Graco 307785D Ultra 1000 Airless Paint Sprayer Owner's Manual

INSTRUCTIONS/ PARTS LIST
367-785
ORAW
SUPERSEDES C
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
....
120 VAC, 15 Amp
:,
ULTRA@I000 AIRLESS PAINT SPRAYER
SWQ Dsi (207 bar) MAXIMUM WORKING PRESSURE
Model 231-034, Series A
Basic sprayer, without hose or gun
Model 231-043
Complete sprayer with hose, gun, R A P IV
DripLess" Tip Guard and SwitchTipTM.
_.
M o d e l 220411
Same as 231-043 except sprayer is CSA certified
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INDEX
Warnings ................................
2. 3
Avertissernent
4. 5
Advertencia ............................
.6, 7
Introduction ................................
8
Setup.........................................
9
Operation
10, 11
Shutdown Et Care........................
11
..12Guidelines
Flushing
Troubleshooting Guide.............13-18
Spin Test
19
Bridge Test
20
ReDair Section Index....................
21
Pa& List & Drawings
' . . X , 33
Sprayer ..........................
How To Order ReplacementPam.33
ControlPressure
...................... 34
Board
Circuit
........................... 35
Technical Data................Back Cover
..........................
,
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WARNING
Hazard of Using Fluids Containing Halogenated Hydrocarbons
Never use 1,1,1-trichloroethane, methylene chloride, other ha!ogenated hydrocarbon solvents orfluids containing
such solventsin this equipment. Such use could result in a senous chemlcal reaction,with the possibilityof explosion, which could cause death, serious bodily injury andlor substantlal property damage.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc parts.
GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55440-1444
@COPYRIGHT 1986 GRACO INC.
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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
Spray'Gun Safety Devices
This equipment generates very
high fluid pressure. Spray from
the gun,leaksor
ruptured componentscaninject
fluid
through your skin and into your body and cause extremely
serious bodily injury, includingthe need for amputation. Also,
fluid injacted or splashed imo the eyes or on the skin can
cause serious damage.
Be sure all gun safety devices are operating properly before
each use. Do not remova or modify any pan of the gun; this
can causa a malfunction and result in serious bodily injury.
NEVER point the spray gun at anyone or at any pan of the
body. NEVER put hand or fingers over the spray tip. NEVER
try to "blow back" paint; this is NOT an air spray system.
ALWAYS have the tip guard in place on the spray gun when
spraying.
- I
ALWAYSfollow the Praasura 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.
Besure equipmentsafetydevicesareoperatingproperly
before each use.
Medical Alert-Airless SDrav
Wounds
,~~~
~
If any fluid appears to penatraie your skin, get EMERGENCY
MEDICAL CARE A T ONCE. DO NOT TREAT AS A
SIMPLE CUT. Tell the doctor exactly whatfluid was injected.
Note to Physlclan: Injection in the skin is a traumatic inthe
surgicallyes soon
jury. It is Important to treat Injury
as possible. Do not delay treatment to research toxicity.
Toxicity is B concern with some exotic coatings injected
directly into the blood stream. Consultation with a plastic
surgeon or reconstructive hand surgeon may be advisable.
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 triggeringof the gun.
....
Diffuser
The gun diffuser breaks up spray and reducesthe risk of fluid
injection whenthe tip is not installed. Check diffuser operation
regularly.Follow the Pressure Relief Procedure, below,
thenremove the spray tip. Aim the gun into ametalpail,
holding the gun firmly to tha pail. Using the lowest possible
pressure, trigger the gun. If the fluid emitted is notdiffused into an irregular stream, replace'the diffuser immediately.
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. Thetip guard alans youto the fluid injection hazard
and helps reduce,but doas not prevent, the risk of accidentally placing your.fingers or any pan of your body close to the
spray tip.
Trigger Guard
Always have the trigger guardin place on the gun when spraying to reduce the risk of accidentally triggeringthe gun ifit is
droppeg or bumped.
Spray Tip Safety
Usa extreme cautionwhen cleaning or changing spraytips. If
the spray tip clogs while spraying, engagethe gun safety latch
Pressure Relief Procedure
To reduce the risk of serious bodily injury, includingfluid injection, splashingfluid or solvent in the eyes or on the skin, or injury
from moving pansor electric shock. alwaysfollow this procedure whenever youshut off the sprayer, when checking or servicIng any pan ofthe spray system, when installing, cleaning
or changing spray tips, and wheneveryou stop spraying. (1) Engage
tha gun safety latch.(2) Turn the ON/OFF switch to OFF. 13) Unplug the power supply cord.
(4) Disengagethe gun safety latch.
(51 Hold a metal pan of the gun firmly to the side of a grounded metal
pail, and triggerthe gun to relieva pressure.(81Engage the
gun safety latch.(7) Open the pressure relief valva, having a container ready
to catch the drainage. 18) Leave the pressure relief
valve open until you are ready to spray again.
If you suspect that the spray tip or hose is completely clogged, or thatpressure hasnot been fully relieved after
following the
stepsabove, VERY SLOWLY loosenthe tip guard retainingnut or hoseend coupling and relieve pressure gradually. then loosen
completely. Now clear the tip or hose.
ENGAGE
SAFETY
TURN
SWITCH
urcn
TO OFF
ANDTRIGGER
GUN:
CORD
UNPLUG
DISENGAGE
SAFETY
ENGAGE SAFETYAGAIN
2
307-785
OPEN PRESSURE
RELIEF VALVE
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EQUIPMENT MISUSE HAZARD
FIRE OR EXPLOSION 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 resultin fluidinjection, splashingin
the eyes or on the skin, or other serious bodily injury, fire, explosion or property damage.
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 unplugginga power supply cord.
Sparks canignite fumes
from solvents and the fluid being sprayed, dust particles and
otherflammablesubstances,whetheryouarespraying
indoorsoroutdoors,andcancause
a fire or explosionand
serious bodily injury and property damage. Always plug the
sprayer into an outlet at least 20 feet (6 m) away from the
sprayerand the sprayarea. Do not plug in or unplug any
power supply cords
in the spray areawhen thereis any chance
of igniting fumes still in the air.
NEVER alter or modify any part of this equipment: doing so
could cause it to malfunction.
CHECK all spray equipment regularly and repair
worn or damaged parts immediately.
or replace
Always wear protective eyewear,glovesand
clothing as
recommended by the fluid and solvent manufacturer.
System Pressure
Thisspraercandevelop
3Mo psi 1207 bar1 MAXIMUM
WORKIN(r PRESSURE. Be sure that all spray equipment and
accessoriesare rated to withstand the maximum working
pressure of this sprayer. DO NOT exceedthe maximum working pressureofany
componentor accessoryused in the
system.
Fluid and Solvent Compatibility
AIwa-read
the fluid andsolventmanufacturer'sliterature
beforb using them in this sprayer.
HOSE SAFETY
High pressure fluid in the hoses canbe very dangerous. If the
hose develops a leak. split or rupture due to any kind of wear,
damage or misuse,the high pressure sprayemitted from it can
cause a fluid injection injuryor other serious bodily injury or
propem damage.
ALL FLUID HOSES MUST HAVE SPRING GUARDS ON
BOTH ENDS1 The spring guards help protect the hose from
kinks or bendsa t or close to the coupling which can result in
hose rupture.
If you experience any static sparking or even a slight shock
whileusingthisequipment,STOP
SPRAYING IMMEDIATELY. Check the entire systemfor proper grounding.Do not
use the system againuntil the problem has beenidentified and
corrected.
Grounding
To reduce the risk of static sparking. around the sprayer and
all other spray equipment used or iocited in the spray area.
CHECKyour local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to
ground all of this spray equlpment:
1.
Sprayer: plug the power supply cord, or extension cord,
each equippedwith 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.
2.
Fluidhoses: use only grounded hoses with a maximum of
500 feet I150 mJ combined hose length to ensure grounding continuity. Refer to Hose Groundlng Contlnulty.
HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on
hoses to move equipment.Do not use fluids or solventswhich
are not compatible with the inner tube and cover of thehose.
DO NOTexposeGracohose to temperaturesabove l W F
(82'CI or below -4O'F (-40°C).
Hose GroundinContinuity
Proper hosegrouning continuity is essentialto maintaining a
grounded spray system. Checkthe 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
resistancelimits. Use a resistancemeter in the appropriate
range for your hose to check the resistance. If the resistance
exceeds the recommended limits, replace it immediately. An
ungrounded or poorly grounded hose can make your system
hazardous. Also read FIRE OR EXPLOSION HAZARD.
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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 metalpails, which are conductive. Do not
place the pail ona non-conductivesurface, such as paper
or cardboard, which interrupts the grounding continuity.
7.
To maintaingrounding continuity when flushing or relievingprnssure, always hold a metal part of the gun firmly to
the side of a grounded metal pail, then trigger the gun.
TIGHTEN ell fluid connections securely before each
use. High
pressure fluid candislodge 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 ormend it with tape or any other device. A
repaired hose cannot contain the high pressure fluid.
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Flushing Safety
Reduce the riskof injection injury, static sparking,or splashing
by following the specific flushing procedure given onpage 12
of this manual.Followthe Pressure Rellef Procedure on
page 2, and remove the,spray
tip before flushing. Hold a metal
part of the gun firmly to the side of a metal pail and use the
lowest possible fluid pressure during flushing.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers oroth.er
body Pam. KEEP CLEAR of moving parts when Starting or
operating the sprayer. Unplug the sprayer,and follow the
Pressure Rellef Procedure on page 2, before checking or
servicing any part of the sprayer to prevent it from starting
accidentally.
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 19Z6"should be consulted.
307-785
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!i
La pulvbrisation d haut
graves.
blessures
trds
R6serv6 exclusivernent B I'usage professionnel. Observer toutes les consignes de s6curit6.
Bien lire et bien cornprendre tous les manuels d'instructions avant d'utiliser le rnat6riel.
RISQUES D'INJECTION
Consignes eBnBrales de s6curitB
Cet appireil produit un fluide B trbs haute pression. Le fluide
pulverise parle pistolet oule fluide sous pression provenant de
fuites ou de ruptures
peut penbtrer sousla peau ouB I'intbrieur
du corpset entrainer des blessures trbs graves, voir
meme une
amputation. MBme sans &re sous pression,
ie fluide Bclaboussant ouentrant
dans les yeux peut aussi entrainer des
blessures graves.
NE JAMAIS pointer le pistolet vers quelqu'un ou vers unepartie quelconque du corps. NE JAMAIS menre la main ou Ies
doigts sur I'ajutage du pulvbisateur. NE JAMAIS essayer de
"refouler" le peinture. Cet appareil N'est PASun compresseur
pneumatique.
TOUJOURS garder la protection de I'ajutage en place sur le
pistolet pendant la pulv6risation.
TOUJOURS Observer la March B Sulvre pour DBtendre-la
Presslon donnee plus loin, avant de nettoyer ou d'enlever
I'ajutage du pulvdrisateur. ou d'effectuer un travail queiconque sur une partie de I'appareil.
NE JAMAIS essayer d'arrdter ou de dbvier les fuites avec la
main ou le corps.
Avant chaque utilisation, bien S'assurer que les dispositifs de
securitb fonctionnent correctement.
Soins rnBdlcaux
En cas de ohnetration de fluide sous la neau: n=MaNncn
IMMEDIATEMENT
DES
MEDICAUX
D'URGENCE. NE PAS SOIGNER
CETTE
BLESSURE
COMME UNE SIMPLECOUPURE.
Avls au medecln: La pdndtration des fluides sous la peau
est un traumatisme. II est Important de tralter
chlrurglcalementcette blessure ImmBdiatement.Ne
pas retarder le traitement pour effectuer des recherchessur
la toxicitd. Certains revetements exotiques
sont dangereuse
ment toxiques quand ils sont iniectds directement dens le
sang. llest souhaitable de consulter
un chirurgien esthdtique
ou un chirurgien spdcialise dans
le reconstruction des mains.
SOINS
"l.,...,."..
Dispositifs de sBcuritB du pistolet
Avant chaque utilisation. bien s'assure quetous les dispositifs
des6curitB du pistoletfonctionnentcorrectement.Ne
pas
1
i
enlever ni modifier
une
partie
auelconaue
nistolet:
du ceci
ris.
querait
d'entrainer
un mauvais fonctionnement' et des
blessures araves.
I
Verrou de sdcuritd
A chaque fois queI'on s'arrhte de pulv6riser. meme s'il s'aait
d u n court instant, toujours menre le verrou de s6curit6 au
pistolet sur la position "ferm4e" ou "s6curit4" ("safe") pour
empbcher le pistolet de fonctionner. Si le verrou de s6curit6
n'est pas mis.le pistolet peut se declencher accidentellement.
Voir la Fig. 3.
DHuser
Le diffuseur du pistolet sen B diviser le jet et B rbduire Ies risques d'injectionaccidentellequandI'ajutagen'est
pasen
place. Verifier le fonctionnement du diffuseur rbgulibrement.
Pour cene vbrification, detendre la pression en observant 18
Marche B Sulvre pour D4tendrela Pression donnee plus
loin puis enlever I'ajutage du pulvbrisateur. Pointer le pistolet
dans un seau en metal, en le maintenant fermement contrele
seau. Puis, en utilisant la pression la plus faible possible, appuyer sur la gachene du pistolet. Si ie fluide projete n'estpas
diffuse sousforme de jet irr6gulier, ramplacer immediatement
le diffuseur.
Protection de Yajuta e
TOUJOURS maintenir aprotection de I'ajutage en place sur
le
pistolet du pulvbrisateur pendant la pulv6risation. La protection de I'ajutage attire l'attention sur Ies risques d'injection et
contribue B r4duire, mais n'6vite pas le risque, que Ies doigts
ou une partie quelconque du corps ne passent accidentellement B proximil6 immediate de I'ajutage
. . du Dulv6risateur.
