Graco 308248C 490st Airless Paint Sprayer Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains important

ELECTRIC, 120 VAC

490st Airless Paint Sprayer

2750 psi (795 bar) Maximum Working Pressure

Model 231-208, Series B

Complete sprayer with hose, gun, RAC IV@ DripLess”

Tip Guard and SwitchTip T”

Table Of Contents

Warnings .....................

Setup ........................

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

Startup ......................

Shutdown and Care ..........

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

Troubleshooting ..............

Repair ......................

Parts. .......................

Technical Data ...............

33

36

Dimensions .................. 36

Grace Phone Numbers ........ 36

Warranty .................... 36

13

14

15

20

2

6

9

11

02821A

NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of charge. See page 36 to order.

I)

!

SKIN INJECTION

HAZARD

- or leaks - especially hose leaks.

Keep body clear of the nozzle. Never stop leaks with any part of the gering of gun B y always setting safety atch when not spraying.

Never spray without a tip guard.

B parts. Avoid accidental trig-

In case of accidental skin injection, seek immediate

Failure to follow this warning can result in death or serious injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

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

@COPYRIGHT 1992, GRACO INC.

WARNINGS

High Pressure Spray Can Cause Serious Injury. For Professional Use Only,

Observe AlI Warnings. Read and understand all instruction manuals before operating equipment.

FLUID INJECTION HAZARD

General Safety

This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through yourskinand into yourbodyandcauseextremelyseriousinjury, including the need for amputation. Also, fluid injected or splashed intothe eyes or on the skin can cause serious damage.

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

Never put hand or fingers over the spray tip. Never try to “blow back” paint; this is Not an air spray system.

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

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

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

Be sure equipmentsafety devices are operating properly before each use.

Medical Alert --Airless Spray Wounds

Ifanyfluidappearstopenetrateyourskin,getemergencymedi- exactly what fluid was injected.

Note to Physlcian: Injection in the skin is a traumatic injury. It is importantto treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern withsomeexoticcoatingsinjecteddirectlyintothebloodstream.

Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

Spray Gun Safety Devices

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

Safety Latch

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

Diffuser

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

Tip Guard

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

Trigger Guard

Always havethetriggerguardinplaceonthegunwhenspraying to reduce the risk of accidentally triggering the gun if it is dropped or bumped.

Spray Tip Safety

Useextremecautionwhencleaningorchangingspraytips.Ifthe spray tip clogs while spraying, lock the gun trigger safety immediately. ALWAYS follow the Pressure Relief Procedure and then remove the soray tip to clean it.

NEVER wipe off build-up around the spray tip until pressure is fully relieved and the gun trigger safety is locked.

Pressure Relief Procedure

To reduce the risk of serious injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electricshock, alwaysfollowthis procedure whenever you shut off the sprayer, when checking or servicinganypartofthespraysystem,wheninstalling,cleaning or changing spray tips, and whenever you stop spraying.

1. Lock the gun trigger safety.

2. Turn the ON/OFF switch to OFF.

3. Unplug the power supply cord.

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


6. Openthe pressure drainvalve, havingacontainer ready to catch the drainage. Leavethevalve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved afterfol- lowing the steps above, very slowly loosen the tip guard retaining nut or hose coupling to relieve the pressure gradually, then loosen completely. Now clear the tip or hose.

2 308-248

General Safety

Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemi- calsandfluids,orusingwornordamagedparts,cancausethem to rupture and result in fluid injection, splashing in the eyesoron the skin, or other serious injury, or fire, explosion or property damage.

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

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

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

System Pressure

This sprayer can develop 275Opsi (795 bar) Maximum Working

Pressure. Be sure that all spray equipment and accessories used are rated

to withstand this pressure. Do not exceed the

maximum working pressure of any component or accessory used in the system.

Fluid and Solvent Compatibility

AIlchemicalsusedinthesprayermustbechemicallycompatibJe with the wetted parts shown in theTechnical Data on page 36.

Consult your chemical supplier to ensure compatibility.

Do not use 1 ,l ,l -trichloroethane, methylene chloride, other ha- logenated hydrocarbon solvents or fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such use could result in aserious chemical reaction, with thepossibilityofexplosion, whichcouldcausedeath,seriousin- jury and/or substantial property damage.

HOSE

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

All fluid hoses must have spring guards on both ends! The spring guards help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture.

Tighten all fluid connections securely before each use. High pressure fluid can dislodge aloosecoupling 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 movementofthehosecouplings.Ifanyoftheseconditionsexist, replace the hose immediately. Do not try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot contain the high pressure fluid.

SAFETY

Handle and route hoses carefully. Do not pull on hoses to move equipment. Keep hoses clear of moving parts and hot surfaces of the pump and gas engine. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose. Do not expose Grace hose to temperatures above 180” F (82” C) or below -40’ F (-40” C).

Hose Grounding Continuity

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

Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or un- plugging a power supply cord or using a gasoline engine.

Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying indoors or outdoors, and can cause a fire or explosion and serious injury and property damage.

Ifyouexperienceanystaticsparking orevenaslightshockwhile using this equipment, stop spraying immediately. Check the entiresystemforpropergrounding. Donotusethesystemagain until the problem has been identified and corrected.

Grounding

To reduce the risk of static sparking, ground the sprayer and all other spray equipment used or located in the spray area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Be sure to ground all of this spray equipment:

1. Sprayer: connect a ground wire and clamp (supplied) to a true earth ground.

2. fluid hoses: use only grounded hoses with a maximum of

500ft (150 meter) combined hose length to ensure grounding continuity. See Hose Grounding Continuity. obtain grounding through connection to a prop-

4. Object being sprayed: according to local code.

5. Fluid supply container: according to local code.

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

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

Flushing Safety

Reducetheriskofskininjectioninjury,staticsparking,orsplash- ing by following the flushing procedure given on page 14 of this manual. Follow the Pressure Relief Procedure on page 4, and removethespraytip beforeflushing. Holdametal partofthegun firmly to the side of a grounded metal pail and use the lowest possible fluid pressure during flushing.

- MOVING PARTS HAZARD -

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

IMPORTANT -

United States Government safety standards have been adopted undertheOccupationalSafetyandHealthAct.Thesestandards

- particularly the General Standards, Part 1910, and the Con- struction Standards, Part 1926 - should be consulted.

308-248 3

Avertissement

La pulverisation 31 haute pression peut causer des blessures t&s graves.

Reserve exclusivement a I’usage professionnel. Observer toutes les consignes de securite.

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

RISQUES D’INJECTION

Consignes generales de securite

Cet appareil produit un fluide h t&s haute pression. Le fluide pulverise par le pistolet ou le fluide sous pression provenant de fuites ou de ruptures peut penetrer sous la peau ou a I’interieur du corps et entrainer des blessures tres graves, voir mQme une amputation. MQme sans dtre sous pression, le fluide eclabous- sant ou entrant dans les yeux peut aussi entrainer des blessures graves.

Dispositifs de securite du pistolet

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

Ne Jamais pointer le pistolet vers quelqu’un ou vers une partie quelconqueducorps. NeJamaismettrelamainoulesdoigtssur

I’ajutage du pulverisateur. Ne Jamais essayer de “refouler” la peinture. Cet appareil N’est Pas un compresseurpneumatique.

Verrou de skurit6

A chaque fois que I’on s’arrhe de pulveriser, meme s’il s’agit d’un court instant, toujours mettre le verrou de securite du pistolet sur la position “fermee” ou “skurite” (“safe”) pour empgcherlepistoletdefonctionner.Sileverroudesecuriten’est pas mis, le pistolet peut se declencher accidentellement.

Toujours garder la protection de I’ajutage en place sur le pistolet pendant la pulverisation.

Toujours observer la March a Suivre pour Detendre la Pres- sion donnee plus loin, avant de nettoyer ou d’enlever I’ajutage du pulverisateur, ou d’effectuer un travail quelconque sur une partie de I’appareil.

Ne Jamais essayer d’arreter ou de devier les fuites avec la main ou le corps.

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

Soins medicaux

En cas de penetration de fluide sous la peau: Demander immediatement des soins medicaux d’urgence. Ne pas soigner cette blessure comme une simple coupure.

Avis au medecin: un traumatisme.

La p&n&ration des fluides sous la peau est

II est important de traiter chirurgicale- ment cette blessure immddiatement. Ne pas retarder le traitement pour effectuer des recherches sw la toxicit&

Cettains revktements exotiques sont dangereusement toxiques guand ils sont inject& directement dans le sang.

II est souhaitable de consulter un chirurgien esth&ique ou un chiruraien sDdcialis& dans la reconstruction des mains.

Le diffuseur du pistolet sert adiviser le jet et a reduire les risques d’injectionaccidenteIlequandl’ajutagen’estpasenplace.V~rif- ier le fonctionnement du diffuseur regulierement. Pour cette verification, detendre la pression en observant la Marche a

Suivre pour DCtendre la Pression donnee plus loin puis enlever I’ajutage du pulverisateur. Pointer le pistolet dans un seau en metal, en le maintenant fermement contre le seau. Puis, en utilisant la pression la plus faible possible, appuyer sur la gachette du pistolet. Si le fluide projete n’est pas diffuse sous forme de jet irregulier, remplacer immediatement le diffuseur.

Protection de I’ajutage

Toujours maintenir la protection de I’ajutage en place sur le pistolet du pulverisateur pendant la pulverisation. La protection de

I’ajutage attire I’attention sur les risques d’injection et contribue a reduire, mais n’bvite pas le risque, que les doigts ou une partie quelconque du corps ne passent accidentellement a proximite immediate de I’ajutage du pulverisateur.

