts included in the kit are marked with an asterisk, for example (212*) in the text and drawings.

WARNING

Be sure the retaining spring (44) is firmly in the groove of the connecting rod, all the way around, to prevent it from working loose due to vibration.

See Fig 32–2.

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.

Removing the Pump Refer to Fig 32–1

.

1. Flush the pump, if possible, and relieve pressure again. Stop the pump with the piston rod (221) in its lowest position.

2. Torque the locknut (41) to 70 ft–lb (95 N.m). Refer to the CAUTION, below.

2. Unscrew the elbow (76) from the pump intake. Hold the wrench on the pump intake valve (220) to keep the pump from loosening.

3. Unscrew the hose (72) from the nipple (40).

4. Use a screwdriver to push the retaining spring (44) up and push out the pin (45).

5. Loosen the locknut (41) and unscrew the pump from the bearing housing (71).

6. Go to Disassembling the Pump on the bottom right side of this page.

CAUTION

If the locknut loosens during operation, the threads of the drive housing (71) will be permanently damaged. Be sure to tighten the locknut firmly.

3. Tighten the packing nut (221) just enough to stop leakage, but no tighter. Fill the wet–cup/packing nut

1/3 full with Graco TSL.

68

45

DETAIL OF

INTAKE VALVE

FACE OF

DRIVE

HOUSING

71

41

TORQUE TO

70 ft–lb (95 N.M)

Fig 32–2

44

71

44

45

41

TORQUE TO

70 ft–lb

(95 N.m)

221

*212

213

40

72

*203

*214

76

220

TORQUE TO

80 ft–lb

(107 N.m)

Fig 32–1

Reinstalling the Pump Refer to Fig 32–2

.

1. Screw the pump about 3/4 of the way into the drive housing (71). Hold the pin (45) up to the pin hole in the connecting rod (68) and continue screwing in the pump until the pin slides easily into the hole. Back off the pump until the top threads of the pump cylinder are flush with the face of the drive housing, and the nipple (40) is facing back. Push the retaining spring

(44) into the groove all the way around the connecting rod.

308–073

Disassembling the Pump

Refer to Fig 33–3, except where noted.

1. Unscrew the intake valve (220) from the cylinder

(219). Remove the gasket (214*), ball guide (213), stop pin (212*) and ball (203*) from the valve. Clean and inspect the parts for wear or damage, replacing parts as needed. Always use a new gasket (214*), provided in the repair kit. See Fig 32–2.

2. Unscrew and remove the packing nut (21 1) and plug (209).

3. Use a plastic mallet to tap the piston rod down. Pull the rod out through the bottom of the cylinder.

4. Remove the throat packings (217*) and glands

(210* and 208*).

5. Clamp the flats of the piston rod in a vise. Use a 7/8 in. wrench to loosen the retaining nut (207), and then to unscrew the piston valve (222) from the rod.

6. Remove the backup washer (216*), seal (204*), packings (215*) and glands (218* and 206*).

DISPLACEMENT PUMP REPAIR

Reassembling the Pump

NOTE: The lips of the throat V -packings MUST face

DOWN.The lips of the piston V-packings MUST face up.The lips of the U-cup seal (204) MUST face down . Incorrect installation damages the packings and results in pump leakage.

11. Screw down the cylinder locknut (41) until it is finger tight at the bottom of the external cylinder threads.

12. Place the flats of the intake valve in a vise. Assemble the intake valve using a new gasket (214*) and screw the pump cylinder onto the valve. See Fig 33–3.

Torque to 80 ft–lb (107 N.m).

Coat the piston rod, inside of the cylinder , and the packings with lightweight oil to help prevent packing damage when inserting the piston rod.

13. Tighten the packing nut (211) just enough to stop leakage, but no tighter. Fill the wet–cup/packing nut 1/3 full with Graco TSL.

1. Check the outside of the piston rod (221) and the inside of the cylinder (219) for scoring or scratches. If the parts are damaged, new packings will not seal properly. Replace these parts if needed.