Consignes de sBcurit6 concernant. I'ajutege du
puivBrlsateur
Faire extremement attention A I'occasion du nenoyage ou du
remplacement des ajutages du pulverisateur. Si I'ajutage se
le
bouchependant la pulv6risation.menreimm4diatement
verrou de skurite du PiStolet. TOUJOURS bien observer la
Marche B Suivre pour DBtendre la Pression puis enlever
I'ajutage du pulver'kateur pour le nettoyer.
NE JAMAIS essuyer cequi s'est accumule autour de I'ajutage
du pulverisateur avant que.la pression ne soit completement
engage.
tombbe et que le verrou de sBcurit6du pistolet ne soit
9
Marche B Sulvre pour DBtendre la Pression
Pour r6dui-a Ies risquesdeblessuresgraves,
y compris 18s blessurespar injection de fluide ou'celles caus4espa'rdes
Bclaboussures dans18s yeux ou sur la peau, des pieces en mouvement ou par Blectrocution, toujours bien observer cene marche
B suivre B chaque fois queI'on arrete le pulv6risateur. B l'occasion de la verification ou dela reparation d'une piece de I'appareil
de pulv4risation. B l'occasion de I'installation,du nenoyage ou duremplacement des ajutageset d'une manibregherale B chadu pinolet.2) Menre I'interrupteur Marche-ArrBt sur
ARRET ("OFF"). 3) DBbrancher
que ar&. 11 Engager le verrou de s6curit6
le cordon d'alimentetion. 4) DBsengager le verrou de &curite du pistolet. 5) En maintenant une partie metallique du pistolet
fermement appuyeecontre le cbt6 d'un seau en mhtal, appuyer surla gachette du pistolet pourlibher la pression. 6) Engager le
verrou de s6curitBdu pistolet. 7) Ouvrir la soupape de skurite en prenant soin d'avoir un recipient pr6t B rbcupbrer le liquide.
8) Laisser la soupape ouverte jusqu'h ce que le pulvbrisateur wit de nouveau p d t B &re utilisd.
Sil'on soupconne queI'ejutage du pulv4risateurou le tuvau est complbtementbouche, ou que la pression n'a pas 818 compl&te
ment Iibdde apr.4~
avoirpmced.4 aux op8rations ci-dessus, desserrer TRES LENTEMENT I'4croude retenuede la protection de
I'ajutage ou le raccord du bout du tuyauet libbrer progressivementla pression, puis terminerle desserrage. On peut maifitenant
debaucher I'ajutage ou le tuyau.
i
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4
307-785
2
3
7
RISQUES EN CAS DE MAUVAISE UTlLlSATlON DU MATERIEL
:
.'
Consignes g6n6rales de s6curit6
Toute utilisation anormale deI'appareildepulvBrisationoudes
accessoirescomme,parexemple,
la misesousunepression
excessive, 1 8 8 modifications depibces, I'utilisation de produits
chimiqueset dematibresincompatibles
et I'utilisation deresister
piecesus& ou abimBes peutcauserdesdbgets B I'appareil ou
des ruptures de pieces et entrainer une injection de liquide ou 4lBments
d'autresblessuresserieuses,unincendie,uneexplosion
ou
d'autres dBg8ts.
NE JAMAIS alt4rer ou modifier une piece
de cet appareil: ceci
risquerait d'entrainer son mauvais fonctionnement.
VERIFIERr6guiiBrement tout I'appareilde pulvbrisationet ses
188
Bquipements et reparer ouremplacerimm4diatement
pieces usbs ou abimbs.
Pression
Ce pulv4risateur peut produire un PRESSIONMAXIMUM DE
TRAVAIL 207 bar 13oao Ib/po. 1. S'assurerquetous
18s
4lBments du pulvbrisateur et sea eccessoires sont concus pour
B la pressionmaximumdetravaildecepulv6risateur.
NE PASdbpasser la pression maximum de traveil d'aucun des
ou eccessoires utilis4s avec cet appareil.
Compatlbllite
chimlque des corps
Toujours lire soigneusement les documents et brochures du
fabricant des fluides et solvants utilises avant de s'en servir
dans ce pulv6risateur.
9
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MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXIBLES
Le fluide B haute pression circulant dans Ies tuyaux peut &re
t r h dangereux. Encas de fuite sur le tuyau,defissure,
dkhirure ou rupture A la suite de I'usure, de dBg&ts ou d'une
meuvaise utilisation, Ies projections de fluide haute pression
qui en proviennent peuvent entrainerdes blessures graves par
p4netration sous la peau ou par contact, ainsi que des d b g h
mat4riels.
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TOUS LES TUYAUX FLEXIBLES DOIVENT AVOlR DES
RESSORTS SPIRALE DE PROTECTION AUX 2 BOUTS1
Les spiraled de protection contribuent B Bviter la'formation de
pliures, de boucles ou de nceuds surIes tuyaux qui pourraient
entrainer la rupture du tuyau B I'endroit du raccord ou B son
voisinag4.
SERRER FERMEMENTtous les raccords want chaque utilisation. Le fluide sou8pression peut fairesauter un raccord
desserre ou produire un jet B haute pression s'4chappant par
le
raccord.
NE JAMAIS utiliseruntuyauendommag6.Avantchaque
utilisation, verifier entibrementchaque tuyau pour dBceler 1 8 8
wupures, fuites, abrasions, boursouflures de. I'enveloppe ou
toute autre ddterioration ou jeu des raccords. Si I'on constate
rune deces d6t6riorations. il feut remplacer le tuyau imm4diatement. NE PAS essayer derefaire le raccord d'un tuyau
haute pressionni de r4parer le tuyau avec du rubanadhhif ou
par tout autre moyen. Untuyau rBparB ne peut pas resister nu
fluide sous Dression.
MANIPULER
LES
TUYAUX AVEC
PRECAUTION
ET
CHOlSlR SOIGNEUSEMENT LEUR CHEMIN. Ne pes dBplacer
18 fluide en tirant sur le tuyau. Ne pas utiliser de fluidesou de
solvants qui ne sont pascompatiblesevec
I'enveloppe intBrieure ou exterieure du tuyau. NE PAS exposer le tuyau A
des temperatures suphrieures B 82°C (180°F) ou inferieures B
-40°C (-40" -1.
Continuit6 de la mise A le terre des t u y a u x
Une bonne continuit4 de la mise B la terredes tuyaux est
essentielle pour maintenir la mise A la terre de I'ensemble de
vaporisation. VBrifiez la r4sistance Blectrique de vos tuyaux B
fluides et B air, au moins une fois par semaine. Sivotre tuyau
ne comporte pas d'etiquette qui precise la resistance 4lenrique maximum, prenez contact avec le fournisseur de tuyaux
ou la fabricant pour avoir 18s limites de resistance maximum.
Utilisez un mbtre de r4sistence de la gamme appropride pour
Ies
votre tuyau et vbrifiez la r4sistence.SiceIIe-cidepasse
le tuvauimm4diatement.
limitesrecommand6es.rernDIacez
Un tuyau sans miseB la terriou avec unamise B la~terreincorrene peut entraner des risques pour votre systbme. Lisez aussi
LES RISQUES D'INCENDIE OU D'EXPLOSION ci-dessus.
RISQUES D'INCENDIE OU D'EXPLOSION
~~
De I'BlectricitB statiqueest produite par le passage du fluide B
grande vitesse dansle pompe et dansIes tuyaux. Si toutes Ies
pieces de I'appareil de pulv4risation ne sont pas convenablement relibs B la masse ou A la terre. des Btincelles peuvent se
produire et I'appareil risque #&re dangereux. Des Btincelles
peuvent Bgalement sa produire B I'occasion du branchement
ou du dhbranchement du cordond'alimentation. Les etincelles
sont sllffisantes
pour allumer Ies vapeurs de solvants' et le
fluide pulvBris6, Ies fines.particules depoussibreainsique
d'autres substances inflammables, quand on pulvbrise B I'intBrieur ou B I'extBrieur, et 8118s peuvent causer un incendie ou
une explosion. ainsi que des blessures graves et desdBgAts
se
materiels..Toujours brancherle pulv6risateur dans une prise
trouvant B au moins 6 m ( 2 0 pieds) de I'appareilet de I'endroit
oh se faa la pulv6risation. Ne pas brancher ou debrancher un
cordon d'alimentation que1 qu'il soit dans la zone OCI se fait la
pulv4risation quand il y a le moindre risque que des vapeurs
encore prkentes dans I'air prennent feu.
S'il sa produit des Btincelles d'6lectricitB statique, ou si vous
rBS8BnteZ 18 moindre dbcharge, ARRETE2 IMMEDIATEMENT
LA PULVERISATION. VBrifiez que le svstbme entier est bien
mis b la terre. Ne vous sewez pas dusystbme avant quele probleme soit identifie et corrig6.
Mise A l a t e r r e ou B la masse
Pour rBduireIes risques de produnion d'etincelles d'Blenricit6
statique, le puldrisateur et tous Ies 6quipements utilises ouse
trouvant dans la zone de pulverisation doivent &re relies B la
terre ouB la masse. Pour connaitrele detail des instructionsde
mise 4 la terre dans le region et le type particulier d'4quipe
ment, CONSULTER le code ou Ies rbglementations Blectriques
locslss. S'ASSURER que tous Ies Bquipements de pulvbrisation suivants sont bien relies A la terre:
1. h M s a t e u r : Brancher 18 cordon d'alimentationou
la
rallonge qui doivent &re Bquip4n d'uneprise B 3 fiches en bon
Btat, dans une prlse de courantconvenablementmise B la
terre. Ne pas utiliser d'edaptateur. Toutes
e
la rallonges doivent
avoir 3 fils et h e p r h e s pour 15 amperes.
2. Tuyaux flexibles: Afin d'assurer la continuit6 de la miseB la
terre, n'utiliser que destuyaux comportant une miseB la terre
et ayant
une
longueur
maximum
combinb de 150 m
11500 pieds). Se reporterBgalementauparagrephe
"Continuit6 du clrcult de mise A la terre des tuyeux".
3. Pistolet: RBeliser la mise B la terre en le raccordant B un
tuyau flexible et B un pulvhrisateurd4jB convenablement relies
B la terre.
4. fldcipient d'alimentation: observer le code ou Ies rbglementations locales.
5. Objets, mat6rid ou surfacesrecevent lapuldrisation:
observer 18 code ou Ies rBglementations locales.
6. Tousles seaux de solvents utilises pour
le rincage: observer
18 code ou 18s rBglementations locales. N'utiliser que des seeux
dtelliques conduneurs de I'blenricite. Ne pas menre 18 seau
sur une surface non conductrice mmme sur du papier ou du
carton car cela interrompreit la continuit4 le la mise B la terre.
7. bur conserver la continuit6da le mise B la terre quand on
rince la metdriel ou quend on lib& la
pression, toujoura
maintenir une partie metallique du pistolet fermement
appuyb
contre le cdtB d'un seau en m6tal puis appuyer sur la detente
du pistolet.
Mesures de SBcurlt6 concernant le Rincage
PourrBduire 1 8 8 risquesdeblessuresparpBn4trationde
la
peau et Ies risques dOs eux Btincelles d'blectricIt6 statique ou
nux Bclaboussures, observerla marche B suivre pour18 rincage
donnee B le page 12 de ce manuel. Obsetver la
"Marche a
Sulvre pour DBtendre le Presslon" donnb B la page 4 en
enlaver l'ajutage du pulwlriseteur avant le rincaga. Maintenir
une partie metellique du pistolet fermement
appuyb wntrele
cOt6d'unseau an mdtel et utiliser la pression la plus faible
possible pendant le rincage.
3O7-m
6
.:... . .:
. .,. ..
. .
AQVEWTEAIC
EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIOMES.
SOLO PARA US0 PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.
Lea y entienda todo el manual de instrucciones antes de rnanejer el equipo.
PELIGRO DE INYECCION DE FLUID0
Seguridad general
Aparatos d e seguridad de la pistola pulverizadora
Blotactor de la boquilla
SIEMPREtener el protector de la boauillacolocado en la
pistola mientras se estb pulverizando. Este protector llama la
atenci6n contra el peligro de inyecci6n y ayuda a a reducir,
per0 no avita, la colocacibn accidental de 10s dedos o cualquier otra perte,deI cuarpo cerce de le boquilla.
Avlso al medlco: Sise Ilega a inyectar
este fluido en
la piel
secausa unalesidntraumdtica.
Es lmportente tratar
qulr#jrglcamente le lesl6n e labrevedad posible. No
demorar el trafamianto pera investigar la toxicidad.La toxicidad es algo desoma importanciaenalgunaspinfuras
exdticas
cuendo
se
inyectan
directamente
a/ torrente
sangulneo. Sire convenient0 consultar a un especielista en
cirugla pldsticao raconstructiva da lasmanos.
~
~~~
~
~
Segurldad de la boquilla pulverizadora
~
~~
~
~
~
~
6
307-785
3
.. .
.
~~~
Para reducir e1 riesgo de sufrirgraves lsiiones corporales, incluyendo inyeccibno lasiones causadaspor piezas en movimiento o
choque elbctrico, siempre seguir esta procedimiento
a1 apagar la mdquina pulverizadora,al revisar o dar servicio a cualquier parte
del sistema de pulverizaci6n. al instalar; limpiaro cambiar Ias boquillas. y cade vez que sa deja de pulverizar. (1) Enganchar e1
pestillo de la pistola. 12) Mover e1 interruptor eldctrico’ ION/OFFJa 18 posici6n OFF lapagadol. (31 Desenchufar e1 cordbn
elbctrico. (4) Desenganchar e1 pestillo de la pistola. (5) Sujetar una parte met6lica de la pistola bien firme contra un balde de
metal, y disparar la pistola para descargar
la presibn. 161 Enganchar el pestillo de la pistola. (7) Abrir la vdlvula de pr4sion
y tener
se est4 nuevamentelisto para
listo un reclipiente para recibirla pintura. (8) Dejar la vhlvula dealivio de pr4sion abiena hasfa que
pulverirar.