Consignes de securite concernant I’ajutage du pulverisateur

Faire extremement attention a I’occasion du nettoyage ou du remplacement des ajutages du pulverisateur. Si I’ajutage se bouche pendant la pulverisation, mettre immediatement lever- rou de securite du pistolet. Toujours bien observer la Marche a

Suivre pour Detendre la Pression puis enlever I’ajutage du pulverisateur pour le nettoyer.

Ne Jamais essuyer ce qui s’est accumule autour de I’ajutage du pulverisateur avant que la pression ne soit completement tombee et clue le verrou de securite du pistolet ne soit enoak.

Marche a Suivre pour Detendre la Pression

Pour reduire les risques de blessures graves, y compris les blessures par projection de fluide ou celles causees par de eclaboussures dans les yeuxou sur la peau, par des pieces en mouvement, toujours bien observecette marche Bsuivrecha- quefoisque I’on arrete le pulverisateur, al’occasion delaverifi- cation, du egale ou du nettoyage du systeme ou lors du chan- gement des ajutages.

1. Engager le verrou de securite du pistolet.

2. Mettre le levier d’arret du moteur sur ARRET (OFF).

3. Debrancher le cord d’aliment maintenant une partie metallique du pistolet fermement appuyd contre le tote d’un seau en metal, actionner le pistolet pour liberer la pression.

5. Engager le verrou de securite du pistolet.

6. Ouvrir la soupape de securite et la laisser ouverte jusqu’h ce que I’on soit prQt a se servir de nouveau du pulverisateur.

Sil’on soupconne que le tuyau ou I’ajutage est compl&tement bouch6 ou que la pression n’a pas &t5 compl6tement lib&e apres avoir pro&de aux operations ci-dessus, desserrer

TRES LENTEMENT un raccord de bout de tuyau ou I’bcrou de retenue de la protection de I’ajutage et liberer progressive- ment la pression.

13 s s

3 6

02822A

4 308-248

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Consignes g&kales de skurit6

Toute utilisation anormale de I’appareil de pulverisation ou des accessoires comme, par exemple, la mise sous une pression excessive, les modifications de pieces, I’utilisation de produits chimiques et de matieres incompatibles et I’utilisation de pieces u&es ou abimees peut causer des degits a I’appareil ou des ruptures de pieces et entrainer une injection de liquide ou d’autres blessures serieuses, un incendie, une explosion ou d’autres degats.

Ne Jamais alterer ou modifier une piece de cet appareil; ceci risquerait d’entrainer son mauvais fonctionnement.

Verifier regulierement tout I’appareil de pulverisation et ses equipementsetr~parerouremplacerimm~diatementlespi~ces u&es ou abimees.

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RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL -

Presslon

Ce pulvtkisateur peut produire une Pression Maximum De Tra- vail 195 bar (2750 lb/Poe). S’assurer que tous les elements du pulverisateur et ses accessoires sont congus pour resister a la pression maximum de travail de ce pulverisateur. NE PAS depasser la pression maximum detravaild’aucun deselements ou accessoires utilises avec cet appareil.

Compatibillte chlmique des corps

Bien s’assurer que tous les corps des solvants utilises sont chimiquementcompatiblesaveclespartiesmouill~esindiqu~es dans les Technical Data, a page 36. Toujours lire soigneuse- mentlesdocumentsetbrochuresdufabricantdesfluidesetsol- vants utilises avant de s’en servir dans ce pulverisateur.

MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXIBLES -

Lefluideghautepressioncirculantdanslestuyauxpeut~tretres dangereux. En casdefuite sur le tuyau, defissure, dechirureou ruptureglasuitedeI’usure,dedeg~tsoud’unemauvaiseutilisa- tion, les projections defluide haute pression qui en proviennent peuvent entrainer des blessures graves par penetration sous la peau ou par contact, ainsi que des degats materiels.

Manipuler les tuyaux avecprecaution et choisirsoigneusement leur chemin. Ne pas deplacer le fluide en tirant sur le tuyau. Ne pasutiliserdefluidesoudesolvantsquinesontpascompatibles avec I’enveloppe interieure ou exterieure du tuyau. NE PAS ex- poser le tuyau a des temperatures superieures h 82°C

(180°F) ou inferieures h -40°C (-40°F).

Tous les tuyaux flexibles doivent avolr des ressotts splrale deprotectionauxbouts!Lesspiralesdeprotectioncontribuent a eviter laformation de pliures, de boucles ou de nceuds sur les tuyaux qui pourraient entrainer la rupture du tuyau a I’endroit du raccord ou a son voisinage.

Serrer fermement tous les raccords avant chaque utilisation. Le fluide sous pression peut faire sauter un raccord desserre ou produire un jet a haute pression s’echappant par le raccord.

Ne Jamais utiliser un tuyau endommage. Ne Pas essayer de refaire le raccord d’un tuyau haute pression ni de reparer le tuyau avec du ruban adhesif ou par tout autre moyen. Un tuyau repark ne peut pas resister au fluide sous pression.

S’il se produit des etincelles d’blectricite statique, ou si vous res- sentezlamoindredecharge,arr&ezimmediatement lapulve- risation. Verifiez que le systeme entier est bien mis a laterre. Ne vous servez pas du systeme avant que le probleme soit identifie et corrige.

Contlnuit6 de la mise a la terre des tuyaux

Une bonne continuite de la mise a la terre des tuyaux est essen- tielle pour maintenir la mise ala terre de I’ensemble devaporisa- tion. Vdrifiez la resistance Blectrique de vos tuyaux a fluides et a air, au moins une fois par semaine. Si votre tuyau ne comporte pas d’btiquette qui precise la resistance Blectrique maximum, prenezcontactaveclefournisseurdetuyauxoulafabricantpour avoir les limites de resistance maximum. Utilisez un metre de resistance de la gamme appropriee pour votre tuyau et verifiez la resistance. Si celle-ci depasse les limites recommandees, remplacez le tuyau immediatement. Un tuyau sans mise a la terre ou avec une mise a la terre incorrecte peut entrainer des risques pour votre systeme. Lisez aussi LES RISQUES D’IN-

CENDIE OU D’EXPLOSION ci-dessus.

RISQUES D’INCENDIE OU D’EXPLOSION

De I’electricite statique est produite par le passage du fluide a grande vitesse dans la pompe et dans les tuyaux. Si toutes les pieces de I’appareil de pulverisation ne sont pas convenable- ment relies a la masse ou a la terre, des etincelles peuvent se produire et I’appareil risque d’btre dangereux. Des etincelles peuventegalementseproduire~l’occasiondubranchementou du debranchement du cordon d’alimentation. Les Btincelles sont suff isantes pour allumer les vapeurs de solvants et le fluide pulverise, les fines particules de poussieere ainsi que d’autres substances inflammables, et elles peuvent causer un incendie ou une explosion, ainsi que des blessures graves et des degats materiels. Toujours brancher le pulverisateur dans une prise se trouvant a au moins 6 m (20 pieds) de I’appareil et de I’endroit

00 se fait la pulverisation.

2. Tuyaux flexibles: Afin d’assurer la continuite de la mise a la terre, n’utiliser que des tuyaux comportant une mise a la terre et ayant une longueur maximum combinee de 150 m nuit6 du circuit de mlse B la terre des tuyaux.

Rdaliser la mise a la terre en le raccordant a un relies a la terre. observer le code ou les regle- server le code ou les reglementations locales. ob- utilises pour le rincage: observer le code ou les reglementations locales. N’utiliser que des saux metalliques conducteurs de I’electricite. Ne pas mettre le seau sur une surface non conductrice comme sur du papier ou du carton car cela interromprait la continuite de la mise a la terre.

7. Pour conserver la continuitk de /a mise B la terre quand on rince le mat&e/ ou quand on lib&e la pression, toujours maintenir une partie metallique du pistolet fermement ap-

Mise 21 ia terre ou B la masse

Pour reduire les risques de production d’etincelles d’electricite statique, le pulverisateur et tous les Bquipements utilises ou se trouvant dans la zone de pulverisation doivent Qtre relies a la terre ou a la masse. Pour connaitre le detail des instructions de mise a la terre dans la region et letype particulier d’bquipement,

Consulter le code ou les reglementations electriques locales.

S’Assurer que tous les equipements de pulverisation suivants sont bien relies h la terre:

1. Pu/v&isateuc Brancher le cordon d’alimentation ou la ral- longe qui doivent etre equip& dune prise a 3 fiches en a la terre. Ne pas utiliser d’adaptateur. Toutes les rallonges doivent avoir 3 fils et btre prevues pour 15 amperes. la detente du pistolet.

Mesures de skurlt6 concernant le rincage

Pourreduire les risquesde blessures par penetration de lapeau etlesrisquesdQsauxetincellesd’electricitestatiqueouaux~cla- boussures, observer lamarche hsuivre pour le rincage donnee a la page 14 de ce manuel. Observer la “Marche a Suivre pour

Ddtendre la Pression” donnee h la 4 en enlever I’ajutage du pulwkisateur avant le rincage. Maintenir une partie metallique du pistolet fermement appuyee contre le cbte d’un seau en metal et utiliser la pression la plusfaible possible pendant le rincage.

308-248 5

ADVERTENCIA

El rociado a alta presidn puede causar graves lesiones. Solo para uso profesional. Respete 10s avisos de advertencia. Lea y entienda todo el manual de instruccibnes antes de manejar el equipo.