14. See Reinstalling the Pump, on page 32.

2. Stack the backup washer (216*), u-cup seal (204* – lips down), female gland (218*), packings (215* – lips up) and male gland (206*) onto the piston valve (222).

See Fig 33–3.

3. Tighten the packing retaining nut (207) against the piston valve (222) and torque to 1–2 in–lb (0.11–0.22

N.m). See Fig 33–1.

Note the alignment of the piston (222) to the nut

(207) and maintain this alignment through Steps 3 to

7.

221

209

211

202*

41

APPLY ONE DROP

OF SEALANT TO

THESE THREADS

TORQUE (214) TO

1–2 in–lb

(0.11–0.22 N.m) *210

MAINTAIN

ALIGNMENT

THROUGH

STEPS 3 TO 7

217*

LIPS OF

V–PACKINGS

IN THROAT

MUST FACE

DOWN

Fig 33–1

*208

4. Apply only 1 drop of adhesive, supplied with the repair kit, to the threads of the piston valve. Place the small ball (202*) on the piston valve (222). See Fig 33–1.

5. Hand tighten the valve assembly into the piston rod just until the nut (207) contacts the face of the rod. See

Fig 33–2.

*202

219

207

207

TORQUE NUT

ONTO ROD TO

19 FT-LB

(25 N.M)

221

MAINTAIN ALIGNMENT

THROUGH STEPS 3 TO 7

*206

Fig 33–2

6. Place the piston rod flats in a vise.

7. Tighten the retaining nut (207) onto the piston rod

(221). Torque to 19 ft–lb (25 N.m). Use two wrenches to maintain the alignment mentioned in Step 3.

8. Stack the male gland (208*), packings (217* –lips down) and female gland (210*), one at a time into the top of the cylinder. See Fig 33–3.

9. Install the packing nut (211) and plug (209), but leave loose for now.

10. Insert the piston rod (221) through the bottom of the pump cylinder. See Fig 33–3.

*218

*204

LIPS FACE

DOWN

*216

222

*212

*203

220

TORQUE TO

80 ft–lb

(107 N.m)

Fig 33–3

215*

LIPS OF

V–PACKINGS

IN PISTON

MUST

FACE UP

213

214*

308–073


PARTS DRAWING – SPRAYER

73

75 64

48

A

61

54

42

55

ID LABEL

68

27

20

71

DANGER LABEL 43

15

20

74

67a

67

9

69

67b

9

12

10

11

10

59

24

44

45 A

C

75

B 74

76

41

39

40

72

66

40

47

B

23

78

8

ID LABEL 58

ID LABEL 57

DANGER LABEL 50

D

33

37

33

8

8

11

30

7

10

35

21 (PLUG)

60

38

22

C

84

63

31

D

36

38

19

14

56 OUTSIDE LABEL

46 INSIDE LABEL

1

34

32

65

308–073

PARTS LIST – SPRAYER


Includes items 1 to 84

REF

NO. PART NO. DESCRIPTION QTY

1

7

8

065–099 CONDUIT specify length when ordering 0.8

186–541 BRACKET

110–963 CAPSCREW, flange head,

5/16–18 x .75”

9 100–069 BALL, 1/4” dia.

10 100–188 NUT, heavy hex, 5/16–18

11 100–214 LOCKWASHER, spring, 5/16”

12 222–678** MOTOR, ELECTRIC, 1/2 HP includes items 12a to 12c and one each of items 9 and 43 1

12a 107–267 .TERMINAL, 0.187, 16–14 AWG, female 2

12b 107–504 .TERMINAL, 0.187, 22–18 AWG, female 1

12c 596–421 .TERMINAL

, 0.250, 16–14 AWG, female 1

14 101–242 RING, retaining

15 101–682 CAPSCREW, socket head,

2

1/4–20 x 5/8”

16 101–754 PLUG, pipe, soc hd, 3/8 npt

2 see page 36

19 154–636 WASHER, flat, 5/8”

20 105–510 LOCKWASHER, spring, 1/4”

21 105–521 PLUG, tubing, frame

22 108–179 WHEEL, semi–pneumatic

23 106–078 SCREW, mach, flat head, thd frmg,

1

2

5

2

2

10–24 x 3/8”