Sise sospecha que
le boquilla o la manguera estd completamenta obstruide,
o que no se ha descargado por completo la presidn
de la bodespuds de haber seguidoelprocedimiento anterior, aflojar MUY LENTAMENTE la tuerca de retenci6n del protector
quilla o acoplamiento de la punta de la manguera y descargar gradualmente la presibn, despu6s. aflojarlo por completo. Luego,
despejar la boquilla o la manguera.
2
.
Tener mucho cuidado al limpiar o cambiarlas boquillas. Si
Ilagara a obstruirse mientras est6 pulveiizando, anganchar el
pestillo dela pistola de inmediato. SIEMPRE seguir el procedimiento dedescarga de presldny despu4s sacar la boquilla para limpiarla.
NUNCA limpiarla acumulaci6n de pintura alredador de laboquillaantes de que se hayadescargado por completo la
presi6n y el pestillo est4 enganchado.
Procedimiento de dascarga de prealdn
1
. .,
y reduce
El difusor de la pistola dispersa el chorro pulverizado
el riesgo de inyeccibn cuando no esth instalada la boquilla.
Revisar con regularidad el funcionamiento del difusor. Seguir
el procedlmlento dedescarga de presi6n.dado mds abajo,
y despu4ssacar la boquilla.Apuntar la pistolaa un balde
metalico,sostenibndolabienfirmecontra
41. Utilizando la
Si el fluido
presi6n mds bajoposible,dispararlapistola.
emitido no sele disperso enun chorro irregular, reemplazar de
inmediato e1 difusor.
Si pareciera qua un poco de fluido penetrb ia piel, conseguir
TRATAMIENTO
MEDICO
DE
URGENCIA
DE
INMEDIATO. NO TRATAR LA HERIDA COMOUN SIMPLE
CORTE. Decir al medico exactamente cua fluido fue.
~~
....
..
Difusor
Tratamlento medico
~~~~~
,
Asegurarque todos 10s aparatosprotectores dela pistola
est6n funcionandobienantesde
cadauso.Nosacar
ni
modificar ninguna piazade la pistola pues podrle causar e1
malfuncionamiento de la misma conIas consiguientes lesiones
personales.
Pestilllo de seguridad
Cada vez que se deje de pulverizar, aunque sea por un breve
momento.siemprecolocar
el pestillo deseguridad en la
posicidn “cerrada”, lo que dejala pistolainoperante. El no
hacerlo puede llevar al disparo imprevisto de la pistola.
Este equipo genera un fluido aunapresi6n
muy aka. El
rociado de la pistola, 10s escapes de fluido o roturas de 10s
componentes pueden inyectar fluido en la piel y el cuerpo y
causar lesionesextremadamentegraves, incluyendo aveces la
necesidaddeamputacibn.
TambiBn, e1 fluido inyectado o
salpicado en 10s 4 0 s puede causar graves dahs.
NUNCA apuntar la pistola hacia alguien o alguna parte del
cuerpo. NUNCA colocarla manoo 10s dedos encima dela boquilla. NUNCA tratar de “hacer retornar la pintura“; este NO
es un sistema de rociado de aire.
SIEMPREtener colocado e1 protector dela boquilla en la
pistola mientrasse est6 pulverizando.
SIEMPRE seguir el procedimiento dedescarga de presl6n.
dado mds abjo, antes de limpiar o sacar la boquilla o de dar
servicio a cualiquier equipo del sistema.
NUNCA tratarde parar o desviar 10s escapes con la mano o el
cuerpo.
Asegurarque todos 10s aparatos de seguridaddelequipo
esthn funcionando bien antes de cada uso.
7
. ..
PELIGRO POR MAL US0 DEL EQUIP0
PELIGRO DE INCENDIO 0 EXPLOSION
Seguridad general
o 10s accesorios, tal
Cualquier mal us0 del equipo pulverizador
comosobrepresurizaci6n.modificaci6ndepieras,us0de
materiales y productos qulmicos incompatibles, o utilizaci6n
se rompan
de piezas dafladaso desgastadas, puede hacen que
y causen la inyeccidn de fluido uotraslesionescorporales
graves, incendio, explosi6n o daflon a la propiedad.
NUNCA alterar o modificar ninguna pieza de este equipo; e1
hacerlo podrla causar una averla.
REVISAR con regularidad el equipo pulverizador y reparar o
reemplazar de inmediato Ias piezas dafiadas o desgastadas.
El flujo a aka velocidad del
fluido alpasar por la bomba y
manguera crea electricidad estbtica. Si todas las partes del
equipopulverizador no tienenbuenatierra,puedenocurrir
chispas, convirtiendo al sistema en algo peligroso. TambiBn,
pueden producirse chispas a1 enchufar o desenchufar el cord6n elbctrico. Estas chispas pueden inflamar 10s vapores de
1 0 8 solventes v el chorro de fluido pulverizado. panlculas de
polvo y otras sustanciai inflamables, sea al sire libre o bajo
techo, Io que podrlacausar una explosi6n o incendio y graves
lesiones corporales y daflos a la propiedad. Enchufar siempre
la pulverizadora aun tomacorriente quese encuentre a porlo
la mdquina y del Brea que se vaa
nenos 6 m (20pies)
rociar. No enchufar o dqsenchufar ning6n cord6n elBctrico en
el lugardonde se est& rociandocuandotodavlaexistala
posibilidad de que queden vapores inflamables ene1 sire.
estSltica o incluso un ligem
Si ocurre una chispa de electricidad
so usa el equipo,DEJARDE
choqueelbctricomientras
PULVERIZARDEINMEDIATO.Revisar
todo e1 sistemaen
busca de una tierra apropiada. No usar de nuevo el sistema
hasta haber identificado y solucionado e1 problema.
Puesta a t l e r r a
Para reducir el riesgo de chispas estaticas, conectar a tierra la
pulverizadora v todo e1 otro equipo de pulverizar quese usa o
se encuentre en e1 lugar que se va a rociar. CONSULTAR el
c6digo elbctricode lalocalidad para Iasinstrucciones sobreIas
conexiones a tierra exigidas para la zona
y tip0 de equipo.
ASEGURAR
de
conectar
tierra
a
todo este equipo
pulverizador:
1. Polverizedora: enchufar e1 cord6n elbctrico, o cable extensor, cada uno con un enchuf de tres patas en buen estado. a
un tomacorriente con puesta a tierra apropiado. No usar un
adaptador. Totos 10s cables extensores tienen que tener tres
hilos y una capacidad de 15 amperios.
2. Mangueras para fluidos:usarsolamentemangueras
con
puesta
tierra
a de
una
longitud combinada
de
150 m
1 3 3 0 pies), para asegurar buenacontinuidad a tierra. Referirse
tambien al pdrrafo
sobre
continuidad a tlerrade
la
manguera.
3. pistola:hacerlapuesta
a tierraconectandoiaauna
rnanguera de fluido y pulverizadora bien conectadas a tierra.
4. Suministrar on recipiente:deacuerdoalc6digodela
localidad.
5. Obieto que seest.4 rociando: de conformidad conel c6digo
local.
6. Todos 10s baldes de solvente usados durante e1 lavado. de
conformidad con el c6digo local. Usar solamente baldes de
metal, que Sean conductivos.Nocolocar
el balde enuna
superficienoconductiva,comopapel
o cart6n.que interrumpe la continuidad a tierra.
7. Para mantener le continuidad e tierre durante el levado o
descerga de presih, siempre apoyar una parte metalica de la
e1 costadodelbaldede
metal,
pistolabienfirmecontra
despuk apretar ei gatillo.
Seguridad d u r a n t e el lavado
Para reducir el riesgo de que se inyecte o salpique fluido en la
piel, o que ocurra una descarga de electricidad estAtica, siempreseguirias INSTRUCCIONES PARA EL LAVADO.dadasen
18 pdgina 12. Seguir el procedimientode
descarga de
presi6n en la pdgna 6, v quitar la boquille rociedora antesde
lever. Apoyar unapane methlica de la pistola bien firme contra
el costado de un belde de mere1 y usar le presi6n mhs baja
posible de fiuido durante el lavado.
Presibn del sistema
Esta pulveriradora puede desarrollar 207 barlas 13ooo psi) de
PRESION DE TRABAJO MAXIMA. Aseaurar oue todo el
equipo pulveriradory sus accssoriostienen la capacidad para
aguentar la presi6n maxima de trabajo de esta pulverizadora.
NOexcederlapresi6nmaximade
trabajodeningBncomponente o accesorio de este sistema.
Compatibilidad de fluido
Siempreleerlasinstruccionesdelfabricantedelfluido
solvente antes de usarlos en esta pulverizadora.
y
SEGURIDAD EN EL U S 0 DE LAS MANGUERAS
El fluido.que escapa a aka presidn por las mangueras puede
ser muy peligroso. Si en la manguerase desarrolla un escape,
una rotura o rajadura debido a cualquier tip0 dedesgaste,
daflo o maltrato, el chorro a aka presi6n emitido
por all1 puede
causarunalesidn por inyecci6n u otras lesiones corporales
graves o daflos a la propiedad.
ITODAS LASMANGUERASPARA FLUIDOS TIENEN
QUETENER GUARDAS DE RESORTE EN AMBOS EXTREMOSi Estas protegen Ias mangueras contra dobleces o
retorceduras en ios acoplamientos o cerca de ellos, 10s que
podrlan traducirse en roturas de la manguera.
Antes de usarlas, APRETAR bien firmes todaslas conexiones.
El fluido a aka presi6n puede desaiojar
un acoplamiento suelto
o dejar que por 81 escape un chorro a aha presi6n.
NUNCAusarunamangueraqueest6daflada.Siempre,
revisarla en busca de cortaduras. escapes, abrasi6n, cubierta
abultada, o acoplamientos sueltoso daflados. Si llegara a encontrarse cualquiera de estas condiciones, reemplazar de inmediato la manguera. NO intentar reacoplar una manguera de
alta presi6n o enmendarla con cinta adhesiva u otro material
similar. Una manguera que ha sido remendada no aguante e1
fluido a aka presi6n.
CUIDADOSAMENTE
LAS
MANEJAR Y PASAR
MANGUERAS.Notirarde
Iasmanguerasparamoverei
equipo. No usar fluidos o solventes que Sean incompatibles
con e1 tub0 interno y la cubierta dela manguera. NO exponer
lasmanguerasatemperaturassobre
82OC (180°F) o bajo
-4OT I-4O"F).
Continuidad del circuito de puesta a tierra de la
rnanguera
La continuidad del circuito de p u m a 8 tierra apropiado es
esencial
para
mantener
conectado
tierra
a
el sistema
pulverizador. Es indispensablerevisarlaresistenciaelbctrica
maxima deIas manguerasde sirey de fluido por lo menos una
vez a la semana. Si la manguera no tiene una etiqueta en la
cual se especifica la resistencia elbctrica maxima, ponerse en
contact0 con el proveedor o fabricante de la manguera para la
informacidn sobre 10s llmites de resistencia. Usar un metro de
resistencia en la gama apropiada para comprobar la resistencia; si excede 10s llmites recomendados, reemplazarla de inmediato. Es muy arriesgado tener una manguera sin puesta a
tierra o con la puesta a tierra enmalas condiciones. Leer tambibn la informaci6n sobre RIESGODE INCENDIO 0 EXPLOSION, mhs arriba.
PELIGRO DE LAS PIEZAS MOVILLES
Las piezas en movimiento pueden pincharo amputar dedos u
otraspartesdelcuerpo.MANTENERSEALEJADOde
188
piezas en movimiento durante e1 crrranque o funcionamiento
de la pulverizadora. Desenchufar Is pulverizadora y descargar
la presi6n antes de revisaro dar servicio, e cualquier parte de
pulverizadora, para impedir que arranque inesperadamente.
IMPORTANT
Se han adoptadolas normas de seguridad del gobierno de10s
Estados Unidos de Norteambrica bajoel Acta de Seguridady
SaludOcupacional. Deberh consultarse estas normas, an
especial Ias Generales, Pane 1910, y Ias Normas de Construcci6n. Parte 1926.
307-785
7
INTRODUCTION
ULTRA@loo0 BASIC COMPONENTS
Model 231-043 shown
PRESSURE CONTROL KNOB
\
ELECTRIC MOTOR
FLUID FILTER
;-
DRIVE ASSEMBLY
CIRCUIT BREAKER
RESET BUHON
ONlOFFSWlTCH
PAIL HANGER
,
.
DISPLACEMENTPUMP
PRESSURE RELIEFVALVE
~
MAIN FLUID1 HOSE-
TIPGUARD
q
Your new Ultra" loo0 Sprayer functions and operates
differently than other airless paint sprayers. This section
will help you become familiar with the sprayer before
operating it.
Pressure Control
The pressurecontrol includes an ON/OFF
switch for the
sprayer, the pressure adjusting controlknob, a pressure
sensing device, and a current overload circuit breaker
with a manual resetbutton. Its function is to control the
motor speed so that the sprayer maintains constant
fluid pressure et the pump outlet.
Motor
The DC motor hassealedbearingsandreplaceable
motor brushes. Its function is to drive the displacement
pump at therate needed to supply sufficient paint
volume at the selected pressure.
Workingtogether,thepressure
control and motor
cause thepump to cyclewheneverthereis
fluid or
pressure demand. Whenthe pumpis cycling, the motor
sounds like an automobile starter cranking. When the
pump is not cycling, the motor hums, hums intermittently, or eppeersto have shut itself off, However, there
will still be power to the sprayerand it will stay
pressurized and readyto use unless you manuallyshut it
off end relieve pressure.
..
..>:...:,. :,,
_.. ,. ..: .
Displacement Pump
The positive displacement, volume-balancedpump providesequal fluid deliveryon both the up end down
pump strokes. The pump has a wet-cup which, when
filled with Graco Throat Seal Liquid,helpsprevent
damage to the throat packings and piston rod.
fluid Filter
The fluid filter provides the final paint straining to help
avoid clogsin the hose and spraytip. The filter includes
a reusable element anda pressure relief valvefor relieving fluid pressure when shutting off the sprayer.
..,
. ..
Hoses
The grounded, nylon spray hoses havespring guards on
both ends. The 50 foot (15.2 m) hose hasa 114 in. ID.