PELIGRO DE INYECCION DE FLUID0

Seguridad general

Este equip0 genera un fluid0 a una presi6n muy alta. El rociado delapistola,losescapesdefluidooroturasdeloscomponentes pueden inyectar fluid0 en la piel y el cuerpo y causal lesiones extremadamente graves, incluyendo a veces la necesidad de amputacibn.Tambi~n,elfluidoinyectadoosalpicadoenlosojos puede causar graves daiios.

Nunca apuntar la pistola hacia alguien o alguna parte del cuerpo. Nunca colocar la mano o 10s dedos encima de la boquilla. Nunca tratar de “hater retornar la pintura”; este no es un sistema de rociado de aire.

Siempre tener colocado el protector de la boquilla en la pis- tolamientras se estti pulverizando.

Siempreseguir el procedimiento de descargade presibn, dado mkabjo, antes de limpiar o sacar la boquilla o de dar servicioa cualiquier equip0 del sistema.

Nunca tratar de parar o desviar 10s escapes con la mano o el cuerpo.

Asegurarquetodoslosaparatosdeseguridaddelequipoest~n funcibnando bien antes de cada uso.

Tratamiento medico

Siparecieraqueunpocodefluidopenetr6lapiel,conseguir ida coma un simple fluid0 fue. urgencia de inmediato. no tratar la her- torte. Decir al medico exactamente cua

Aviso al mhdico: Si se llega a causa una lesih traum&ica. Es importante quirrirgicamente la lesih a la brevet-iad posible. No demorar el tratamiento para investigar tratar la toxicidad. La toxicidad es a/go de suma importancia en algunas pin- turas exbticas cuando se invectan directamente al torrente sanguineo. Siri convenient6 consultara un especialista en cirugia pkktica o reconstructiva de las manos.

Aparatos de seguridad de la pistola pulverizadora

Asegurar que todos 10s aparatos protectores de la pistolaestdn funcibnando bien antes de cada uso. No sacar ni modificar ningtina pieza de la pistola pues podria causar el malfuncibna- miento de la misma con las consiguientes lesiones personales.

Pestillo de seguridad

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

Difusor

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

Revisar con regularidad el funcitkamiento del difusor. Seguir el procedlmlento de descarga de preslh, dado mb abajo, y despuk sacar la boquilla. Apuntar la pistola a un balde metGli- co,sosteni&~dolabienfirmecontrael. Utilizandolapresi6nm& bajo posible, disparar la pistola. Si el fluid0 emitido no sale dis- persoen un chorro irregular, reemplazardeinmediatoeldifusor.

Protector de la boquilla

Siempre tener el protector de la boquilla colocado en la pistola mientras se esta pulverizando. Este protector llama la atenci6n contra el peligro de inyecci6n y ayuda a reducir, pero no evita, lacolocaci6n accidental de 10s dedos o cualquier otra parte del cuerpo cerca de la boquilla.

Seguridad de la boquilla pulverizadora

Tenermuchocuidadoallimpiarocambiarlasboquillas.SiIlega- raaobstruirse mientras est&pulverizando, engancharel pestillo de la pistolade inmediato. Siempre seguir et procedimiento de descarga de presih y despuks sacar la boquilla para lim- piarla.

Nunca limpiar la acumulacidn de pintura alrededor de la bo- quillaantesdequese hayadescargadoporcompletolapresi6n y el pestillo este enganchado.

Procedimiento de descarga de presi6n

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

1. Enganchar el pestillo de la pistola.

2. Mover el interruptor elktrico (ON/OFF) a la posicibn

OFF (apagado).

3. Desenchufar el cord6n electrico.

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

5. Enganchar el pestillo de la pistola. presi6n abierta hasta que se este nuevamente listo para pulverizar.

Si se sospecha que la boquilla o la manguera estG com- pletamente obstruida, o que no se ha descargado por com- pleto la presi6n despuks de haber seguido el procedimiento anterior,aflojarmuylentamentelatuercaderetenci6ndelpro- tector de la boquilla o acoplamiento de la punta de la manguera y descargar gradualmente la presibn, desp&s, aflojarlo por complete. Luego, despejar la boquilla o la man-

8 308-248

Seguridad general

Cualquier mal uso del equip0 pulverizador o 10s accesorios, tal coma sobre presurizacion, modification de piezas, uso de materiales y productosquimicos incompatibles, o utilizacionde piezas danadas o desgastadas, puede hacen que se rompan y causenlainyecci6ndefluidouotraslesionescorporalesgraves, incendio, explosion o daiion a la propiedad.

Nunca alterar o modificar ninguna pieza de este equipo; el hacerlo podria causar una averia.

Revisar con regularidad el equip0 pulverizador y reparar o reemplazar de inmediato las piezds datiadas o desgastadas.

Presidn del sistema estl pulverizadora puede desarrollar 195 barias (2750 psi) De

Presih De Trabajo Mhima. Asegurar que todo el equip0 pulverizador y sus accesorios tienen lacapacidad paraaguantar la presion maxima de trabajo de est6 pulverizadora. NO exceder la presion maxima de trabajo de ningirn componente o ac- cesorio de este sistema.

Compatibilidad de fluid0

Siempreleerlasinstruccibnesdelfabricantedelfluidoysolvente antes de usarlos en esta pulverizadora, dadas en la pagina 36.

Siempre usar gafas, guantes, vestimetas protectora y un respiradero, tal coma recomiendan 10s fabricantes del fluid0 y del solvente.

SEGURIDAD EN EL US0 DE LAS MANGUERAS

El fluid0 queescapaaalta presion por las mangueras puede ser muy peligroso. Si en la manguera se desarrolla un escape, una rotura o rajadura debido a cualquier tipo de desgaste, datio o maltrato, el chorro a alta presion emitido por alli puede causar una lesion por inyeccion u otras lesiones corporales graves 0 danos a la propiedad.

!Todas las mangueras para fluidos tienen que tener guardas de resorte en ambos extremosf Estas protegen las mangueras contra dobleces o retorceduras en 10s acoplamientos o cerca de ellos, 10s que podrian traducirse en roturas de la manguera.

Antes de usarlas, Apretar bien firmes todas las conexiones. El fluid0 a alta presidn puede desalojar un acoplamiento suelto o dejar que por el escape un chorro a alta presion.

Nuncausar unamanguera que estadanada. Siempre, revisarla en busca de cortaduras, escapes, abrasion, cubierta abultada, o acoplamientos sueltos o daiiados. Si llegara a encontrarse cualquiera de es& condicibnes, reemplazar de inmediato la manguera. NO intentar racoplar una manguera de alta presion o enmendarla con cinta adhesiva u otro material similar. Una manguera que ha sido remendada no aguante el fluid0 a alta presion.

Manejar y pasar cuidadosamente las mangueras. No tirar de las mangueras para mover el equipo. No usar fluidos o solventes que Sean incompatibles con el tubo interno y la cubierta dela manguera. No exponer las mangueras a temperaturas sobre

82” C (180” F) o bajo -40” C (-40” F).

Continuidad del circuit0 de puesth a tierra de la manguera

Lacontinuidaddelcircuitodepuestaatierraapropiadoesesen- cialparamantenerconectadoatierraelsistemapu1verizador.E~ indispensable revisar la resistencia electrica maxima de las manguerasdeaireydefluidoporlomenosunavezalasemana.

Si la manguera no tiene una etiqueta en la cual se especifica la resistencia electrica, ponerse en contact0 con el proveedor o fabricante de la manguera para la informacidn sobre 10s limites de resistencia. Usar un metro de resistencia en la gama apropiade para comprobar la resistencia; si excede 10s limites recomendados, reemplazarladeinmediato. Esmuyarriesgado tener una manguera sin puesta a tierra 0 con la puesta a tierra en malas condiciones. Leer tambien la information sobre

RIESGO DE INCENDIO 0 EXPLOSION, m&s arriba.

PELIGRO DE INCENDIO 0 EXPLOSION

El flujo a altavelocidad del fluid0 al pasar por la bomba y manguera crea electricidad estatica. Si todas las partes del equip0 pulverizador no tienen buena tierra, pueden ocurrir chispas, convirtiendo al sistema en algo peligroso. Tambien, pueden producirse chispas a enchufar o desenchufar el cordon electrico. Estas chispas pueden inflamar losvapores de 10s solventes yelchorrodefluidopulverizado,particulasdepolvoyotrassus- tancias in flamables, sea al aire libre o bajo techo, lo que podria causar una explosion o incendio y graves lesiones corporales y daiios al a propiedad. Enchufar siempre la pulverizadora a un tomacorriente que se encuentre a por lo menos 6 m (20 pies) de la maquina y del area que se va a rociar.

Si ocurre una chispa de electricidad estatica o incluso un ligero choqueelectrico mientras se usael equipo, dejar de pulverizar de inmediato. Revisar todo el sistema en busca de una tierra apropiada.Nousardenuevoelsistemahastahaberidentificado y solucionado el problema.

Peusta a tierra

Para reducir el reisgo de chispas estaticas, conectar a tierra la pulverisadora y todo el otro equip0 de pulverisar que se use o se encuentre en el lugar que se va a rociar. Consultar el codigo electric0 de la localidad para las instrucciones sobre las conexiones a tierra exigidas para la zona y tipo de equipo. Asegurar de conectar a tierra todo este equip0 pulverisador:

1. Pulverizadora: enchufar et cordon electrico, o cable exten- sor, cada uno un enchuf de t&s patas en buen estado, a un tomacorreinte con puesat a tierra aporpiado. No usar un adaptador. Totos 10s cables extensores tienen que tener tres hilos y una capacidad de 15 amperios.