24 100–259 SCREW, mach, oval hd,

4

8–32 x 3/8”

25 107–258 CAP, see page 36

27 107–445 CAPSCREW, socket head,

4

1

1/4–20 x 1.5”

28 107–447 SEAL, conduit, see page 36

30 108–460 CONNECTOR, conduit, 45 _

31 220–455 PRESSURE CONTROL

3

2

1

32 221–077 see parts list on page 36

PRESSURE DRAIN VALVE

33 110–346 SCREW, mach, binding head,

1

1

8–32 x 3/8”

34 108–982 CONNECTOR, tube

35 220–678 CART KIT

8

1 includes replaceable items 14, 19, 21, 60

36 110–037 SCREW, mach, panhead, thd forming,

1

10–24 x 1/2”

37 110–240 CLIP

38 176–884 WASHER, backup

39 222–688 DISPLACEMENT PUMP

4

2

4 see page 38 for parts 1

9

2

9

9 ft

2

REF

NO. PART NO. DESCRIPTION QTY

40 162–453 NIPPLE, hex, 1/4 npsm x 1/4 npt

41 176–762 NUT, hex, 1–1/2–18

42 170–113 TUBE, suction

43 185–954* LABEL, DANGER

44 176–817 SPRING, retaining

45 176–818 PIN, straight, hdls, 5/16” dia x 1”

46 177–762* LABEL, WARNING

47 178–034 TAG, WARNING

48 178–342 CLAMP, tube

50 185–951* LABEL, DANGER

52 180–041 PIN, straight, see page 36

54 181–073 STRAINER

55 186–514 LABEL, identification



58 186–512 LABEL, i dentification

59 178–040 COVER, housing

60 183–275 SPACER

61 183–281 TUBE, drain

63 185–447 COVER, pressure control

64 186–526 SHIELD, MOTOR

65 206–994 THROAT SEAL LIQUID,

8 oz. (0.27 liter)

66 183–285 NIPPLE, 3/8 npt x 1/2 npsm

67 218–242 CRANKSHAFT ASSEMBLY, includes items 67a and 67b

67a 180–131 .BEARING, thrust

67b 107–434 .BEARING, thrust

68 218–359 CONNECTING ROD

69 218–364 GEAR REDUCER

70 218–405 CIRCUIT BOARD, see page 36

71 223–917 DRIVE HOUSING

Includes one of item 9

72 223–748 HOSE, grounded, nylon, 1/4” ID, 21.75”

1

(736 m) long, cpld 1/4 npsm (fbe), spring guard full length

73 176–920 HOSE, suction

74 103–927 CLAMP, hose

75 103–473 TIE, wire strap

76 221–020 SWIVEL, 90 _ , 1/2 npsm 1

78 183–573 BRACKET, mounting, pressure control 1

84 106–228 TEE, street, 1/4 npt (f x m x f) 1

2

3

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

*Extra Danger and Warning labels and tags available free.

**Motor Brush Kit 220–853 is available. Purchase separately .

308–073

PARTS – PRESSURE CONTROL

PRESSURE CONTROL ASSEMBLY 220–455

The terminals listed in this parts list are shown on the wiring diagram on page 37, except Ref. 325, which is shown on this page.

Part numbers for reference numbers 12a–12c, 16, 25,

28, 52 and 70, shown below or on page 37, are given on page 35.

REF

NO. PART NO.

DESCRIPTION QTY

301 218–126

302 180–043

303 105–679

304 105–659

305 107–255

306 218–168

308 218–170

309 107–256

310 107–254

311 218–169

312 107–268*

316 107–262*

BARE PRESSURE CONTROL

Includes replaceable items 302 to 305 1

.MICROSWITCH

.ON/OFF SWITCH

.BOOT, switch

.GUARD, locking

JUMPER WIRE

RECTIFIER, bridge

CIRCUIT BREAKER

BOOT, circuit breaker

CORD, power supply

ADAPTER, terminal

314 107–267** TERMINAL, female

TERMINAL, female

317 107–396** TERMINAL, male

318 107–294** TERMINAL, female

319 107–260*

320 107–266*

322 103–886*

TERMINAL, female

TERMINAL, male

TERMINAL, female

323 107–265*,** TERMINAL, male ( two with kit 220–455,

324 107–263* one with circuit board)

TERMINAL, female

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

3

1

REF

NO. PART NO.