The 3 foot (0.9 ml, 3/16 in. ID whip hose allows flexible gun movement. The nylon hose material acts as a
pulsation dampener to absorb pressure fluctuations.
Spray Gun RAC IV DripLessm Tip Guard
Graco high pressure spray guns have a trigger safety
which prevents accidental triggering when
it is engaged
(see Fig 1). The Reverse-A-Clean IV SwitchTip" uses
high pressure fluid to remove clogs from the spray tip
without removing it from the gun. It includes a safety tip
guard which helps reduce the risk of fluid injection in-
iv.
,-,",
.i
\
Because the motor is DC, it is less sensitive to low
voltage or voltage fluctuations than AC
an motor. and a
heaG gauge extension cord of up to 150 feet (45 mi
can be used.
Drive Assembly
The sealed drive assembly transfers powerfrom the DC
motor to the displacement pump.
8
307-785
I
SETUP
1. Connect Hose and Gun IRefer to Fig 2.)
a.Remove
theplasticcapplug
from the filter
outlet nipple and screw the50 ft (15.2 m) main
fluid hose onto the nipple.
b. Connect the whip hose between the fluid hose
and the gun inlet connection.
c.
Don't use threadsealant,anddon't
spray tip yet1
.
install the
.
WARNING
If you ere supplying your own hoses end spray
gun,besure they are electrically grounded and
ratedfor at least 3ow psi (210 bar) Working
Pressure, and that the gun~hasa tip guard. This is
to reduce the risk of serious bodily injury caused
by staticsparkingand
fluid injection or overpressurizing and rupturing the equipment.
60 FT MAIN HOSE
. .. .
,.,...
... ,..
2. Two Gun Hookup. (Refer to Fig 2.) Remove the
DEVICE HERE
cap from the 1/2 npsm(f) nipple and attach an accessory hose and gun.
CAUTION
the pressurecontrol, which
mayresult in poor equipment performance and
component damage, follow these precautions:
Always use nylon spray hose a t least 50 ft
(15.2 m) long.
2. Never use a wire braidhose as it is too rigid
to act as a pulsation dampener.
3. Never install any shutoff device between
the filter and the main hose. See Fig 3.
4. Always use the main filter outlet for onegun operation. Never plug this outlet.
1.
...,..:,...>
SECONDARY HOSE
ne 3
3. Fill Packing Nut/Wet-CUD (SeeFia 3.1
Fillthe pacTting nut/wet-cup 1/3 f h with Graco
Throat Seal Liquid (TSL), supplied.
4. CheckElectrical 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. Usean extension cord which has 3 wires of a
minimum 12 gaugesize,and
a maximum of
150 ft (45 m) long. Longer lengths may affect
sprayer performance.
5. Plug in the Sprayer
a.
Be suretheON/OFF
Fig 4.
switch is OFF,Refer to
b. Plugthepowersupplycord
into a grounded
electrical outletthat is a t least 20 ft (6 m) away
from the spray area to reduce the chance of a
spark igniting the spray vapors.
c.
Do not removethe third prong of the power
supplycord
plug. which is thegrounding
prong, and do not use an adapter.
8. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after factory testing.
a. Before
using
water-base
paint,
flush with
mineral spirits followed by soapywater,and
then a clean water flush.
b. Beforeusingoil-basepaint,
spirits only.
flush with mineral
c. See FLUSHING GUIDELINES on page 12fw
flushing procedure.
7. Prepare the palntaccordingto the manufacturer's
recommendations.
a. Remove any skin that may have formed.
b. Stir the paint
to dissolve pigments.
c. Strain the paint through a fine nylon mash bag
(available at most paintdealers) to remove perticles that could clog the filter or spray tip.This
is probablythemostimportantstep
toward
trouble-fre8 spray painting.
307-785
9
OPERATION
WARNING
Pressure Relief Procedure
Toreduce the risk of serious bodilyinjury, including fluid injection or splashing in the eyes or
on theskin, or injury from moving partsor electric
shock,always follow this procedurewfienever
you shutoff the sprayer, when checking or sewicing any part of the spray system, when installing,
cleaningorchangingspraytips,andwhenever
you stop spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
4. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to the
side of a metal pail, and trigger thegun to
relieve pressure.
6. Engage the gun safety latch.
7. Open the pressurereliefvalve,
having a
containerready to catchthe drainage.
-.
0. Leave the pressurereliefvalveopen
until
you are ready to operate the sprayer again.
If you suspect that the spray tip or hose is completely clogged, or thatpressure has notbeen fully
relieved after following thestepsabove,VERY
SLOWLYloosen the tip guardretaining nut or
hose end coupling andrelieve pressure gradually.
Then loosenthe nut completely. Now clear thetip
or hose obstruction.
Prime the Sprayer with Paint.
a. Close the filter's pressurereliefvalve.
If a
is not installed, be
secondaryhoseandgun
sure the cap is securely plugging the nipple.
See Fig 2.
b. Don't install the spray
tip yet1
c. Put the suction tube into the paint container.
d. Turnthe pressureadjustingknob all theway
counterclockwiseto lower the pressure setting.
e.Disengage
f.
thegunsafetylatch.
Hold a metal part of the gun firmly against and
aimed into a metal waste container.See Fig 5.
Squeeze the trigger and hold it open, turn the
ON/OFF switch to ON, and slowly increase the
pressure setting until thesprayerstarts.This
procedurereducesthe
risk of staticelectric
dischargeandsplashing.Keep
thegun triggered until all air is forced out of the system and
the paint flows freely from the gun. Release the
trigger and engage the safety.
I
... .,...
MAINTAIN FIRM
CONTACT
METALTOMETAL
B E l W
GUN AND CONTAINER
E
E
N
t
L
u
-
Fig 5.
.... . .
..... .....,.
.;
NOTE: If the pump is hard to prime, place a container under the pressure relief valve and
open it. When fluid comes from the valve,
close it. Then disengage the gun safety
latch and proceed as in Step If, above.
g. Check all fluid connections for leaks: If any are
found, follow the Pressure Relief Procedure
Warning, above, then tighten connections.
2. Install the Spray Tip and Tip Guard
a. Be sure
the gun safety latch is engaged.
b. Installthe spray tip. If usingthe Reverse-AClean IV, refer to manual 307-848,supplied
with the gun, for installation instructions.
I.:
307-785
''
3. Adjusting the Spray Pattern
a.
Increase the pressure adjusting knob setting
just until spray from thegun is completely
atomized. To avoidexcessiveoversprayand
fogging, and to decrease tip wear and extend
the life of the sprayer, always use the lowest
possiblepressureneeded to get the desired
results.
b. If morecoverageisneeded,use
a larger Ap
rather than increasing the pressure.
c. Test the spray pattern. To adjust the direction
of thespraypattern,engagethegunsafety
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.
I
1 :i.... ..
''
!
!
I '
. .
i
10
. .
! ,.....,.... .:;
.
.
CAUTION
4. Operating l l p s . These suggestions will help pre-
Never leave water or any
paint in the sprayer overnight to: (11 prevent pump corrosion; (2) to prevent the paint or watar from freezing in the pump
andpressure control which cancause loss of
pressure, stalling orserioussprayerdamage.
Always use mineralspirits for the final flush.
Relieve pressure. This leaves a protective coating
of mineral spirits in the sprayer.
vent the motor from running too hot or operating
intermittently.
a. Decrease the pressure when using a small tip.
b. Keep the sprayer in a shaded area when spraying outdoors.
c. Turn off the sprayer
and
relieve
pressure
whenever you stop spraying.
L
4.
For very short shutoffperiods, leave the suction
tube in the paint, follow the Pressure Relief Procedure Warning on page 10, and clean the spray
tip.
5. Cleenlng e Clogged Tip
---"------.IAIARNING
To reduce the risk of serious bodily injury from
fluid injection or splashing in the eyes or on the
skin, uae extremecautionwhencleaningor
changing spray tips. If the spray tip clogs whila
spraying, engage the gun safety latch immediately, then follow theprocedure in Steps %-%,
below.
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.
NEVER wipe off build up around the spray
tip until
pressure isfully relieved and the gun safety Mtch is
engaged.
a. Clean the front of the tip frequently during the
day'soperation.First,
follow the Pressure
Relief Procedure Warning on page 10. Then
use a solvent-soaked brushto keep paint from
building up and clogging the tip.
b. If the spray tip does clog, release the gun trigger, engage the gun safety
latch, and rotate the
RAC IV handle 180°. See Fig 6.
c. Disengage the gun safety
latch and trigger the
gun into a wastecontainer.Engage
thegun
safety latch again.
Fig 6
d. Returnthehandle
to theoriginalposition,
disengage thegunsafetylatch,
and resume
spraying.
e.
If the tip is still clogged, engage the gun safety
latch,shut off and unplugthe sprayer,and
open
the
pressure
relief
valve
to relieve
pressure.Clean
the spray tip as shown in
manual 307-848 supplied with the RAC IV.
SHUTDOWN AND CARE
1. Checkthepackingnutlwet-cupdaily.
First
follow the Pressure Relief Procedure Warnlng
on page 10. Be sure the wet-cup is 1/3 full of TSL
at all times to help prevent paint buildup on the
piston rod andprematurewear of packings.The
packing nut should be tight enough to stop
leakage, but no tighter. Overtightening may cause
binding and excessive packing wear. Use a screwdriverand light hammer to adjust the nut. See
Fig 7.
2. Clean the fluid filter often
andwhenever the
sprayer is stored. First follow the Pressure Relief
Procedure Warnlngon page 10. Refer to manual
307-273, supplied, for the cleaning procedure.
3. flush the sprayer et the end of each work day
and fill it with mineral spirits to help preventpump
corrosion and freezing. See "Flushing Guidelines"
on page 12.
-
307-785
11
FLUSHING GUIDELINES
When t o Flush
1 . New Sprayer. Yournew Utrla@' 1000 Sprayerwas
factory tested in lightweight oil which was left in to
protect pump parts.
Before using water-base paint, flush with mineral
spirits, followed by soapy water, and then a clean
water flush.
Before using oil-base paint,flush with mineral
spirits only.
2. Changing Colors. Flush with a compatible solvent
such es mineral spirits or water.
3. Changing from water-base to oil-base paint.
Flush with soapy water, then mineral spirits.
4. Changing from oil-base t o water-basepalnt.
Flush with mineral spirits,followed by soapy water,
then a clean water flush.
5. Storage.
Water-base mint: flush with water. then mineral
spirits andl&ve the pump, hose andgun filled with
mineral spirits. Shut off and unplug the sprayer,
open the pressure relief valve
to relievepressure
and leave open.
Oil-base palnt: flush with mineral spirits. Shut off
and unplug the sprayer,openthepressurerelief
valve to relieve pressure and leave open.
6. Startup after storage.
Betore uslng water-base palnt. flush out mineral
spirits with soapy water andthen a clean water
flush.
When uslng oil-base paint, flush out the mineral
spirits with the paint to be sprayed andthe sprayer
is ready to use.
How t o Flush
1 . Followthe Pressure Relief ProcedureWarnlng
on page 2 or 10.
2. Remove the filter bowl andscreen; see manual
307-273 supplied. Clean the screen separately and
install the bowl without the screen to flush it. See
Fig 8.
"
SCREEN
FILTER
SUPPORT
CLOSE PRESSURE
RELIEF VALVE
Fig 8
Fig 9
3. Close the filter pressure relief valve.
4. Pour one-half gallon (2 liters) of compatible solvent
7. Check all fluid connections for leaks. If anyleak,
first follow the Pressure Relief Procedure Warning on page 2 or 10. Now tighten the connections,
start the sprayer, and recheck the connections for
leaks.
8. Remove the suction tube from the pail. Disengage
the gun safety and trigger thegun to force solvent
from the hose. Do not let the pump run dry tor
more than 30 seconds to evold damaging the
pump packlngslThen turn ONlOFF switch to OFF
and engage the gun safety latch.
5.
into a bare metal pail. Put the suction
pail.
Remove the spray tip from the gun.
tube in the
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 gunfirmly to the
side of and aimedinto a grounded metal pail when
6. Disengage the gun safety latch. Point the spray
gun
into a metal waste container end with a metal part
of thegun firmly touchingthemetalcontainer,
squeeze the gun trigger. See Fig 9. Thls pro
cedure helps reduce the risk of static sparking
and splashing. With the gun triggered, turn the
ON/OFF switch to ON and slowly turn the pressure
adjusting knob clockwise lust until the sprayer
starts. Keep the gun triggered until clean solvent
comes from the nozzle.Release thetrigger and
engage the gun safety latch.
'9. Unplug the power supply cord. Open the pressure
relief valve and leave open
until you are readyto use
thesprayeragain.Unscrewthe
filter bowl and
reinstall the clean screen. Reinstall the bowl, hand
tight only.
10. If you have flushed with mineral spirits andare going to use a water-basepaint, flush with soapy
water followed by a clean water flush. Then repeat
SteD 1.
TROUBLESHOOTING GUIDE
WARNING
Pressure Relief Procedure
To reduce the risko f serious bodily injury, including fluid injection, splashing fluid in eyes
the or onthe 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 the
of spray system, when installing, cleaning or changing spray tips,
and whenever
you stop spraying.
1.
I
Engage the gun safety latch.
Turn the ON/OFF switch t o OFF.
Unplug the power supply cord.
Disengage the gun safety latch.
Hold a metal part of the gun firmly to side
the of a grounded metal pail, and trigger thegun t o relieve pressure.
Engage the gun safety latch.
Open the pressure relief valve, having a container ready to catch the drainage.
Leave the pressure relief valve open until you are ready t o spray again.
2.
3.
4.
5.
6.
7.
8.
If you suspect that the spraytip o r hose is completelyclogged, or that pressure hasnot been fully relieved
after
following the steps .above, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve
oressure araduallv. then.loosen comDletelv. Now clear the tiD or hose.