2. Mangueras para fluidos: usar solamente mangueras con puesta a tierra de una longitud combinada de 150 m (500 tambien al parrafo sobre continuidad a tierra de la manugeura. hate la puesti a tierra conectandola a una manguera de fluid0 y pulverizadora bien conectadas a tierra.

4. Suministrar un recipiente: localidad. de acuerdo al codigo de la de conformidad con el usados durante el lavado, de solamente baldes de metal, que Sean conductivos. no colocar el balde en una superficie no conductiva, coma papel o carton, que interumpe la continuidad a tierra.

7. Para mantenar la continuidad a tierra durante el lavado o descarga de presih, siempre apoyar una parte metalica balde de metal, despues apretar el gatillo.

Seguridad durante el iavado

Para reducir el riesgo de que se inyecte o salpique fluid0 en la piel, o que ocurra una descarga de electricidad estatica, siempre seguir las Instrucciones Para El Lavado, dadas en la pagina. Seguir el procedimlento de descarga de presidn en la pagna 6, y quita la boquilla rociadora antes de lavar.

Apoyar unaparte metalicade la pistola bien firme contra el cos- tado de un balde demetaly usar le presion mas baja posible de fluid0 durante el lavado.

308-248 7

l/4 npsm(m) fluid outlet

Do not install any shutoff device here

Rotate clockwise to increase pressure

Shown in closed or spray position

Fill

A 3

6

Fig.

‘-

67’- v

WARNING

If you suppfy your own hoses and spray gun, be sure the hoses are electrically conductive, that the gun has a tip guard, and that each part is rated for at least 2750 psi (195 bar) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or over-pressuriza- tion and rupture of the hose or gun.

CAUTION

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

1. Always use nylon spray hose at least 50 ft.

(15 m) long.

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

3. Never install any shutoff device between the pump and the hose. See Fig. 1.

02821A

1. Connect the hose (74) and gun (67) and screw it onto the outlet nipple (28). Don’t use thread sealant, and don’t install the spray tip yet!

2. Fill the wet-cup (102). Pry off the wet-cup seal.

Fill the cup l/3 full with Grace Throat Seal Liquid

(TSL), supplied. Install the wet-cup seal.

3. Plug in the sprayer. Be sure the ON/OFF switch

(52) is OFF. Plug the cord into a grounded outlet at least away from the spray area.

4. Check the electrical service. Be sure it is 120 V,

60 HzAC, 15 Amp (minimum). Use a properly grounded outlet. Do not remove the third

(grounding) prong of the power supply cord, and do not use an adapter.

Use a 3-wire, minimum 12 ga (16 AWG), 15 amp extension cord up to 150 ft. (45 m) long. Longer lengths affect sprayer performance.

8 308-248

5. Ground the sprayer and spray system.

WARNING

To reduce the risk of static sparking, ground the pump and all other equipment used or located in the spray area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Ground all of this equipment. a. Sprayer: plug into a properly grounded outlet.

Do not use an adapter. Extension cords must have three wires and be rated for at least 15 amps. b. Fluid hoses: use only grounded hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. See

Hose Grounding Continuity. c. Spray gun: obtain grounding through connection to a properly grounded fluid hose and sprayer. d. Object being sprayed: according to local code.

Setup

e. Fluid supply container: according to local code.

f.

A//

solvent pails used when flushing, accord-

ing to local code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity. g. To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the gun firmly to the side of a grounded metal pail, then trigger the gun.

6. Flush the pump to remove the oil which was left in to protect pump parts after factory testing. See page 14.

7. Prepare the paint according to the manufacturer’s recommendations. Remove any paint skin.

Stir the paint to mix pigments. Strain the paint through a fine nylon mesh bag (available at most paint dealers) to remove particles that could clog the gun filter or spray tip. This is an important step toward trouble-free paint spraying.

Operation

How to use the gun trigger safety,

When locked, the gun trigger safety prevents the gun from accidental triggering. See Fig. 2.

How to use the pressure drain valve.

Use the pressure drain valve to relieve fluid pressure from the pump and to help prime the pump. If the valve senses an over pressure condition, it opens au- tomatically to relieve fluid pressure. If this happens, stop spraying immediately, shut off and unplug the sprayer. Determine the cause of the problem and correct it before operating the sprayer again. Refer also to the Troubleshooting, page 15. See Fig. 3.

Open or drain, position

A

Locked

308-248 9

Operation

How to use the pressure control.

The pressure control controls the motor operation so the sprayer maintains constant fluid pressure at the pump outlet. Turn the pressure control knob fully counterclockwise to obtain the minimum setting. Turn the knob clockwise to increase pressure. See Fig. 4.

The tip guard alerts you to the risk and helps prevent placing any part of the body close to the spray tip.

The tip guard also adjusts the vertical or horizontal spray pattern. See page 12. The tip guard holds a reversing spray tip. The tip is in the spraying position when the tip handle points forward. See Fig. 5.

Clean the front of the tip frequently during the day’s operation. First, follow the Pressure Relief Proce- dure on page 11. before doing this procedure. Unplug the sprayer!

Fig. 4 02824A

How to use the RAC IV tip guard.

WARNING

To reduce the risk of serious injury from from fluid injection:

NEVER operate the spray gun with the tip guard removed.

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

DO NOT try to “blow back” paint; this is NOT an air spray sprayer.

A

Fig. 5

How to remove a tip clog.

1. Releasethe gun trigger. Lock the safety latch. Ro- tate the RAC IV tip handle 180”. See Fig. 5.

2. Unlock the safety latch. Trigger the gun into a pail or onto the ground to remove the clog.

3. Lock the safety latch. Rotate the tip handle to the spraying position.

4. If the tip is still clogged, lock the safety latch, shut off and unplug the sprayer, and open the pressure drain valve to relieve pressure. Clean the spray tip as shown in manual 307-848, supplied.

10 308-248

Pressure Relief Procedure.

WARNING

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

Startup

3. Put the suction hose (32) into the paint. If you are pumping from a pail, push the drain hose (33) down below the top of the pail to avoid splashing paint when the drain valve is opened.

4. Turn the pressure knob (64) to the minimum setting.

5. Unlock the gun trigger safety. See Fig. 2, page

9.

CAUTION

To reduce the risk of damage to the displacement pump packings, never run the pump without fluid in it for more than 30 seconds.


2. Turn the ON/OFF switch to OFF.

3. Unplug the power supply cord.

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


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

If you suspect that the spray tip of hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the the tip guard retaining nut or hose coupling to relieve pressure gradually, then loosen completely.

Startup Procedure.

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

6. To prime the pump, turn the sprayer switch (52) on. Slowly increase the pressure until the sprayer starts. When fluid comes from the pressure drain valve, close the valve. r

WARNING

To reduce the risk of static sparking and splashing when priming or flushing the system, hold a metal part of the gun firmly to the side of a grounded metal pail before triggering the gun.

NOTE: If this is a first-time startup, flush the sprayer.

See page 14.

NOTE: Refer to Fig. 1 and the other figures refer- enced in the text as you start the sprayer.

1. Open the pressure drain valve (42).

2. Don’t install the spray tip until the pump is primed!

7. To prime the hose, lower the pressure to reduce splashing. Hold a metal part of the gun firmly against and aimed into a grounded metal pail.

See the WARNING, above. Hold the trigger open and slowly increase the pressure until the pump starts. Keep the gun triggered until all air is forced out of the system and the fluid flows freely from the gun. Release the trigger and lock the gun trigger safety.

308-248 11

8.

9.

Startup

Check all fluid connections for leaks. Relieve pressure before tightening any connections.

NOTE: Spray patterns will change as tips wear.

Change the spray tip if adjusting the pressure will not improve the spray pattern.

Install the spray tip. Lock the gun trigger safety first! See manual 307-848 for how to install the tip.

10. Adjust the spray pattern a. Increase the pressure just until spray from the gun is completely atomized. To avoid excessive overspray and fogging, and to extend tip and sprayer life, always use the lowest pressure needed to get the desired results. b. If more coverage is needed, use a larger tip rather than increasing the pressure.

C. Test the spray pattern. To adjust the direction of the spray pattern, lock the gun trigger safety and loosen the retaining nut (A). Posi- tion the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern. Hold the tip guard in place while tightening the retaining nut. See Fig. 6.

For a horizontal

12 308-248

Shutdown and Care

1.

9

Check the packing nut/wet-cup daily (102). Re- lieve pressure first. Keep the wet-cup l/3 full of

TSL at all times to help prevent fluid buildup on the piston rod and premature wear of packings.

WARNING

See the warning section HOSE SAFETY on page

3 for information on the hazard of using damaged

2. Tighten the packing nut/wet-cup (102) just enough to stop leakage. Over-tightening causes binding and excessive packing wear. Use a round punch or brass rod and a light hammer to adjust the nut. See Fig. 7.

3. Clean the gun’s fluid filter often and whenever the gun is stored. Relieve pressure first. Refer to manual 307-614.

4. Periodically clean paint residue from the pressure transducer (29) vent hole area. See Fig. 8.

Replace the transducer when leakage is excessive. See page 30.

5. Lubricate the bearing housing after every 100 hours of operation. Remove the front cover. Fill the bearing housing cavity (A) with SAE 10 non- detergent oil. See Fig. 8.

6. Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing. See page 14.

CAUTION

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

Fig. 7

02829A

7. For very short shutoff periods, leave the suction hose in the paint, relieve pressure, and clean the spray tip.

6. Coil the hose when storing it, even for overnight, to help protect the hose from kinking, abrasion, coupling damage, etc.