DESCRIPTION QTY

325 102–799*

327 157–021

328 108–295

331 101–273

332 100–179

333 100–718

334 178–797

335 178–035

336 107–261*

{ LABEL, WARNING

337 107–503**

341 157–350

342 100–840

343 100–035

344 162–453

345 108–460

{

TERMINAL, ring

LOCKWASHER, no. 8, internal

BUSHING, strain relief

SCREW, mach; flat hd;

10–24 x 5/8”

NUT, hex, 10–24

LOCKWASHER, internal, no. 10

LABEL, WARNING

TERMINAL, female

TERMINAL, male

ELBOW, street; 1/4 npt(m x f)

SCREW, mach; slotted pan hd; 8–32 x 5/16”

NIPPLE, 1/4 npt(m) x 1/4 npsm

CONNECTOR, conduit

1

1

1

1

1

1

1

2

1

ADAPTER, 3/8 npt(m) x 1/4 npt (m) 1

1

2

1

2

2

* Supplied with Kit 220–455

** Supplied with replacement circuit board

{ Extra warning labels available free.

301

334,335

LABELS

304

305

303

310

REF 70

302

REF 25,52

341

342

(REAR

)

344

309

308

331,332,333

306

DETAIL


28

345 16

343,327

325

328

311 345

308–073

BLUE

WHITE

BLACK

YELLOW

RED

336

REF 25,52

320

318

317

318

302

303

324

316

WIRING DIAGRAM

BLACK WHITE

12a

323

GREEN

GROUND

WIRE


AC1 G1

AC2 G2

_

+

309

306

337

312

12c

322

12b

319

308

323

314

12a

MOTOR

THERMAL SWITCH

308–073 37

PARTS DRAWING


Displacement Pump

Includes items 202 to 222

NOTE: See the repair instructions on pages 32–33 for important torque values and procedures

209

211

*210

*217

*208

219

*212

213

203*

214*

220

218*

204*

216*

222

221

202*

207

206*

215*

PARTS LIST

REF

NO. PART NO.

DESCRIPTION QTY

202 105–444* BALL, stainless steel

203 105–445* BALL, stainless steel

204 108–995* SEAL, u–cup, polyethylene

206 183–236* GLAND, male, brass

207 176–751 NUT, hex

208 183–556* GLAND, male, brass, throat

PLUG 209 180–656

210 183–237* GLAND, female, brass, throat 1

1

1

211 176–758 NUT, packing/wet–cup

212 176–759* PIN, ball stop

213 176–760 GUIDE, ball, sst

214 176–761* GASKET, copper

1

1

1

1

1

1

1

1

1

5

1

215 176–882* V–PACKING, polyethylene

216 183–557* WASHER, backup, brass

217 176–997* V–PACKING, polyethylene, throat

218 183–558* GLAND, female, brass

219 183–238 CYLINDER, hard chrome over stainless steel

220 215–455

221 183–239

222 218–197

VALVE, intake

ROD, piston, hard chrome over stainless steel

VALVE, piston

5

1

1

1

1

1

*Included in Repair Kit 222–687 sold separately .

308–073

TECHNICAL DATA

Power Requirements

Maximum Delivery

Power Cord

Inlet Paint Strainer

. . . . . . . . . . . . . . . . . . . 120 VAC, 60Hz,

1 phase, 15 amp minimum

Working Pressure Range

Cycles/Gallon (liter)

. . . . . . . .

. . . . . . . . . . . . . .

0 – 2750 psi (0 – 190 bar)

. . . . . . . . . . . . . . . . . . . . . . . . . . . 470 (124)

Pump Inlet Size

Fluid Outlet Size

. . . . . . . . . . . . . . . . 0.5 GPM (1.9 liter/min)

No. 14 AWG, 3 wire, 8’6” (2.6 m)

. . . . . . . . . . . . . . . . 16 mesh (1190 micron)

Stainless Steel Screen, reusable

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted Parts:

Displacement Pump . . . . . . . . . . . . . . . . . . .