YPE OF PROBLEM
WHAT TO DO
WHAT TO CHECK
If check Is OK, go t o next check
When checkis not OK refer to thls colurn
AOTOR WON'T OPERATE
lasic Fluid Pressure Problems
1. Check the pressure control knob setting. Thf
motor will not run if it is at the minimum set
1. Slowly increase the pressure setting to
the motor starts.
888
i
ting ifully counterclockwise).
lasic Mechanical Problems
2. Check for a clogged spray tip. Refer to your
2. Relieve pressure, refer to your separate gun
or tip instruction manual for tip cleaning.
1. Check for frozen or hardened paint in the
1. Thaw'. Plug in sprayer and turn on. Slowly
increase pressure setting to see if motor
starts. If it doesn't, replace the displacemen1
pump packings (see manual 307-7931 andlot
replace the bare pressure control box (301)'.
See page 26.
2. Check displacement pump connecting rod
2. Push pin into place and secure with the
pump (391 andlor pressure control bourdon
tube. Using a screwdriver, carefully try to
rotate fan at back of motor by hand. See
page 19
pin (20).It must be completely pushed into
connecting rod (29) and spring retainer (35)
should be firmly in groove of connecting rod,
see
spring retainer.
m.
3. Check for motor damage. Remove drive
housing assembly (18). See page 29. Try to
3. Replace motor (11 if fan won't turn.
rotate fen by hand.
lasic Electrical Problems
..
1. Check sprayer circuit breaker (3091 button to 1 Depress circuit breaker button to reset. If
be sure it has not popped up.
cit
cuit breaker continues to open, sea "Electrical Short", page 18.
2. Check electrical supply with volt meter.
Meter should read 105 to 125 VAC.
2. Reset building circuit breaker; replace
building fuse. Try another electrical outlet.
3. Check extension cord for visible damage.
3. Replace extension cord.
4. Check sprayer power supply cord (3111 for
visible damage such e8 broken insulation or
wires.
4. Replace power supply cord.
5. Check motor brush leads, terminals and
5. lighten terminal screws; replace brushes.
See page 22.
Use a volt meter or test lamp et extension
cord outlet to check.
brush length. Brush length should be 112"
minimum. Sea page
22.
'Thew the sprayer if water or water-based paint has frozen in
due to exposure to low temperatures, by placing it in a
warm area. Do not try to mart the sprayer until it has thawed
completely. If the bourdon tube was not damagedby the
freen
i g.
the pump should operate.If paint hardened (dried)in
the sprayer. the pump packingsand/or bare pressure control
See
page
28 manual
or 307-793.
Troubleshooting
mum be replaced.
.it,
See page 23.
When replacing the barepressure control box (item 301).
remove the circuit breaker, ONIOFF switch, bridge. circuit
board andelectricalhardwareandreinstalltheseparts
in the
bare box.
conrinued on
nexr
pege.
N P E OF PROBLEM
-WHAT TO CHECK
If check la OK, to tonext check
WHAT TO DO
When checkle not OK refer to thls columl
"
1. Check leads from bridge 1308) to motor to bf 1. Replace any loose terminals and crimp to
sure they are securely fastened and properly
leads. Be sure male terminal blades are
mated.
straight and firmly connected to mating part
Diagnosing circuit board indicator lamps. The normal
condition is red lamp on,
clear lamp on when board is
tel/ing pump to run.
Follow Pressure Relief Pro.
cedure Warning. Remove
gun from hose. Remove
pressure control cover and
check for faulty condition of
circuit board lamps.
Condition A both lamps on;
pump won't operate and
motor is not running
2. Check G1 end G2 connections beween cirwit board 123) and bridge 1308) for damage
or loose terminals.
2. Clean circuit board mala terminals. Replace
loose or damaged terminals. Securely recon.
nect leads.
3. Check for loose motor brush lead connections and terminals, See page
3. Tighten terminal screws. Replace brushes if
4. Check brush length which should be 112"
minimum. See page
NOTE also that the brushes do not wear at
the same rate on both sides of the motor.
4. Replace brushes. Sea page 22.
5. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush. See page 22.
5. Replace spring if broken. Realign spring witb
6. Check motor brushes for binding in brush
5. Clean brush holders. Remove carbon with
22.
22.
holders. See page 22.
leads are damaged.
i
See page 22.
brush. See page 22.
. .. .. .
. . .,
.
small cleaning brush. Align brush lead with
slot in brush holder to assure free vertical
brush movement.
7. Check motor armature commutator for burn
spots. gouges and extreme roughness.
Remove motor cover and brush inspection
plates to check. See page 22.
1. Remove motor and have motor shop resur- ,
face commutator if possible. See page 30.
8. Check motor armature for shorts using armature tester Igrowler) or perform spin test.
See page 19.
3. Replace motor. See page 3 0 .
9. Check bridge 1308) by substituting with a
good bridge or performing bridge test. See
page 20.
CAUTION: Do not perform this check until
armature is determinedto be good. A bad
armature will immediately burn out a good
bridge.
3. Replace bridge. See page 24.
iI '.........:. ,. ..
"
Dndition B
Dth lamps Off
1. Check circuit breaker 1309) button to be sure I. Depress circuit breaker button to reset. If cir
it has not popped up.
cuit breaker continues to open, see "Electrical Short", page 18.
2. Check sprayer'power:supply cord 1311).
Disconnect TP6 female and TP1 female and
connect volt metar to these leads. Plug in
sprayer. Meter should read 105 to 125 VAC.
Unplug sprayer. Reconnect TP1.
1. Replace power supply cord. See page
23.
3. Check ON/OFF switch 1303). Disconnect TP2 I. Replace ONlOFF switch. See page 2 3 .
and connect volt meter to TP6 female and
TP2 male. Rug insprayer and turn on. Meter
should read 105 to 125 VAC. Turn off and
unplug sprayer. Reconnect TPZ.
.. .
25.
4. Check jumper wire 1306). Disconnecl TP3
and connect volt meter to TP6 female and
TP3 female. Plug in sprayer and turn on.
Meter should read 105 to 126 VAC. Turn off
and unplug sprayer. Reconnect TP3.
1. Replace jumper wire. See page
5. Check circuit breaker 1309). Connect volt
i. Replace circuit breaker. See page 24.
meter to TP6 female and TP4. Plug in
sprayer and turn on. Meter should read 105
to 125 VAC. Turn off and unplug sprayer.
-
j
Troubleshooting continued on nextpage.
14
307-785
.
I
WHAT TO CHECK
If check is OK, go to next check
6. Check motor thermal cutout switch.
Connect volt meter to TP6 female and TP9
female. Plug in and turn on sprayer. Meter
should read 105 to 125 VAC. Turn off and
unplug sprayer.
WHAT TO DO
When checkIs not OK refer to this column
6. Allow motor to cool. Correct cause of overheating. If switch remains open after motor
cools, check continuity between TPS female
and TPlO with ohmmeter. If open, replace
motor.
7. Check microswitch 1302).Reconnect TP6
connectors. Connect volt meter to TP15
male and TP4. Meter should read 50-125
VAC.
7. Clean microswitch male terminals. Replace
loose or damaged terminals. Securely reconnect lesds.
8. V h a l l y inspect microswitch (3021 button.
Adjustment stud should not depress the
microswitch button when fluid pressure is
zero. Manually check by depressing button
with small screwdriver; an audible click indicates microswitch is in normal position.
B. Microswitch is faulty. Return sprayer for
repair.
9. Check microswitch (302) continuity with ohn
meter. Be sure sprayer is unplugged1 Meter
should read zero ohms with no fluid pressun
in thesprayer.
9. Microswitch is faulty. Return sprayer for
repair.
.. . .
..
, .
... .
.. .
"
10.Check all terminalsfor damage or loose fit.
Reconnect TP6 connectors.
I0.Replace damaged terminals and reconnect
securely.
11.Check circuit board (231 by substituting with
a good board. See page 25.
11.Replace circuit board. See page 2 5 .
1. Check circuit board ( 2 3 1 by removing from
box without disconnecting wires; see page
25 for removal procedure.
I. Replace circuit board. See page
25.
....:....: ..
WARNING: Removing the circuit board
while still wired over-rides the optical detector which could causa the sprayer to overpressurize, if the microswitch does not function properly. Turn the sprayer on ONLY
long enough to check lamp condition, then
shut off immediately.
WARNING: To reduce the risk of electric
shock, handle board by edges onlyl Do not
allow any metal objects to come in contact
with the boardl
Plug in and turn onsprayer. Clear lamp
should be on now - removing the circuit
board over-ridesthe optical detector. Turn
off and unplug sprayer.
2. Check bourdon tube flag and detector position. Reinstall circuit board (seepage 25).
Turn pressure setting to maximum;~flag
should extend less then half way into optical
detector slot from the bottom.
l . Calibrate pressure control to see if that corrects problem. See page 21.
If not, replace bare pressure control box
1301I*. See page 28.
..
VIEW OF OPTICAL DETECTOR AND FLAG
'When replaclng the bare preglura control
b o x (30li. remove the circuit brenker,brldge,
circuit board and elactrlcal h a m r e and reinstall In the new bars box.
Troubiashooting continued on next page.
307-785
16
rYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When checkIs not OK refer to this colurnl
,OW OUTPUT
1. Check for worn spray tip.
1. Follow Pressure Relief Procedure Warning then replace tip. See your separate gun
or tip manual.
2. Check to sae that pump does not continua
2. Service pump. See manual 307-793.
to stroke when gun trigger is released. Plug
in and turn on sprayer. Prime with paint.
Trigger gun momentarily, then releasa and
engage safety latch. Relieve pressure, turn
off and unplug sprayer.
3. Check electricel supply with volt meter.
Mater should read 105 to 125 VAC.
3. Reset buiidina circuit breaker: reoiace
building fuserRepair electricaloutlet or try
another outlet.
4. Check extension cord size and length; must
be a t least 12 auge wire and no longer than
150 n 115.2 my.
4. Replace with a correct, grounded extension
cord.
5. Check G l and G2 leads from bridge 1308) to
circuit board 123) for damage or loose wires
or connectors. Refer to page 2
5.
5. Clean circuit board male terminals. Replace
loose or defective lead terminals. Securely
reconnect lead terminalsto board.
6. Check stall pressure. Refer to Calibration
Procedure on page 27.
6. Calibrate pressure control. See page27.
7.Check bridge 1308) + and - leads and terminals to motor. Inspect wiring insulation
and terminalsfor signs of overheating. See
page 24.
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. Check for loose motor brush leads and terminals. See page 22.
8. Tighten terminal screws. Repiece brushes if
leads are damaged. See page 22.
9. Check for worn motor brushes which shoulc
be 1IT' minimum. See page 22.
9. Replace brushes. See page
10.Check for broken and misalignedmotor
brush springs. Roiled portion of spring must
rest squarely on top of brush.
10.Replace spring if broken. Realign spring with
brush. See page
11.Check motor brushes for binding in brush
holders. See page 22.
11.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holder to assure free vartical brush movement.
12.Check circuit board 123) by substituting witt
a good circuit board. See page
12.Replace circuit board. See page 25.
25.
~.
22.
22.
13.Check motor armature for shorn by using 81 13.Raplace motor. See page 30.
armature tester lgrowier) or perform spin
test. See page 19.
14.Check bridge 1308) by substituting with a
good bridge or by performing.the bridge
test. See page 20 or 24.
CAUTION: Do not perform this check until
armature is determined to be good. A bad
armature will immediately burn out a good
bridge.
14.Replace bridge. See page 24.
1. Check paint supply.
1. Refiii and reprime pump,
2. Check for clogged intake strainer 17). See
page 28.
2. Remove and clean, then reinstall.
'0 OUTPUT
lotor runs and pump strokw
3. Check for loose suction tube
See page 28.
I 4 2 1 or fittings.
3. Tighten; use thread sealant or sealing tape
on threads if necessary.
Troubleshooting continued on neM page.
~~
YPE OF PROBLEM
0 OUTPUT
:ontinued)
~
~~
WHAT TOCHECK
If check Is OK, a0 to next check
4. Check to see if intake valve ball and piston
ball are seating properly. See manual
307-793.
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.See manual 307-793.
lotor runs but pump does
It stroke
1. Check displacement pump connecting rod
pin. See page 28.
4. Remove intake valve and clean. Check balls
and seats for nicks; replace if necessary. See
manual 307-793.
5. Replace packings. See manual 307-793. Also
check piston valve seat for hardened paint or
nicks and replace if necessary.
.I
,
.. .
I. Replace pin if missing. Be sure retainer
spring is fully in groove all around connecting rod. See page 28.
2. Replace connecting rod assembly. See page
3. Be sure crank in drive housing rotates; plug
I. Check drive housing assembly for damage
in sprayer and turn on momentarily to check
Turn off and unplug sprayer. See page 29.
pray pattern variations.
When check Is not OK refer to thls column
2. Check connecting rod assembly for damage.
see page 28.
KCESSIVE PRESSURE
LUCTUATIONS
WHAT TO DO
28.
and replace if necessary. See page
29.
..... ..,.
See page 24 and
25.
1. Be sure both G1 and G2 leads from bridge
(338)to circuit board (23)are firmly
connected. See page 25.
I. Reconnect securely.
2. Check stall pressure. Refer to Calibration
procedure on page 27.
L. Calibrate pressure control. See page 27.
3. Check bourdon tube flag and detector posi-
I, Carefully bend flag into alignment with
detector slot to see if that corrects problem.
If not, replace bare pressurecontrol
assembly (301)’. Calibrate pressure control
after reassembly.
tion. Turn pressure setting to maximum; flag
should not drag or bind in optical detector
slot of circuit board.
,-CIRCUIT
lb”
BOARD
. . ..
..
FLAO
VIEW OF OPTICAL DETECTOR ANDFL.AG
4. Check circuit board (23) by substituting with
a good board. See page 25.
1. Replace circuit board. See page
25.
5. Check LOW OUTPUT section on page 16.
IOTOR IS HOT e
UNS INTERMWfENTLY
1. Check to see if sprayer has been operating a1
high pressure with small tips, which causes
low motor RPM and results in excessive heat
build up.