Fig. 8 02827A

308-248 13

Flushing

When to flush

1. Before using a new sprayer: flush out the 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 as mineral spirits or water.

3. Changing from water-base to oil-base paint: flush with warm, soapy water, and then mineral spirits.

4. Changing from oil-base to water-base paint: flush with mineral spirits, then warm, soapy water, and then a clean water flush.

5. Storage after using water-base paint: flush with water and then mineral spirits. Leave the system filled with mineral spirits. Relieve pressure. Leave the drain valve open.

Storage after using oil-base paint: flush with mineral spirits. Relieve pressure. Leave the drain valve open.

CAUTION

NEVER leave water or water-based fluids in the sprayer if there is a chance it could freeze. Push the water out with mineral spirits. Frozen fluid in the sprayer prevents it from being started and may cause serious damage.

5. To save the paint still in the pump and hose, follow Step 6, except put the drain-hose in the paint pail. When solvent appears, close the drain valve. Put the drain hose in the flushing pail. Trig- ger the gun into the paint pail. When solvent appears, release the trigger. Continue with Step 6.

WARNING

To reduce static sparking and splashing, always remove the spray tip from the gun, and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing. See Fig. 9.

A

6. Lower the pressure setting. Turn on the sprayer.

Maintaining metal-to-metal contact, trigger the gun into the flushing pail. Slowly increase the sprayer pressure just until the pump starts. Keep the gun triggered until the solvent flows freely from the gun. Circulate the solvent to thoroughly clean the sprayer. Release the gun trigger. Lock the gun trigger safety.

6. Startup after storage. Before using water-base paint, flush out the mineral spirits with soapy water and then clean water. When using oil-base paint, flush out the mineral spirits with the paint.

How to flush

1. Follow the Pressure Relief Procedure on page

11.

2. Remove the spray tip and clean it separately.

Remove the filter screen and then reinstall the bowl, hand tight, without the screen. Clean the screen separately. See Fig. NO TAG.

7.

8.

9.

Open the drain valve and circulate the solvent through the drain hose to thoroughly clean it.

Close the drain valve.

Remove the suction hose from the pail. Unlock the gun trigger safety. Trigger the gun and run the pump a few seconds to push air into the hose. Do not run the pump dry for more than 30 seconds to avoid damaging the pump packings! Relieve pressure.

Remove and clean the inlet strainer. Wipe paint off the suction hose and drain hose.

3. Pour one-half gallon (2 liters) of compatible solvent into a grounded metal flushing pail. Put the suction hose in the pail.

10. Refer to When To Flush, Step 1 again. Relieve pressure.

4. Open the pressure drain valve. See Fig. 3, page

9.

11. Leave the drain valve open until you use the sprayer again.

14 308-248

WARNING

Troubleshooting

1

Basic Problem Solving

Check everything in the guide before disassembling the sprayer,

PlPE OF PROBLEM

‘luid pressure dechanical

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK, refer to this column

1. Check pressure control knob setting. The pump 1. Slowly increase pressure setting to see if won’t develop much pressure if it is at minimum motor starts. setting (fully counterclockwise).

2. Check for a clogged spray tip or fluid filter, if used. See page 10.

1. Check for frozen or hardened paint in pump

(20). Using a screwdriver, carefully try to rotate fan at back of motor by hand. See page 19.

2. If tip is still clogged, relieve pressure; refer to separate gun or tip instruction manual for tip cleaning. Clean or replace filter element. See manual 308-249.

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

Ilectrical

2. Check pump connecting rod pin (17). It must be 2. Push pin into place and secure with completely pushed into connecting rod (15) spring retainer. and retaining spring (18) must be firmly in connecting rod groove. See Fig. 18, page 22.

3. Check for motor damage. Remove drive hous- 3. Replace motor (4) if fan won’t turn. See ing assembly (11). See page 28. Try to rotate page 26. motor fan by hand.

1. Check electrical supply with volt meter. Meter 1. Reset building circuit breaker: replace should read 105-125 VAC. building fuse. Try another outlet.

2. Check extension cord for visible damage. Use a 2. Replace extension cord. volt meter or test lamp at extension cord outlet to check.

4. Check motor brushes for the following: a. Loose terminal screws. b. Broken or misaligned brush springs. c. Brushes binding in holders.

4. Refer to page 21. a. Tighten. b. Replace broken spring and/or align spring with brush c. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement. d. Replace brushes e. Replace brushes if less than long. d. Broken leads. e. Worn brushes.

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

NOTE: Thaw sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing in a warm area. Do not try to start sprayer until completely thawed or damage to motor and/or start board may occur. If paint hardened

(dried) in sprayer, the pump packings (page 22) and/or pressure transducer (page 30) must be replaced.

308-248 15

IYPE OF PROBLEM

~IeCtriCal

(continued)

NPE OF PROBLEM

-0w output

Basic Problem Solving

WHAT TO CHECK


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

6. Check motor armature for shorts using armature 6. tester (growler) or perform motor test.

See page 19.

WHAT TO DO


5. Remove motor and have motor shop resurface commutator if possible. See page 26.

Replace motor. See page 26.

7. Check leads from pressure control and motor to 7. Replace loose terminals; crimp to leads. motor start board (47) to be sure they are securely fastened and properly mated.

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

8. Check motor start board (47) by substituting with a good board. See page 27.

8. Replace board. See page 27.

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

9. Check power supply cord (50). Disconnectblack 9. Replace power supply cord. See page and white power cord terminals; connect volt 27. meter to these leads. Plug in sprayer. Meter should read VAC. Unplug sprayer.

10. Check ON/OFF switch (52). Disconnect the “c’ 10. Replace ON/OFF switch. See page 27. wire between motor start board (47) and switch and connect volt meter between exposed terminal on switch and power cord’s white wire.

Plug in sprayer and turn ON. Meter should read

VAC. Turn off and unplug sprayer.

11. Check motor thermal cutout switch. Connect ohmmeter between motor’s red leads. Meter should read 1 ohm maximum.

11. Allow motor to cool. Correct cause of overheating. If switch remains open after motor cools, replace motor.

12. Remove pressure control (64) and check micro- 12. Replace pressure control. See page 30. switch operation with ohmmeter:

(1) With pressure knob at lowest setting and stem pushed into control, readings should be: white & black = 1 ohm max. white & red = open.

(2) With pressure knob at highest setting,readings should be: white & black = open; white & red = 1 ohm max.

13. Check pressure transducer (29) for hardened 13. Replace transducer. See page 30. Thor- paint or damaged or worn components. See page 30. ough system flushing will help extend life of transducer.

Intermediate Problem Solving

WHAT TO CHECK

If check is OK, go to nex? check

1. Check for worn spray tip.

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure then replace tip. See your separate gun or tip manual.

2. Be sure pump does not continue to stroke when 2. Service pump. See page 22. gun trigger is released. Plug in and turn on sprayer. Prime with paint. Trigger gun momen- tarily, then release and lock safety latch. Relieve pressure, turn off and unplug sprayer.

16 308-248

YPE OF PROBLEM

.ow output (continued) lrain valve leaks rransducer leaks


WHAT TO CHECK


WHAT TO DO


3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with pump rod (107). rod (107) fully extended, the piston packings and/or piston valve may be worn.

Service the pump. See page 22.

4. Check electrical supply with volt meter. Meter 4. Reset building circuit breaker; replace should read VAC. building fuse. Repair electrical outlet or try another outlet.

5. Check extension cord size and length; must be 5. Replace with a correct, grounded exten- at least wire and less than 150 ft sion cord.

(45 m).

6. Check motor brushes. See Electrical - What To 6. See page 21.

Check, item 4, on page 15.

7. Check motor start board (47) by substituting with a good board.


CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature can burn out a good board. a. Check motor armature for shorts by using an 6. Replace motor. See page 26. armature tester (growler) or perform motor test.

See page 19.

9. Tighten to 165 in-lb (21 N.m). Clean valve and replace with new gasket (42a) and sealant (42d). See page 32.

1. Slight leakage from transducer is normal. 1. Periodically remove residue from its cyliri-

308-248 17


IYPE OF PROBLEM WHAT TO CHECK


4. Check motor start board (47) by substituting with a good board.

WHAT TO DO

When check is not OK, refer to this column spray pattern variations dotor is hot and runs ntermittently

1. Spray tip worn beyond sprayer pressure capability.

2. Check transducer (29) for wear or damage.

3. Check pressure control (64) for smooth operation.

1. Replace spray tip.

NOTE: A smaller size tip will provide longer life.

2. Replace transducer. See page 30.

3. Replace pressure control. See page 30.

4. Check Low output section, page 17.

1. Determine if sprayer was operated at high pres- 1. Decrease pressure setting or increase tip sure with small tips, which causes excessive size. heat build up.

2. Be sure ambient temperature where sprayer is 2. Move sprayer to shaded, cooler area if located is no more than and sprayer is not lo- possible. cated in direct sun.

3. Check motor. 3. Replace motor. See page 26.

Glding circuit breaker opens 1, Check all electrical wiring for damaged insula- 1. urned on. tion, and all terminals for loose fit or damage.

Also check wires between pressure control and motor. See page 30.

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

2. Check for missing motor brush inspection plate 2. Correct faulty conditions. gasket (see page 19), bent terminal forks or other metal to metal contact points which could cause a short.

3. Check motor armature for shorts. Use an arma- 3. Replace motor. See page 26. ture tester (growler) or perform motor test. See page 19. Inspect windings for burns.