3/8 npt (f)

1/4 npsm

Stainless steel, zinc–plated steel, polyethylene, brass, copper

PTFE R

DIMENSIONS

Weight (dry w/o packaging)

Height

Length

Width

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 lb (34 Kg)

18 in. (457 mm)

31 in. (787 mm)

16 in. (406 mm)

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 labels to apply to your sprayer. The drawing below shows the best placement of these labels for good visibility.

Order the labels directly from Graco, free of charge.

Toll Free: 1–800–423–8594

In Minnesota: 1 –612–623–6921

Apply other language here

French

Spanish

German

Greek

Korean

English

ACCESSORIES

185–957

185–959

186–039

186–043

186–047

185–591

308–073

THE GRACO ULTRA

t

-LINE WARRANTY AND DISCLAIMERS

WARRANTY

Graco warrants all equipment manufactured by it 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. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for twenty–four months from the date of sale and the electric motor (excluding brush replacement, which is routine maintenance) or pressure control assembly which will be repaired or replaced for twenty-four months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by

Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non-contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco.

These items sold, but not manufactured by Graco (such as electric motor , switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)

Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–073 5–90

308–073

Graco 308073A LoPro 500 SPRAYER Owner's Manual

INSTRUCTIONS-PARTS LIST

ABATEMENT TECHNOLOGIES

LoPro 500 SPRAYER

Model 231–123, Series A

308–073

SAFETY WARNINGS

FLUID INJECTION HAZARD

General Safety

Medical Alert––Airless Spray Wounds

Spray Gun Safety Devices

Safety Latch

Diffuser

Tip Guard

Trigger Guard

Spray Tip Safety

Pressure Relief Procedure

MOVING PARTS HAZARD

EQUIPMENT MISUSE HAZARD

General Safety

System Pressure

Fluid and Solvent Compatibility

FIRE OR EXPLOSION HAZARD

Grounding

HOSE SAFETY

Flushing Safety

IMPORTANT

AVERTISSEMENT

RISQUES D’INJECTION

RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIEL

MESURES DE SÉCURITÉ CONCERNANT LES TUYAUX FLEXIBLES

RISQUES D’INCENDIE OU D’EXPLOSIÓN

ADVERTENCIA

PELIGRO DE INYECCIÓN DE FLUIDO

PELIGRO POR MAL USO DEL EQUIPO

SEGURIDAD EN EL USO DE LAS MANGUERAS

PELIGRO DE INCENDIO O EXPLOSIÓN

SETUP

SETUP

OPERATION

Startup

OPERATION

Cleaning a Clogged Tip

SHUTDOWN AND CARE

FLUSHING GUIDELINES

TROUBLESHOOTING GUIDE

SPIN TEST

BRIDGE TEST

MOTOR BRUSH REPLACEMENT

POWER SUPPLY CORD REPLACEMENT

ON/OFF SWITCH REPLACEMENT

BRIDGE RECTIFIER REPLACEMENT

CIRCUIT BREAKER REPLACEMENT

CIRCUIT BOARD REPLACEMENT

PRESSURE CONTROL REPLACEMENT

PRESSURE CONTROL ADJUSTMENT

PRESSURE CONTROL ADJUSTMENT

Adjust the Overpressurization Switch

Maximum Working Pressure Adjustment

DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT

DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT

MOTOR REPLACEMENT

MOTOR REPLACEMENT

DISPLACEMENT PUMP REPAIR

.

.

DISPLACEMENT PUMP REPAIR

PARTS DRAWING – SPRAYER

PARTS LIST – SPRAYER

PARTS – PRESSURE CONTROL

WIRING DIAGRAM

PARTS DRAWING

PARTS LIST

TECHNICAL DATA

DIMENSIONS

ACCESSORIES

THE GRACO ULTRA

-LINE WARRANTY AND DISCLAIMERS

Related manuals

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