I. Decrease pressure w i n g or increase tip
2. Check to see if ambient temperature where
L
sprayer is located is more than W0F (3Z0C)
or if sprayer is located in direct sun.
3. Check to see if sprayer has been leh in a
stalled condition (sprayer turned on,
pressurized, but not operating) for long
periods of time.
SIZB.
Move sprayer to shaded, cooler area if
possible.
I. Turn off sprayer whenever you stop spraying
for a while and relieve fluid pressure.
W e n replacing ths bare
p m u r e control boxlr)ll, remove the clrcuk board, bridge,
clrcuh board, and electrical hardware and reinatall In the newbars box.
Troubleshooting continued on next page.
307-785
’17
NPE
OF PROBLEM
WHAT TO CHECK
if check is OK. no t o next check
WHAT TO DO
When checkis not OK refer t o thls colum
ELECTRICAL SHORT
3uilding circuit breaker opens
1s soon as sprayer switch is
:urned on.
. Check a11 electrical wiring for damaged in-
sulation, and all terminals for loose fit or
damage. Be sure to check wires between
pressure control and motor which are encased in conduit 122). See page 30.
CAUTION
4ny short in any part of thl
notor power circutt, which si
mnnected to the output sidl
If the bridge, will cause thl
,ridge to burn out immediate
y. Correctly
diagnose
an(
.epair all shorts before check
ng
and
replacing bridge
. Check
for missing inspection plate gasket
(see page 221, bent terminal forks or other
I. Repair or replace any damaged wiring or ter
minais. Securelv reconnect all wires.
!. Correct faulty conditions.
metal to metal contact points which could
cause a short.
. Check motor armature for shorts by using an
armature tester (growler) or perform spin
test. Seepage 19. Inspect windings for
burns.
,
Check bridge (308)by substituting with a
good bridge or by performing bridge test.
See page
20.
i. Replace motor. See page 30.
I. Replace bridge. See page 24.
j
_.
. . .. .
. . .. .
CAUTION: Do not perform this check until
armature is determined to be good. A bad
armature will immediately burn out a good
bridge.
3uilding circuit breaker opens
ISsoon as sprayer is plugged
nto outlet and sprayer is NO1
'urned on.
Check 'Basic Electrical Problems' on page 13,
,
23.
Check ONlOFF switch 1 3 0 3 ) See page
Re sure the sprayeris unplugged! Disconnen
wires from switch and check switch with
ohm meter. The ohm meter should read infinity with the ONIOFF switch OFF, and zero
with the switch ON.
I.
Repiace ONlOFF switch. See page 23.
.. .... . ..
CAUTION: A short in the motor circuit wil,
burn the bridge out immediately, which in turr
usually causesthe ON/OFF switch to fail in thc
\
i
!
closed mode.
brayer circuit breaker opens
lfter sprayer operatesfor only
i to 10 minutes.
Check electrical supply with volt meter.
Meter should read 105 to 125 VAC.
. if voltage is too high, do not operete sprayel
Check tightness of pump packing nut. Overtightening nut tightens packings on rod,
restricts pump action, end damages
packings.
,. Loosen packingnut. Check tor leaking
Check stall pressure. Remove the plug from
the top of the fluid filter, and install a 5ooo
psi 1350 bar) fluid-filled pressure gauge. See
page 27. Plug in and turn on sprayer. Slowly
increase pressure sening to maximum. Pump
should stall at 2800-3ooo psi (196-207 bar).
Turn off and unplug sprayer.
i.
After determining that there is no short in
system, reset circuit breaker button.
!
until corrected.
around throat. Repiace pump packings, if
necessary. See manual 307-793.
I
i
.7n7-7R5
.:
. If circuit breaker continues to ooen (button
pops up), replace the circuit breaker. See
page 24.
,
18
,
Calibrate pressure control. See page 7.7.
I
......
SPIN TEST
-WARNING"----.-------r
Before doing this procedure, follow the Pressure
Rellef ProcedureWarning onpage 13 to reduce
the risk of a fluid injection injuty,injury from moving parts, or electric shock.
For checking armature, motor winding and brush electrical continuity.
. :.
..
setup
Remove the drive housing from the sprayer as des1-6,
cribed in "DriveHousingReplacement",Steps
page
Remove the pressure control cwer andscrews, the
motor cover,thefancover
(F), and theinspection
covers (J). See Fig 10.
Disconnect thetwo leads from the motor to the bridge
(308). See Fig 11.
Armature Short CircuitTest
Quickly turn the motor fan by hand. If theraare no
shorts, the motor will coast two or three revolutions
before coming to a complete stop.
If the motordoes not spin freely and resists rotation, the
armature is shorted and the motor must be replaced.
See page
Armature, Brushes, end
Motor
Wlrlng
Open
Clrcuit Test (Contlnultyl
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 the
following: a) brokenbrush springs; b) brokenbrush
leads; c) loose brush terminalscrews; d) worn brushes;
e) broken motor leads; f) loose motor lead terminals.
Repair parts as needed. See page
If there is still uneven or no turning resistance, replace
the motor. See page
29.
.. .~.
30.
, ,.
22.
30.
n g 11
:
..
.. .
...
...
.
I
~
307-785
19
.
'.
~
BRIDGE TEST
Remove the bridge from the pressure control box end
perform this test to determine if the bridge is functional.
See Bridge Rectlfier Replacement, page 24. Use a
continuity tester,suchesmulti-metersetonthe
X1
ohmsscale ( 0 I.
Eight individual checks, or tests, must be performed. If
the bridge fails even one test, it must be replaced.
the bridge. UsFig 12 shows the positionof the wires on
ing the chart at the right, connect the meter wires
as indicated by the black dots for each test, then check the
continuity.
In Tests 1, 2 and 3, there should be NO continuity.
In Tests 4.5 and 6, connect the + and meter wiresas
indicated, check continuity, then switch the meter wire
connections and check continuity again.
You should
continuity the
get NO continuity oneway,andYES
other way.
In Tests 7 and 0. connect the metar 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.
-
BRIDGE WIRES
0
0
2
5
z
E
2
' TEST 6
YES
NO
YES
uo
Fig 12
6"
6"""--
---~.--nr-.-3
r'-nr-&
TEST,
TEST 8
(,
.,. .
,
,. .. ., .
i
I
,. , ...
. .
i.
20
307-785
Repair
REPAIR SECTION INDEX
Procedure
Page
21
General
Motor Brush Replacement
................................... 22
Power Supply Cord Replacement..........................
23
ONIOFF Switch Replacement
23
Bridge Rectifier Replacement
............................... 24
Circuit Breaker Replacement
................................ 24
Circuit Board Replacement
25
Pressure Control Replacement
26
Stall Pressure Calibration
27
Bearing Housingb Connecting Rod Replacement.....28
Drive Housing Replacement
................................. 29
Motor Replacement :
30
Parts Lists b Drawings
32, 33
Sprayer
Pressure
............................................ 34
Circuit
35
How To Order Replacement Parts.....................
33
.........................................
..............................
..................................
.............................
....................................
..... .....................................
..................................................
................................................
NOTE:
Seeseparatemanual
ment pump repair.
307-793 for displace"
The following tools are needed when repairing this
sprayer.
Phillips screwdriver
Small flatblade screwdriver
Needle nose pliers
Plastic mallet
Adjustable wrench
2" adjustable, open-end wrench
Torque wrench
1/4" hex key wrench
3/16" hex key wrench
518'' socket wrench
318" open end wrench
1lZ' open endwrench
314, open end wrench
718" open end wrench
High quality motor oil
Bearing grease
... . ... .
,..
...
.........
.. .
:
For calibration procedureonly:
318" ianition wrench
0.015"spray tip
High pressure, oil-filled test gauge, Part No. 102-814
5 gallon pail
Clean water
Mineral spirits
NEW 3ooo psi (207 bar1 high pressure spray hose,
Part No. 214-915.
GENERAL REPAIR NOTES
Before repairing any part
of the sprayer, readthe following general repair notes and the repair procedure.
Be
sure you have the necessary tools and parts available.
1. Whendisconnecting wires in the pressure control
assembly, use needle nose pliersto separate mating
connectors.
When reconnectingthe wires, be sure theflat blade
of the insulated male connector is centered in the
wrap-around blade of the female connector when
the connection is made.
.:,, ..,....
,.......
. ,.. .,.
4. Testyourrepair
beforeregularoperation
of the
sprayer to be sure the problem is corrected.
If the sprayer doesnot operate properly, review the
repair procedure again
to verify that everything was
done correctly. If necessary, refer to the
Troubleshooting Guide, pages 13-20, to help identify other possible problems and solutions.
WARNING
To reduce the risk of serious bodilyinjury, including electricshock, DO NOT touch any moving
parts or electrical partswith your fingersor a tool
while inspecting the repair.
Shut off the sprayer and unplugit as soon as you
complete the inspection.
. .
.....
.,. .,
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
2. Route
wires
in the pressure control assembly
carefully through the legs of the U-shaped bourdon
tube, where appropriate, to avoid interfering with
the bourdon tube which moves as the pressure setting changes and to avoid pinching the wires between the pressure control box and cover.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
3. Keep all screws,nuts,washers,gaskets,andelectrical fittings removedduringrepairprocedures.
These parts ere not normally providedwith replacement assemblies.
CAUTION
Do not runthesprayer
dry for more than 30
seconds to avoid damaging the pump packings.
5. Reinstall the motor cover before regular operation
of the sprayer and replace it if it is damaged. The
cover directs cooling air around the motor to help
prevent overheating.It cen elso help prevent burns,
fire or explosion; see the WARNING, below.
WARNING
Duringoperation.themotorbecomesvery
hot
and could burn your skin if touched. Flammable
materialsspilledonthehot,bare
motor could
cause a fire or explosion. Always have the motor
cover in place during regular operation to reduce
the risk of burns, fire or explosion.
307-785
21
MOTOR BRUSH REPLACEMENT
Tools Needed:
Phillips screwdriver
Flatblade screwdriver
NOTE:
Replace the brusheswhen they have worn
to no less than 1/2 in. See STEP 1, Fig 14.
Note that the brusheswear differently on
eachside of themotor.Brush
Repair Kit
220-349 is available.
..
Fia 13
1. Remove the motor cover (14). See Fig 13.
2. Remove the screws (H),inspection covers IJ) and
gaskets (K)on each side of the motor. See. Fig 13.
3. Push down and thenin on the spring clip, and then
pull the clip out of the brush holder. Referto STEP
3, Fig 14. Keep the spring clip.
..'
4. Loosen the brush lead terminal screw and. remove
the lead.
5. Remove anddiscardthebrush.
6. Inspect the commutator for excessive pitting, burning or gouging.
NOTE:
A black color on the commutator is normal.
Have the
commutator
resurfaced
by a
qualified motor repairshop if the brushes
seem to be wearing too fast.
7. Place a new brush in the holder so the lead is at the
top of the holder. Place the brush lead terminal on
the terminal screw so the terminal is parallel with
the brush holder. Tighten the terminal screw. See
STEP 1, Fig 14.
8. With the spring roll touching the brush,push the
forked end of the spri.ng clip into the brush holder.
See STEP 2, Fig 14. When the fork passes through
the and of the holder, pushthe clipup or down until
the fork hooks theend of the holder. See STEP 3,
Fig 14.
9. Position the brush leadas shown in STEP 3, Fig 14.
Be sure the brush lead does not touch any part of
the armature or motor housing.
10. Test the brushes:
a. With the
ON/OFF
switch OFF. turn the
pressure control knob all the way counterclockwise to minimum pressure. Plug in the sprayer.
JI /
.
STEP 3
-Fork must hook
holder when
lnstalllng
" T o remove brush
push down and In.
than pullout
spring clip
BRUSH LI
b.Turnthe
ONlOFF switch ON and slowly increase the pressure untilthe motor comes up to
full speed.
c.
Inspect the brushand commutator contact area
for excessive arcing. Arcs should not "trail" or
circle around the commutator surface.
WARNING
Do not touch the brushes, leads, springs or brush
holders while the sprayer is plugged in to reduce
the risk of electric shock and serious bodily injury.
Fig 14
CAUTION
Do not run the sprayer dry for more than 30
seconds whilecheckingthebrushes
to avoid
damaging the displacement pump.
11. Reinstall the brush inspection covers, gaskets, and
screws.Reinstall
themotor
cover,screwsand
washers.
22
307-706
POWER SUPPLY CORD REPLACEMENT
Before doing this procedure, follow the Pressure
Relief Procedure Warnlng on page 13 to reduce
the risk of e fluid injection injury, injuryfrom movelectric
the sDreverl
ing mrts.
/ w
A Ror N
' Nshock.
G UnDlug
l
1. Remove the pressure control cover end screws.
2. Disconnectthepowersupply
cord lead from the
ONlOFF switch (3031, the white wire going to the
bridge (3081, and the green wire to the grounding
screw (343)end lockwssher (3271. See Fig 15.
3. Loosen the strain relief bushing (328).Remove the
power supply cord(31 I.1
4. Installthenewcord
In the reverse
order
of
disassembly.
5. Reinstall the coverandscrews.
... .
343,3271
ms
$=%-I
...
. . .,.
31 1
Fig 16
..... ..,
, _..,.
ONlOFF SWITCH REPLACEMENT
WARNING
Before doing this procedure, follow the Pressure
Rellef Procedure Warningon page 13 to reduce
the riskof a fluid injection injury, injuryfrom mov-
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the pressure control cover and screws.
Use a needlenosepliers to disconnecttheupper
terminal wirefrom the microswitch(302)
for ease in
removing the -ON/OFF switch (303). Refer to Fig
15.
Use thepliers to disconnect the two blackwires
from the ONlOFF switch (3031. Refer to Fig 15.
Use s 5/8" socketwrench to loosenandremove
the nut and rubber boot 1 3 0 4 ) from the toD of the
pressure control box. Remove the switch guard
(305).See Fig
.16.
Remove the ON/OFF switch.
Install the newswitch so the internal tabof the antirotation ring (Wl engages with the vertical groove
in the threads of the switch, and the externel tab
engages with the blind hole
(D) of the pressure control box. See Fig 16.