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

:ircuit breaker opens after 1. Check ‘Basic Problems - Electrical’ on

10 page 15.

3uilding circuit breaker

Ipens as soon as sprayer s plugged into outlet and

1. Check electrical supply with volt meter. Meter should read VAC. tightening tightens packings on rod, restricts pump action, damages packings.

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

2. Loosen packing nut. Check for leaking around throat. Replace pump packings, ii necessary. See page 22.

Jnit will not run on gener- 1. Check the generator’s “peak” voltage. This star but does run on AC power

3. Check for damaged motor. 3. Replace motor. See page 26.

4. Check ON/OFF switch (52). Be sure sprayer is 4. Replace ON/OFF switch. See page 27. unplugged! Disconnect wires from switch.

Check switch with ohmmeter. The reading should be infinity with ON/OFF switch OFF, and zero with switch ON.

CAUTION: A short in motor circuit can damage switch and or motor start board (47).

1. Use AC power or a different generator sprayer will not run if the peak voltage is above

19OV

118 308-248

- _-.

Motor Test before doing this procedure. Unplug the sprayer!

For checking armature, motor winding and brush electrical continuity.

Setup

Remove the drive housing. See page 28. This is to ensure that any resistance you notice in the armature test is due to the motor and not to worn gears in the drive housing.

Remove the motor brush inspection covers (A). See

Fig. 11.

Remove the junction box screws (56). Lower the junction box. Disconnect the two leads (C) from the to the board (47). See Fig. il.

motor

Armature Short Circuit Test

Remove the fan cover (6). See Fig. 10.

Spin the motor fan by hand. If there are no shorts, the motor will coast two or three revolutions before com- ing to a complete stop. If the motor does not spin freely, the armature is shorted and the motor must be replaced. See page 26.

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

When turning the fan on a DC motor, normally you sense an even, pulsing resistance. If there is irregular turning resistance, or no turning resistance, check and repair the following as needed: broken brush springs, brush leads, motor leads; loose brush terminal screws or motor lead terminals; worn brushes.

See page 21.

If there is still uneven or no turning resistance, replace the motor. See page 26.

BLACK/

Fig. 11

\

MOTOR

02829A

308-248 19

General Repair Information

I

Tool List

3. Route wires carefully through the drive housing and motor. Avoid pinching the wires between the junction box and the motor or pressure control.

I

Improper wire routing can result in poor sprayer

These are the tools required to service all parts of the sprayer.

4. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair proce- dures. These parts are not normally provided with replacement assemblies.

3/l 6” Allen@ wrench: gear housing, legs, handle

318” Allen@ wrench: pump manifold

#l Phillips@ screwdriver: junction box, pressure control, front cover

3/8” socket wrench: motor mount

5/8” socket wrench: drain valve, outlet fittings, on/off switch boot, piston

13/l 6” socket wrench: drain valve l-l 14” socket wrench: pump in/et valve l/2” open end wrench: pump rod

1 l/l 6” open end wrench: piston jam nut

15/l 6” open end wrench: flats of in/et tube l-3/4” open end wrench: pump jam nut

5164” drive pin: drain valve pin

3” needle nose pliers: wiring, onloffswitch

Hammer & punch: packing nut

Torque wrenches: various fasteners

5.

6.

Test your repair before regular operation to be sure the problem is corrected.

If the sprayer does not operate properly, verify that everything was done correctly. Also refer to the Troubleshooting Guide, pages 15- 19, to help identify other possible problems and solutions.

WARNING

To reduce the risk of serious injury, including electric shock, DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair.

1, When disconnecting wires in the junction box assembly, use needle nose pliers to separate mating connectors.

Shut off the sprayer and unplug it as soon as you complete the inspection.

2. When reconnecting the wires, be sure the flat blade of the insulated mate connector is centered in the wrap-around blade of the female connector.

Reinstall all covers, gaskets, screws and washers before operating the sprayer.

To reduce the risk of a pressure control malfunc-

WARNING

During operation, the motor and drive housing become very hot and could burn your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire or explosion.

20 308-248

Motor Brushes

NOTE: Replace brushes when worn to about 0.5 in.

(12.5 mm) . Always CtleGk both brushes. Bruoh Repair

Kit 236-967 is available for motors manufactured by

Pacific Scientific. Consult Rev. A of this manual for repair kit and instructions if your unit has a Leeson motor.

NOTE: Replacement brushes may last only half as long as the original ones. To maximize brush life, break in new brushes by operating the sprayer with no load as instructed in this procedure.

9. Test the brushes. a. Remove the pump connecting

See Fig. 16, page 22. rod pin (17). b. With the sprayer OFF, turn the pressure control knob fully counterclockwise to minimum pressure. Plug in the sprayer. c. Turn the sprayer ON. Slowly increase the pressure until the motor is at full speed. d. Inspect the brush and commutator contact area for excessive arcing. Arcs should not circle around the commutator surface. doing this procedure. Unplug the sprayer!

1. Remove both inspection covers (A) and their gaskets. See Fig. 12.

10. Install the brush inspection covers and gaskets.

11. Break In the brushes. Operate the sprayer for at least one hour with no load. Install the pump connecting rod pin.

Motor lead; do not disconnect

Fig. 1 2 ME31A

2. Push in the spring clip (F) and release its hook

(G) from the brush holder (6). Pull out the spring clip. See Fig. 13.

3. Slide off the brush lead terminal (E) off the blade connector. Remove the old brush (C). See Fig. 13.

4. Inspect the commutator for excessive pitting, burn- ing or gouging. A black color on the commutator is normal. Have the commutator resurfaced by a quali- fied motor repair shop if the brushes seem to wear too fast or arc excessively. See Step 9.d., also.

5. Repeat for the other side.

NOTE: The motor brushes on the other side are upside down.

6. Place a new brush (C) in the holder (B) so the ramp (H) faces the spring. See Fig. 13.

7. Holding the spring clip (F) at a slight angle, slide the spring clip into the brush holder and hook it over the end of the holder. See Fig. 14. Pull on the spring clip to be sure it stays in place.

8. Repeat for the other side.

Fig. 13

Fig. 14

IJ

\ \

308-248 21

Displacement Pump Repair

To reduce the risk of serious injury, follow the

4. Tighten the packing nut (102) just enough to stop leakage, but no tighter. Fill the packing nut/wet- cup l/3 full with Grace TSL. Push the plug (123) into the wet-cup.

Removing the pump

(See Fig. 15.)

1. Flush the pump, if possible. Relieve pressure.

Stop the pump with the piston rod (107) in its lowest position, if possible. To lower the piston rod manually, rotate the motor fan blades.

2. While pulling upward on the suction hose (32), unscrew the hose from the inlet tube (38). Un- screw the drain hose (33) from the displacement pump nipple (36).

NOTE: If repairing only the intake valve assembly, go to Intake valve repair, page 23.

3. Use a screwdriver to push the retaining spring

(18) up and push out the pin (17).

4. Loosen the screws (21). Remove the pump (20).

lnstailing the pump

(See Fig. 15 and 16.)

1. Mount the pump on the drive housing. Tap it into the alignment pins with a soft hammer. Tighten the screws (21) to 50 ft-lb (68 N.m).

2. Align the hole in the rod (107) with the connecting rod assembly (15). Use a screwdriver to push the retaining spring (18) up and push in the pin (17).

Push the retaining spring (18) into place around the connecting rod.

WARNING

Be sure the retaining spring (18) is firmly in the groove all the way around, to prevent the pin (17) from working loose due to vibration. See Fig. 16.

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

I

3. Replace the o-ring (27) if it is worn or damaged.

Reconnect the suction and drain hoses (32,33).

Install the front cover (13).

Fig. 15

Fig. 16

32’ ,s \:

U

01068

22 308-248


NOTE. Packing Repair Kit is available. Reference

numb&s of included in the kit are marked with an asterisk, i.e., (121*). For the best results, use all the new parts in the kit, even if the old ones still look good.

1. Check the outside of the piston rod (107) and the inside of the cylinder (115) for wear. Replace worn parts ings.

to ensure

a good seal with the new pack-

NOTE: To minimize down time, and for the best sprayer performance, check the motor brushes (see page 21) and clean the transducer (see page 30) whenever you repack the pump. Replace these parts as needed.

2. Stack these parts onto the piston valve (108) one at a time: the backup washer (126*) and u-cup

(125*), the female gland (114*), alternately three plastic (112*) with two leather packings (113*), and the male gland (1 1 1 *). See Fig. 18.

Intake valve repair

(See Fig. 17)

1. Remove the suction hose. See Step 2, Removing the pump.

2. Unscrew the intake valve (118). Remove the o-ring (119*), ball guide (120), stop pin (122*) and ball (121*) from the valve.

3. Clean and inspect the parts for wear or damage.

Replace parts as needed. Use a new o-ring

(119*). If no further service is needed, reassemble the pump.

Disassembling the pump

(See Fig. 18.)

1. Remove the intake valve (118). See page

2. Loosen the packing nut (102) and plug (123).

3. Use a plastic mallet to tap the piston rod (107) down, and then pull the rod out through the bottom of the cylinder.

4. Remove the packing nut (102) and throat packings.

5. Loosen the jam nut (117). Remove the cylinder

(115) and the o-ring (116*).

6. Clamp the flats of the piston rod in a smooth jaw vise. Use an open-end wrench to loosen the nut

(110) and then unscrew the piston valve (108).

7. Remove all parts from the piston valve (108).

Reassembling the pump

NOTE: Alternate plastic and leather packings. See

Fig. 18. The lips of the throat V-packings face down.