Install the switch guard (3051, aligning the internal
tab with the groove in the threads. See Fig 16.
Install the nut andrubber boot (304)end tighten.
See Fig 16.
Reconnect the wires to the ONlOFF switch (303)
and reconnect the wire to the microswitch (302).
Refer to Fig 15.
Reinstall the pressure control cover and screws.
n
. .
&305
TOPOF
PRESSURE
,..
CONTROL BOX
303
Flg 16
307-705
23
.
~
~
~
-~
~
~~~
~
BRIDOE RECTIFIER REPLACEMENT(Refer to Fig 17)
6. Make surethe bridge is flush
with the side of the box
and tighten the screws securely.
7. Connect all wires. Carefully route the wirea.
1. Remove the preasure control cover and scraws.
2. Disconnect all wires from the bridge(308)at the appropriate terminals.
3. Outside the pressure control box onthe right side are
two screw (331). Loosen, but don't remove the
screw near the back of the control box. Then loosen
and remove the front screw. Slide the bridge out.
4. Slide the new bridge 13081 into the box being sure
the lockwasher 1 3 3 3 ) on the rear screw 13311 is IN
FRONT of the bridge. Refer to the Detail in Fig 17.
5. Install the front screw, lockwasher and nut (3321.
"
CAUTION
,
Thelockwashers (3331 must be in front of the
bridge to avoid overheating which will result in
bridge failure. Refer to the Detail in Fig 17.
i
Be sure the flat blade of the insulated male connector is centered
in the wrap-around bladeof the
femaleconnectorwhen.theconnectionsare
made. Improper
connections
may
cause
the
sprayer to malfunction.
. .
Route all wires carefullyto avoid interferencewith
the movementof the bourdontube, circuit board,
or control box coverwhich could cause e malfunc-
8. Reinstall the pressure control cover and screws.
i' . .
NOTE:
The most common causa of bridge failure is
a faulty motor. Checkthe motor before
replacingthebridge to preventdemaging
..
the new bridge.
i
i
.:
. .
flg 17
w
BRIDGE INSTALLATION DETAIL
Ld
CIRCUIT BREAKER REPLACEMENT(See Fig 17)
5. Push down on the top of the circuit breaker and pull
it out of the box.
6. Install thenew circuit breaker in the reverse order of
disassembly.
7. Reinstall the pressure control cover and screws.
1. Remove the pressure control cover and screwa.
2. Use a small screwdriver to slide the terminal adapter
off the circuit breaker terminal.
3. Disconnectthesingleblackwire
from the circuit
breaker 13091 to the ON/OFF switch (3031.
4. Use e 5/8" socket wrenchto loosen the nut and boot
(3101 on the circuit breaker button.
24
307-785
CAUTION
thebourdon tube, which will cause a short.
lighten the circuit breaker nut firmly to prevent
~~
CIRCUIT BOARD REPLACEMENT
WARNING
1
Before doing this procedure, follow the Pressure
Relief Procedure Wernlngon page 13 to reduce
the risk of a fluid injection injury, injuryfrom mov-
1. Remove the pressure control cover and screws.
2. Turn the pressure control knob all the way countarclockwise to the minimum settingto release spring
tension on the circuit board (23). Also check to be
sure only threeor four threads of the pressure control knob shaft are exposed below the pressure adjustment nut (S). Back down the nut, if necessary.
See Fig 18.
I
I
6. Perform the Stall Pressure Calibration on page 27.
CAUTION
Step 2 is essential to reduce the risk of damaging
the circuit board while removingor installing it.
. ... . ..
~.
3. Disconnect ALL wires from the board, including the
two heavy black wires. Refar to Fig 19. Pay close
attention to where connections are made.
4. To remove theboard from the box, pull out-the
black plastic-tipped pin (330). Push the bottom of
the circuit board toward the wall of the box and
carefully slide the board out.
5. Install the board in the box at the sama angle as it
was removed. Reconnect the wires as indicated in
Fig 19. Ease the pin (330)into the retainer.
CIRCUIT BOARD 218-397 A, 5 Wires
Fig 18
. ...
..
. .. . ,:
..., .,:,
.
..
Flg 19
307-785
26
~
.
PRESSURE CONTROL REPLACEMENT (Refer to Fig 201
1. Disconnect the main fluid hose ( 9 0 1 and the secondary fluid hose, if used, from the sprayer.
2. Disconnectthe fluid hose (471 from betweenthe
displacement pump outlet nipple(461 and pressure
control inlet nipple (3441.
3. Loosen the filter bracket nut (281 and washer (13)
using a 3/4" open end wrench.
4. Hold the pressure control adapter (3411 firmly with
a 3/4" open end wrench.Use an adjustable wrench
to loosen the swivelunion (8).then remove the fluid
filter (481.
5. Remove the pressure control cover and screwsl36,
151, and disconnect the four motor leads
at the appropriate terminals.
6. Refer to Circuit Board Replacement on page 25,
remove the circuit board and retain.
7. Remove theconduit (221.
8. Use a 112" open end wrench to loosen and remove
the pressure control mounting screws (37)located
below the pressure control box. Remove the box.
9. Installthe newpressure control assembly in the
reverseorder of disassembly. Be sure to reinstall
the conduit seal ($not shown1 aroundthe wires in
the conduit connector (3451 to prevent motor contamination from entering the control box.
CAUTION
27.
10. Perform the pressure control calibration procedure
before'ragular operation
of the sprayer.
on page
28
307-785
Fig 20
STALL PRESSURE CALIBRATION
I
USE EXTREME CAUTION WHEN PERFORMINGTHIS CALIBRATION PROCEDURE to reduce the risk of a
fluid injection injury or other serious bodily injury which can result from splashing, component rupture, electric
shock,
This procedure sets the sprayer to 3000 psi (207 bar)
MAXIMUM WORKING PRESSURE. This procedure
must be performed whenever a new or used circuit
board, or pressure control assembly is removed and
reinstalled or replaced, to be sure the sprayer is properly calibrated.
Improper calibration can cause the sprayer to overpressurize andresult in component rupture, fire or
explosion. It may also prevent the sprayer from obtaining the maximum workingpressure which would
result in Door sDraver oerformance.
I
NEVER attempt to increase the fluid outlet pressure
byperforming this calibration in anyotherway.
3OOO psi (207 bar) -MAXIMUM
NEVER
EXCEED
WORKINGPRESSURE.Normaloperation
of the
sprayer at higherpressures could result in component rupture, fire or explosion.
AVOID touching the wires in thepressure control
assembly with your fingersor tools when the control
box cover is removed to reduce the risk of electric
shock.
.... >..
.. . ~.
.
.. ,
~
"
Calibration Setup (See Fig 21 and 22)
1. Follow thePressure Relief Procedure Wernlngon
page 13. Remove the spray hose and gun. Install a
0.018' spray tip in the gun. Connect the g'un to the
new test hose and connect the hose to the sprayer
outlet.
2. Remove the pressure control screws and cover.
3. Remove the plug from the top of the fluid filter, and
install the test gauge (W).
4. Place the pump suction tube in a 5 gallon pail of
clean water.
5. Be sura the gun safety latch is engaged.
6. Use e 318" ignition wrench to turn the pressure adjustment nut (SI counterclockwiseabout lwo full
turns. See Fig
. ..
j
.:....
22.
7. With the pressure control knob a t the minimum setting, turn the sprayer switch ON.
THE SPRAYER SHOULD NOT STARTI
I f it does srerr, shutthe
sprayer switch OFF,
disengage the gun safety latch, trigger the gun
into a
grounded waste container until pressure is relieved.
Engage the gun safety latch. Turn the pressure edjustment nut (SI a little furthercounterclockwise.
Turn the sprayer on to be sure it does nor start.
8. Slowly turn the pressure control knob clockwise to
the maximum setting and hold it there. Use a 3/8"
ignition wrench to slowly turn the Pressure adjustment nut (SI clockwise -until the test gauge reeds
EXACTLY 3000 psi (207 bar).
9. The calibration procedureis now completed.
\
.. .
A
Fig 21
WARNING
Follow thePressure Rellef Procedure Warning
on page 13.
CAUTION
Topreventpump corrosion, flush thewater out of
the pump, hose and gun with mineral spirits. Be
sure to close the pressure relief valve,
first. Use
the lowestpressure necessary to flush. Follow the
Pressure Relief Procedure Warning on page
13. Leave the mineral spirits in the pump to protect it until you are aready to spray again.
I
Flg 22
10.Remove the teat gauge assembly and
reinstall the
plug. Flush out water with mineral spirits.
307-786
27
BEARING HOUSING b CONNECTING ROD REPLACEMENT (See Fig 23)
ARNING
E-.
Before doing this procedure, follow the Pressure
Relief Procedure Warnlngon page 13 to reduce
the risk of an injection injury, injury from moving
-
1. Stop the sprayer et the bottom of its stroke to get
thi crank (E) in its lowest position. If the crank (E)
must be lowered manually, csrefully rotate the
blades of the fan with a screwdriver.
2. Remove the front cover and screws (31; 32).
3. Unscrew the suction tube (421 from the pump,
valve to keep
holding a wrench on the pump intake
the pump from loosening.
4. Disconnect the pumpoutlet hose 190) from the
displacement pump outlet nipple (46).
5. Use a screwdriver to push asidethe retaining spring
(35) at the top of the pump. Push the pin ( X u out
the rear.
6. Loosen the jam nut (38)with an adjustable wrench.
Unscrew and remove the displacement pump.
7. Use a 3/16" hex key wrench to remove the four
screws (33)and lockwashers (49)from the bearing
housing.
8. Lightly tep ihe lower rear of the bearing housing
(27) with a plastic mallet to loosen it from the drive
housing.Th6npullthebearinghousingandthe
connecting rod sbsembly (29)straight off the drive
housing.
9. Inspect the crank(E) for excessive wear and replace
parts as needed.
10. Evenly lubricate the inside of the bronze bearing in
the bearing housing with high quality motor oil.
Liberally pack the roller bearing in the connecting
rod assembly (29) with bearing grease.
11. Assemble the connectingrod ( 2 9 ) andbearing
housing (27).
12. Clean the mating surfaces of the bearing end drive
housings.
13. Align the connecting rod with the crank (E) and
csrefully align the locating pinsin the drive housing
with the holm in the front cover (31). Push the
it into
bearing housingonto the drive housing or tap
place with a plastic mallet.
I
CAUTION
DO NOT use the bearinghousingscrews (33)to
try to align or seat the bearing hGusing; the bearing and drive housing will not align properly and
will reault in premature bearing wear.
1
14. Install the screws (33)and lockwashers (49)on the
bearing housing endtighten evenly.
15. Screw the displacementpumpabout 3/4 of the
way into the bearing housing(271. Hold the pin (20)
up to the pin hole in the Connecting rod assembly
(29) and continue screwing in the pump until the
pin did- easily into the hole. Back off the pump
until the topthreads of the pump cylinder are
flush
with the face of the bearing housing and the
outlet
nipple (46) is facing back. Push the retaining spring
(35)into the groove allthe way aroundthe connecting rod. Tighten the locknut(38)very tight--about
.. .
.,
. .,
.,. . .
.,. .
..,: ..
..
..,~
. . ... . ,.
. . ..
i
. ..:.,.,.
,..
,..; ... ,
..
TORQUE TO
76.85 ft-lb
1102-116 N m l
I
Flg 24
75-85 ft-lb (102-115 Nm)-with a 2 in. open end
wrench and a light hammer. See Fig 24.
to prevent the pin(20)from working loose due to
vibration. See Fig 24.
If the pin works loo8e. it or other parts
could break
off due to the forceof the pumping action.These
parts could be projected through the
air endrmult
in serious bodily injury or property damage, including damage to the pump, connecting rod or
bearing housing.
16. Reinstall the front cover and screws(31.32). Reconnect the suction tube (42)and pump outlet hose
(471.
I
\
DRIVE HOUSING REPLACEMENT (See Fig 25)
ARNING
CAUTION
DONOT allow the gear cluster 19) to fall when
removingthedrivehousing
(18). It is eesiM
damaged if dropped. The gear may stay engaged
in either the front end bell or the drive housing.
Before doing this procedure, follow the Pressure
Relief Procedure Warning on
page 13 to reduce
the risk of a~fluidinjection injury,injuiy from mov-
NOTE:
1. Remove the front cover and acrews (31, 32).
2. Disconnect the pumpoutlet hose (47) from the
displacement pump outlet nipple 146).
3. Use a 3/16 in. hex key wrench to remove the four
screws 1 3 3 ) and lockwashers 1 4 9 ) from the bearing
housing.
4. Lightly tap the lower rear of the bearinahousing
(27) with a plastic malletto loosen it fIom the drive
housing. Then pull the bearing housmg and connecting rod assembly straight off the drive housing.
5. Use a 114 in. hex key wrench to remove the two
screws (51 and lockwashers (63)from the recess of
thedrivehousingandthe
two screws 130)and
lockwashers (63)from the rear of the motor front
end bell IP).
6.
Lightly tap the drive housingwith a plastic mallet to
loosen it from the front end bell, thenpull it straight
Off.
DO NOT lose the thrust bells 110) located at each
end of the gear cluster 19) or allow themto fall between gears. The ball,
which is heavily covered'
with grease, usually stays in the shaft recesses,
but could be dislodged. If caught between gears
and not removed, the balls will seriously damage
the drive housing.If the balls Bra not in place, the
bearings will wear prematurely.
Stop the sprayer at the bottom of its stroke
to get the crank (E)in its lowest position.To
lower it manually, carefully rotate the blades
of the fan with a screwdriver.
7. Liberallyapplybearinggrease
to the gear cluster
19). Check to besurethe thrust balls (10) are in
place.
. .
.. . ,.
, .,..,.
.
....:.
,
,
,,.:;>:?
. .
8. Place the bronze-colored washer (1%) and then !he
silver-colored washer (1%) an the shaft protrudlng
from the big gear in the drive housing (18). Align
the gears and push the new drive housing straight
onto the front and bell and locating pins.
9.
Starting at Step 5 andworking backwards, continue to reassemble the sprayer.
, .. ...: .
......
,
~,...
..
.... :;
. ..
MOTOR REPLACEMENT (Refer to Fig 26)
WARNING
Before doing this procedure, follow the Pressure
Relief Procedure Warning on page 13 to reduce
the risk of a fluid injection injury,injury from mov-
1.
2.
3.
4.
5.
6.
Remove the motor shield (14)and,screws (64).
Disconnectthepump
outlet hose (47)from the
displacement pump outlet nipple (46).
Remove the screws (15) and pressure control cover
(36)and disconnect the four motor leads. See Fig
19, page 26.
Use anadjustablewrench to loosen the conduit
connector nut (345) at the pressure control
assembly (431.
Swingtheconduit
(22) away from the conduit
elbow (345).
Remove the conduit seal (5)from around the wires
in the pressure control.Pullthe
motor leads
through the elbow, one et a time.
CAUTION
Always pull the motor leads oneat a timeto avoid
loosening the terminals
which could resultin a bad
connection and poor sprayer performance.
7 . Loosen the nut of the connector (54)at the motor
and pull the conduit(22) awayfrom the motor, then
pull the leads through the conduit, one at a time.
8. 'Unscrew the connector elbow from the motor.
9. Pull the wires through the elbow, one at e time.
10. Remove the front cover and screws (31.32).
11. Use a li4" hexkey wrench to remove the two
screws (51)and washers1 6 3 ) from the recess of the
drive housing, and the
two screws (30)and washers
(63)from the lower rear of the motor front end bell
(PI.
12. Use a plastic mallet to gently tap the displacement
pump (39)from the rear to loosen the drive housing
from the front end bell. Thenpull the drive housing
away from the end bell.
CAUTION
DO NOT allow the gear cluster (9) to fall when
(18). It is easi&
removingthedrivehousing
damaged if dropped. The cluster may stay engaged in either thefront end bellor the drive housing.
DO NOT lose the thrust balls (10) located at each
end of the gear cluster (9) or allow them to fall
between gears. The ball, which is heavily covered
with grease, usually staysin the gear recesses, but
could be dislodged. If caught between gears and
not removed, the balls will seriously damage the
drivehousing. If the ballsare not in place, the
bearings will wear prematurely.
13. Whilesupportingthemotor
to keep the sprayer
from tipping, removethe nuts (41),lockwashers
(40). and capscrews ( 4 4 ) holding themotor mounting plate (72)to the frame. Lift the motor assembly
off the frame.
14. Remove the mounting plate (72).four screws 179)
and lockwashers ( 6 3 ) from the old motor, and install them on the new motor.
/~
.
.
.. . .
...:
...
.
,. :
! :
,:.
j
Be sure to installthecorrectlength
of screw.
Longer screws will damage the motor.
15. Place the new motor assemblyon the frame and
align with the frame mounting holes. Installthe
screws (44). lockwashers (40). and nuts (41),
tightly.
.,:,
.,...
..~
1.: ,.,..
:.,.
I
i
16. Liberally grease the gear cluster (9) and piniongear
( 0 )and pack ell bearings in the motor front end
bell. Check to be sure the thrust balls (10) are in
place.
17. Place the bronze-colored washer (18b) and then the
silver-colored washer (la)on the shaft protruding
from the big gear in the drive housing (18).
18. Align the gearsandpush thedrivehousing (18)
straight onto the front end bell and locating pins.
19. Starting at Step 11 and.working backwards, continue to reassemble the sprayer.
NOTE:
Us6 a turning motion onthe conduit when
feeding wires through it.
wires in the conduit elbow (345)at the'pressure
control to keepcontaminants from entering the
pressure control.
21. Reinstallthemotorcoverandpressure
control
cover.
307-785
.
,
Ic
1
20. Reinstall the conduitseal ($not shown) around the
30
... ..
.. ..
.,.. ,.
307-785 31
PARTS DRAWING
Ultra@1000 Sprayers
PARTS LIST
Ultra"o
o
l
0Sprayers
Model 231-034. Series A
Model 220-411
Includes items 1-83
Basic Sprayer
Same
as
Model 231-043
Includes items 1-92
Includes items'l-92
Complete Sprayer
Model 231-043
Certified
CSA
except
is
QTY
REF PART
DESCRIPTION
NO. NO.
QTV
REF PART
DESCRIPTION
NO.
NO.
..
..,. .,....
.
~
1
220-355 MOTOR, electric
Includes replaceable items la to IC,
and one each of items 10 and 11
1
107-267 .TERMINAL, female
la
2
107-504 .TERMINAL, female
lb
1
596-421 .TERMINAL, snap on
IC
1
181-639 LABEL, identification
2
1
181-640 LABEL, identification
3
1
4
181-641 LABEL, identification
1
107.447 SEAL, conduit (see page 341
5
1
220-365 FRAME
6
Includes replaceable items 58 & 76
1
181-072
STRAINER
7
1
155-665UNION,adapter,
3/8 npsmif)
8
swivel x3/8 nptlm)
1
179-961
GEAR
REDUCER
9
1
10
2
100.069 BALL. 1 / 4 " , SST
11
'178-934 LABEL, warning
1
1
12
220-285 CAP
13
100-322 LOCKWASHER, external,
1
shakeproof; 7 / 1 6
181-743 SHIELD, motor; includes
14
1
one of item 11
106-075 SCREW, mach. oval head; thread
15
forming; No. 10-24,Type C; 1/2"
8
16
179-936 BRACKET, mounting
1
18
218-032 HOUSING, drive
Includes 18a and 18b
1
178-967 .WASHER, silver-colored
1%
1
107-089 .WASHER, bronze-colored
1
18b
176-818 PIN
1
20
101-682CAPSCREW,sch;
1/4-2Ox5/8"
21
2
22
065-099CONDUIT,electrical;specify
length
when ordering
0.79 ft
218-405CIRCUIT
BOAR0 lseepage34
23
& 351
1
bearing
27
HOUSING,
218-035
'150-513NUT,jam;
7/16'
28
1
218-034
ROD,
connecting
29
1
100-643CAPSCREW.sch;
1/4-20unrc-3a
30
Y 1 no
..
31
1
179-899
COVER,
housing
32
107-209SCREW,mach;
filh;No. 8-32x 1"
4
107-210CAPSCREW,sch;
3/8-16unc-3a
33
4
x 1-1/2'
179-945ADAPTER,elbow,special;
1/4-18
34
n p t hxf)
1
176-817
SPRING,
retaining
35
1
36
179-959COVER,pressure
control
1
108-751CAPSCREW,hexhead;
37
5/16-unc-3a
x 5/8"
2
178-941
NUT,
hex
1
38
217-577PUMP,displacement;See307-793
39
for parts
1
100-214LOCKWASHER. 5 / 1 6
40
6
100-188NUT,heavyhex;5/16-18unc-2a
4
41
42
1
180-573
TUBE.
intake
220455 PRESSURECONTROL ASSEMBLY.
43
1
See page 34
44
100-057' CAPSCREW,hexhead; 5/16-unc-2a
x 3/4"
4
162-453NIPPLE,114
nptlml x 114 npsm
46
2
218-083HOSE, grounded,nylon; 1/4" ID;
47
cpld 114 npsmlf); 29" I715 mm) long;
1
spring guard both ends
"
~
1
~
~
48
49
50
51
54
57
58
59
60
63
64
71
72
73
74
76
79
80
81
82
83
90
91
92
214-570FLUIDFILTER;See307-273
for parts
106-115LOCKWASHER,spring;
3/8"
220-288 VALVE,pressurerelief
107-218CAPSCREW,sch;
1/4-20 x 2.314"
108-460CONNECTOR,
conduit, 45O
'178.034
TAG,warning
101-242
RING,
retaining
206-994THROATSEALLIClUID,
8 02.
106-062
WHEEL
105-510LOCKWASHER, spring, 1/4"
108-865SCREW,mach;
pan head; No. 8
x 3/8"
'177-762
LABEL,
warning
181-829
PLATE.
mountino
~ 8 1 - 6 0 8 LABEL; warning178-460ADAPTER. 3/8 n d.h .l x 1/2 nDtlfl
. .
176-E34 WASHER,'^^^^^, k/E*
101-550 CAPSCREW. soc hd: 1/4-20 unc-3a
x 1/2"
183-035 BRACKET
108.662 NUT, retainer
183-037 HANGER, pail
104-811 HUBCAP
210-541 HOSE, grounded, nylon; 1/4" ID;
cpld 1/4 npsmIf); 50 ft I15 m) spring
guard both ends
214-701 HOSE, grounded, nylon; 3/16' ID;
cpld 1/4 npsmIf); 3 ft 10.9 ml; spring
guard both ends
220-955 SPRAY GUN; See 307-614 for parts
1
4
:: :':.
1
2
1
1
2
1
2
10
4
1
1
1
1
2
4
2
2
1
2
..... ..,:
..
.. .
..
,. :
:.,,.
. ..
,
1
1
1
~~~~
-
*Extra Warning labelsand rags available at nocharge.
HOW TO ORDER REPLACEMENT PARTS
. . ..
1. To be sure youreceive the correct replacementparts,
kit or accessories, always give all of the information
requested in the chart below.
..
2. Check the parts list to identify the correct part number;
do not use the ref. no. when ordering.
3. Order all parts from your nearest Graco distributor.
I
II
."..
6 digit
DAW
NUMBER
I
I
I
I
QTY
I
1
I
I
I PARTDESCRIPTION
I
307-785
I
33
. .. ...
PRESSURE CONTROL ASSEMBLY
Model No. Po46
Includes items 301 to 345
NOTE: A circuit boardis not included with the pressure
control assembly. See item 23, page 33 to order.
The terminals listed in this pan8 list are shown in
the wiring diagram on page 35.
342 (rear)
-
344-
31 1
REF PART
NO.
NO.
218-128
301
302
303
304
107-255
305
180-043
306
308
309
310
218-168
105679'
105-659
z1avo
107-256
107-254
218-169
311
107-268
312
107-267
314
107-293
315
107-294
316
107-396
317
107-262
107-260
318
319
320
103-885
321
322
323
324
325
l"021 327
3&
329
107-266
.
103.886
107-265
107-263
102-753
108-295
330
107-258
180-041
34
307-785
DESCRIPTION
BARE PRESSURE CONTROL BOX
Includes items302 to 305
.MICROSWITCH
.ON/OFF SWITCH
.BOOT. ON/OFF switch
.GUARD, locking
JUMPER WIRE
BRIDGE, rectifier, SCR
CIRCUIT BREAKER
BOOT, circuit breaker
CORD, power supply
ADAPTER, terminal
TERMINAL, male
TERMINAL, female
TERMINAL, male
TERMINAL, male
TERMINAL, female
TERMINAL, female
TERMINAL, female
TERMINAL, male
TERMINAL, female
TERMINAL, female
TERMINAL, female
TERMINAL, ring
LOCKWASHER, No. 8, internal
BUSHING, strain relief
TIP, pin, black plastic
PIN
QN
331
332
333
23
335
1
1
338
337
107-503 TERMINAL. female
338
107-504 TERMINAL; male
157-350 ADAPTER, 3/8 npt(m1x 1/2 npt(ml
100440 ELBOW, street; 114 n p t h x f )
341
3
2
1
1
101-273 SCREW,
machlne,
flat head;
No. 1024 x 5/8" lono
100-179 NUT, hex, mcr, No,"1024 thd
100-718 LOCKWASHER. internal. shakeproof;
No. 10
*'17&79? LABEL, WARNING
"178035 LABEL. WARNING
107-261 TERMINAL, mal.-
342
343
344
345
SCREW. mach.. slotted Dan hd:. No.
8x5/18;' long
162-453 NIPPLE. 114 n o t h t x 1/4 n o m
102-932 CONNECTOR.'conduit
100-035
~
1
1
1
1
1
1
1
2
1
1
1
~~~
1
1
I
3
1
2
2
**Exha Warning labelsand tags suppliede t no charge.
See "How To Order Replecementparts" on page 3.
1
CIRCUIT BOARD 218-405
.. . . .
.. ..,. :.
. ....
. ,. ,.
.<,
.. ,
. ,. ..
307-785
35
SERVICE INFORMATION
Listed below by the assembly changed are OLD, NEW,
ADDED and DELETED parts.
I
I
REF PART
ASSEMBLY PART
NO.
NO.
CHANGED
STATUS NAME
OLD
NEW
Model
231-034
W
108-681 Screw
108-685 Screw
Basic
Sprayer
INTERCHANGEABILITY
NOTE:
NEW
OLD part listed directly above it.
II
part replaces
ULTRA o
lo
0TECHNICAL DATA
Power Requirements: 115 VAC, 60 Hz, 1 Phase, 15 AMP minimum
Operating Range:0-3000 psi (0-207 bar1
Cycles/Gallon (liter):200 (53)
Maximum Delivery:0.85 GPM (3.2 liter/min)
Power Cord: No. 14 AWG, 3 wire, 86" (2.6 m) long
Inlet Paint Strainer: 16 mesh, (1190 micron), Stainless Steel Screen, reusable
Outlet Paint Filter:60 mesh,
micron),StainlessSteelScreen,reusable
Pump Inlet Size:3/4 npt w120O ID chamfer
Fluid Outlet Size: 1/4 npsm from fluid filter
Weight: 100 Ib ( 4 5 Kg) approximately
Dimensions:Width: 22.5 in. (572 mm)
Height: 28.0 in. (711 mm)
Length: 26.0.in. (660rnm)
Factory 6ranohes:Atlanta. Dallas, Detrolt, Los Angelas. West Caldwell (N.J.1
Subsidiary and Affiliate Companies:Canada; England; Swltzerlend: France; Qerrnany; Hong Kong; Japan
GRACO INC.
P. 0. Box 1441 MINNEAPOLIS, MN 55440-1444
PRINTED IN U S A . 3
0
7
.
7
8
5 7-86 Rsvired 587