The lips of the piston V-packings face up. Incorrect installation damages the packings and causes pump leaking.

NOTE: Soak the leather packings in oil before reassembling the pump.

Fig. 17

a

a 2 Piston packings

A

Intake valve

A

Fig.

OlC67A

308-248 23

Apply one drop of sealant to these threads

Fig. 19


9. Stack these parts one at a time into the top of the manifold (101): the male gland (106*), alternately three plastic packings (104*) with two leather packings (105*), and then the female gland

(103*). See Fig. 21.

01070

10. Install the packing nut (102) and plug (124), but leave loose for now. See Fig. 21.

A

Leather packings

A Poly packings

A

Lips of V-packings must face down

-

A

Lips of V-packings must face up

A ~;;cget; 53 ft-lb

3. Tighten the nut (110) onto the piston valve (108) to 2 in-lb (0.23 N.m). See Fig. 19.

NOTE: Note the alignment of the piston (108) to the nut (110). Maintain this alignment through Step 8.

4. Clean all residue from the piston valve threads. Ap- ply one drop of adhesive, supplied, to the threads.

5. Place the ball (109”) on the piston valve (108).

See Fig. 19.

6. Hand tighten the valve into the piston rod just until the nut (110) contacts the rod. See Fig. 20.

7. Place the flats of the rod (107) in a smooth jaw vise.

8. CAREFULLY tighten the nut (110) against the piston rod to 19 ft-lb (25 N.m). See Fig. 20.

Use two wrenches to maintain the alignment men- tioned in NOTE below Step 3.

A Torque nut against rod to

19 ft-lb (25 N.m) to move relative to piston (108) when

107

110/W

108

01071 Fig. 20 Fig. 21

24 308-248

01073

A Torque jam nut (117) to 73 ft-lb (98 N.m)

A Torque cylirker (115)

53 ft-lb (71 N.m)

A

Torque intake valve (116) into cylinder (115) to

53 ft-lb (71 N.m)

A

Piston assembly


11. Place a new o-ring (116*) firmly groove, See Fig. 22. in the cylinder

,--..

/lo7

12. Coat the piston rod and packings with oil. Care- fully slide the assembly into the top of the cylinder (115). See Fig. 22.

13. Put the manifold in a vise. Fully thread the jam nut

(117) onto the cylinder (115). Guide the rod/ cylinder assembly down through the manifold

(101). Screw the cylinder (115) into the manifold.

See Fig. 22.

14. Place the ball guide (120), stop pin (122) and ball

(121*) in the cylinder (115). Screw the intake valve into the cylinder and torque to 53 ft-lb

(71 N.m). This will also properly torque the cylinder into the manifold. See Fig. 22.

15. Torque the cylinder jam nut (117) to 73 ft-lb

(98 N.m). See Fig. 22.

16. Install the pump. See page 22.

Fig. 22

01072A

308-248 25

1.

2. c

NOTE: See Fig. 25 except where noted.

Relieve pressure.

Try to stop the pump with the piston rod (107) in its lowest position. To lower the piston rod manually, rotate the motor fan blades. Use a screwdriver to push the retaining spring (18) up and push out the pin (17). See Fig. 23.

Motor

9. Align the new motor with the base and reinstall the screws (46).

10. Assemble the drive housing to the motor. Follow steps 8 to 11 on page 28.

11. Connect the wires in the junction box. Refer to

Fig. 26 on page 26. Install the junction box.

12. Connect the piston rod (107) to the drive housing; see page 22, Installing the Pump, Step 2 and the WARNING following it.

15

3.

4.

5.

6.

7.

8.

Remove the screws (56) and lower the junction box (59). Disconnect the motor wires and the pressure control wire (A) from the motor start board. Refer to Fig. 26 on page 26.

Remove the drive housing cover (13).

Turn the displacement pump rod (107) so the pin hole aligns with the bottom drive housing screw

(19). See Fig. 24. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 25.

Remove the two motor screws and lockwashers

(56).

Tap the lower rear of the drive housing (11) with a plastic mallet to loosen the motor. Pull the drive housing straight off the motor while guiding the harness (A) from the motor. Do not allow the gear

(16) to fall. Read the CAUTION on page 28.

Remove the two screws (46) and lift the motor off the base (66).

Fig. 23

Fig. 24

I

18

19,6

01074

A

A

Torque to 80 in-lb (9 N.m)

Quantity of three

Quantity of one

13-

A31?P

26 308-248

r-

WARNING on page 11 before

Motor Start Board

NOTE: See Fig. 26 for this procedure.

1. Relieve pressure.

2. Remove the junction box screws (56) and lower the junction box (59).

3. Disconnect the motor wires (B) and the 3-wire connector (A) from the motor start board (47).

Observe where connections are made.

4. Remove the screws (58) and motor start board

(47). Transfer the white thermal paste from the old board to the new board.

5. Install the new motor start board. Reconnect all wires. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) in installed.

CAUTION

Be sure the flat blade of the insulated male connector is centered in the wrap-around blade of the female connector when the connections are made.

Route all wires carefully to avoid interference with the motor start board or junction box.

These precautions are essential to reduce the risk of a malfunction.

Power Supply Cord




3. Disconnect the power supply cord leads, including the green wire to the grounding screw (49).

4. Loosen the strain relief bushing (51). Remove the power supply cord (50).

5. Install the new cord (50) in the reverse order of disassembly.

6. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) in installed.

On/Off Switch




3. Remove the nut and rubber boot (55).

4. Disconnect the black wires from the ON/OFF switch (52) and remove the switch.

5. Place the ring terminal of the ground wire (53) over the barrel of the new switch. Install the switch so the internal tab of the anti-rotation ring

(54) engages with the vertical groove in the threads of the switch, and the external tab engages with the blind hole (C) of the junction box.

6. Powder the inside of the rubber boot (55) with talcum, then shake the excess out of the boot.

Install the nut and rubber boot and tighten.

7. Reconnect the ON/OFF switch black wires.

8. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) in installed.

89

59

58

5

308-248 27

Drive Housing, Connecting Rod, Crankshaft

c

NOTE: Inspect parts as they are removed. Replace parts that are worn or damaged.

Do not lose the thrust balls (11 a or 4a) or let them fall between the gears, which will damage the drive housing if not removed. The balls, which are heavily covered with grease, usually stay in the gear re- cesses, but could be dislodged. If the balls are not in place, the bearings will wear prematurely.

1. Remove the displacement pump. See page 22.

CAUTION

Do not allow the gear (16) to fall; it may stay at- tached to the drive housing or to the motor.

6. Remove and inspect the crankshaft (12) and the connecting rod (15). 2. Remove the pressure control (64). See page 30.

7. Install the connecting rod.

3. Turn the displacement pump rod (107) so the pin hole aligns with the bottom drive housing screw

(19). See Fig. 27. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 28.

8. Lubricate the inside of the drive housing bearing with SAE non-detergent oil. Pack the roller bearing and gears with the grease supplied. f,

NOTE: The gears and bearings between the drive housing (11) and motor front end bell (C) should contain a total of 3 fl. oz. of grease.

9. Route the wire harness (A) through the motor passages to the junction box (59).

19,6

10. Place the large washer (12a) and then the small washer (12b) on the crankshaft (12).

I

Fig. 27 11. Lift the crank to the top of the stroke and insert crankshaft (12). Align the gears and push the drive housing (11) straight onto the motor and the locating pins. Install the screws (19, 5) and their lockwashers (6). Torque to 80 in-lb (9 N.m).

4. Remove the two motor screws and lockwashers

(5,6). See Fig. 28.

12. Install the displacement pump. See page 22.

5. Tap the lower rear of the drive housing (11) with a plastic mallet to loosen the motor. Pull the drive housing straight off the motor.

13. Install the pressure control (64). See page 30.

Install the front cover (13).

28 308-248

Drive Housing, Connecting Rod, Crankshaft

A

Torque to 80 in-lb (9 N.m)

A Quantity of three

A Quantity of one

A

Apply a total of

A%

Note: Filter not shown

Fig. 28

308-248 29

Pressure Control

7. Loosely install the screws (63) and then torque them to 21 in-lb (2.4 N.m).

To reduce the risk of serious injury follow the

Pressure Relief Procedure on page 11 before doing this procedure. Unplug the sprayer!

8. Install the front cover (13). Connect the harness

(A) to the motor start board (47).


9. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board.

NOTE: The pressure control (64) cannot be repaired or adjusted. If it has malfunctioned, replace it.

I. Remove the front cover (13). Remove the screws

(56). Lower the junction box (59).

2. Disconnect the harness connector (A) from the motor start board (47).

3. Remove the screws (63). Pull forward on the pressure adjusting knob and tip the pressure control

(64) forward and up to detach it from the drive housing (11).

4. Guide the harness (A) through the motor and drive housing and remove the pressure control.

5. Guide the harness of the new pressure control through the drive housing and motor passages.

6. Install the new pressure control. Tip the pressure control down and back into the drive housing

(11). Do not pinch or damage the harness (A).

Fig. 29

Pressure Transducer

02816A


1. Remove the displacement pump. See page 22.

2. Use a pull-twist motion to remove the transducer

(29) from the pump manifold (101).

3. Clean paint residue from the hole in the manifold; do not scratch the surface of the hole.

4. Lightly apply oil to the o-ring of the new transducer.

5. Install the transducer in the pump manifold, while guiding the o-ring and backup ring into place.

6. Align the holes in the transducer as shown by the arrows in Fig. 30.

7. Install the displacement pump. See page 22.

30 308-248

Fig. 30 02817A

Suction Hose

To reduce the risk of serious injury, follow the

1. Remove the drain hose (33) from the clip. Re- move the front cover (13).

2. Pull upward on the hose (32) while unscrewing it from the inlet tube (38). The hose coupling (A) threads will engage and the hose will separate from the tube.

3. Replace the o-ring (27) if it is worn or damaged.

4. Lubricate the o-ring (27) and the inlet tube (38) threads with light grease.

5. Align the suction hose coupling with the threads of the inlet tube (38). Tighten the hose onto the tube at least 4 turns to ensure that the threads have C& enaaged and can function as a swivel joint.

A

Note: Filter not shown

Fig. 31

38’=

02818A

308-248 31

E

42a

Drain Valve

A Apply thread sealant

Repair

1. Unscrew the spring retainer from the valve body.

Remove the spring, washers and stem/ball. Clean any debris from the ball or seat area.

2. If replacing the gasket (42a) or seat (42b), pry out the gasket.

NOTE: Whenever the gasket (42a) is removed, replace it with a new one.

Torque into pump

(21 N.m)

A

3. Coat the o-ring (42d) with grease. Press the stem into the valve body. Install the spring, washers and spring retainer into the valve body.

Fig. 32

1.

2.

3.

Turn the handle (45) to the closed position. Drive out the pin (44). Remove the handle.

Remove the base (43).

A 4

45l

02819

4. Place the seat (42b) in the valve body so the lapped side is toward the ball. Apply a small amount of grease to the new gasket (42a) and install it in the valve body.

NOTE: The gasket will protrude from the end of the valve until the valve is tightened into pump, which correctly seats the gasket.

Replacement

1. Apply a small amount of thread sealant (42e) onto the valve (42) threads. Tighten the valve into the pump manifold to 185 in-lb (21 N.m).

2. Lightly grease the face of the base (43) and install the base. Turn the stem so the pin hole is vertical.

3. Securely install the handle (45) and drive pin (44).

Unscrew the drain valve (42). The gasket (42a) and seat (42b) will stay in the valve.

32 308-248

Parts - Displacement Pump

Model 236-787, Series A

Includes items 101 to 127

Ref

No. Part No. Description

101 187-611 MANIFOLD, pump

102 176-758 PACKING NUT

103* 176-757 GLAND, female, throat

104* 176-997 V-PACKING, plastic, throat

105* 176-755 V-PACKING, leather, throat

106* 176-754 GLAND, male, throat

107 187-613 DISPLACEMENT

108 224-808 PISTON VALVE

109* 105-444 BALL, 5/l 6”, piston

110 176-751 NUT, hex, l/2-20 unf-2b

111* 176-750 GLAND, male, piston

112* 176-882 V-PACKING, plastic, piston

113* 176-749 V-PACKING, leather, piston

114* 180-073 GLAND, female, piston

115 187-634 CYLINDER, pump

116* 108-526 PACKING, o-ring,

119* 11 l-603 PACKING, o-ring,

120 176-760 GUIDE, ball

ROD

PTFE

117 187-614 NUT, jam,l-3/8 18 unef-2b

118 224-966 INLET VALVE

PTFE

121* 105-445 BALL, l/2”, inlet

122” 176-759 PIN, ball stop

123 180-656 PLUG

124* 102-969 SEALANT (not shown)

125 105-522 PACKING, u-cup, polyurethane

126 180- 161 WASHER, backup, steel

127A 188-663 LABEL, Warning

Qty

1

1

1

1

1

3

2

1

1

1

1

1

1

3

2

1

1

1

1

1

1

1

1

1

1

1

1

*116

*Supplied in Repair Kit 235-703.

Keep a repair kit on hand to reduce down time.

Manual Change Summary

112*

118

* Use Motor Brush Kit 235-727 for the old motor 235-968.

Use Motor Brush Kit 236-967 for the new motor 237-458.

*The brush kit replacement instructions on page 21 have changed.

308-248 33

ihM231-208,

30

Parts - Conwlete Sprayer

Series B

HOSE AND GUN NOT SHOW

IN PROPORTION TO SPFiAYE on page 31

67 p+y , REF 33

34 308-248

U

43/

44 A

2

)

2

45

A37

T

8

/25

Parts - Complete Sprayer

4a

4b

4c

4dA

4eA

4fA

5

6

10

11

Ref.

No. Part No. Description

3

4t lla llb

12

12a 180-131

12b 107-434

13

14A

187-789

177-762

15 218-359

16

17

18

19

218-364

176-818

176-817

103-345

20

21

23

24

25

26

27

28

111-700

237-458

29 235-009

34

35

36

37

30

31

32

33

38

39

42

111-602

108-850

187-624

187-652

111-705

188-421

111-612

187-895

187-627

235-004

235-014 loo-069

111-616

107-503

187-784

187-791

187-975 loo-643

105-510

224-965

224-965 loo-069

111-726

224-803

235-699

111-706

111-715

187-631

111-611

235-037

104-938

162-453

42a 111-699

42b 187-615

42~ 224-968

GRIe handle

MOTOR KIT

Includes items 4a to 4g

. BALL, sst, 114” dia.

.TERMINAL, flat, l/4”

(9,

18 awg

.TERMINAL, 3/16” (m), 16 awg

. LABEL, DANGER French

. LABEL, DANGER, English

. LABEL, WARNING, electric shock

SCREW, socket head, l/4-20 x 1”

LOCKWASHER, l/4”

PLUG, l/4 npt

DRIVE HOUSING KIT

Includes item 1 la, 1 lb

. BALL, stainless steel, l/4” dia.

. PLUG

CRANKSHAFT

Includes items 12a, 72b

. BEARING, thrust

. BEARING

COVER, front

LABEL, WARNING

CONNECTING ROD

GEAR REDUCER

PIN, headless, 3/8” dia. x 1”

SPRING, retaining

SCREW, socket head, l/4-20 x 1 -l/4”

PUMP KIT seepartsonpage29

CAPSCREW, 7/l 6- 14 x l-3/4”

SCREW, 5/l 6- 18 x I- l/4”

HANDLE, sprayer

CAP, tubing

LEG, with gusset

O-RING

NIPPLE, hex, l/4 npsm x l/4 npt, i-3/16”

PRESSURE TRANSDUCER

CLIF 3/4”

SCREW, filh, 8-32 x 1 -l/4”

SUCTION HOSE &TUBE

DRAIN HOSE

SCREW, filh, 8-32 x2-1/2”

LABEL KIT, identification

ADAPTER, tube, 9/l 6- 18

LEG, sprayer

INLET TUBE

STRAINER

DRAIN VALVE KIT includes items 42a to 42e

. GASKET, valve seat

. SEAT, drain valve

. STEM, drain valve

QW

1

3

1

1

1

1

1

2

1

1

5

1

2

2

1

1

1

1

3

1

1

1

1

1

1

1

1

1

Ref.

No.

56

58

59

63

52

53

54

55

64

66

67

42d

42e

43

44

45

46

47

48A

49

50

51

68

74

89

Part No.

168-110

110-110

224-807

111-600

187-625

110-997

235-707

186-620

11 O-037

235-010

111-617

105-679

235-035

105-658

105-659

111-703

100-035

187-795

111-704

224- 828

189-932

220-955

206-994

223-541

187-963

Description

.O-RING, stem

. SEALANT, pipe (not shown)

BASE, valve

PIN, grooved, 3/32 x 1”

HANDLE, drain valve

SCREW, washer/hex hd, 5/16”

MOTOR START BOARD includes items 47a to 47~

LABEL, ground terminal

SCREW, math, pnhd, 1 O-24 x 5/8”

POWER CORD SET

STRAIN RELIEF BUSHING,

318-18 npt

SWITCH, ON/OFF

GROUND HARNESS

LOCKING RING

BOOT, switch

SCREW, filh, 1 O-24 x 3”

SCREW, pan hd, 8-32 x 5/16”

JUNCTION BOX

SCREW, filh, lo-24 x l-518”

PRESSURE CONTROL KIT

BASE, motor

CONTRACTOR GUN

See manual 307-614 for parts

TSL, 8 oz. (not shown)

HOSE, grounded, nylon; l/4” ID; cpld l/4 npsm(f); 50 fl (15 m);’ spring guards both ends

GASKET

A Extra warning labels available free of charge.

Qty.

1

1

1

1

1

1

1

1

1

4

2

1

1

1

1

1

2

1

1

1

1

1

1

1

2 t Motor Brush and Spring Replacement Kit,

RN. 236-967 is available. Purchase separately

MOTOR

GREEF

“I

LA

58

308-248 35

Technical Data

Power Requirements . . . . . . . . . , . . . . . . . . , . . 120 VAC,GOHz,

1 phase, 15 amp minimum

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Watt minimum

Working Pressure Range . . . . . . . . O-2750 psi (0 - 195 bar)

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4HP

Cycles/Gallon (liter) . . . . , . . . . . . . . . . . . . . . . . . . , . 164 (620)

Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 gpm (1.90 Ipm)

TipSize . . . . . . . . . . . . . . . . . . . . . . . onegunto0.023newtip with latex at 138 bar (2000 psi)

Power Cord . . . . . . . . . . . . . . . No. 14 AWG, 3 wire, 6’ (1.8 m)

Inlet Paint Strainer . . . . . . . . . . . . . . . . 1525 micron (12 mesh)

Stainless Steel Screen, reusable

Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/2 npt(f)

Fluid Outlet Size . . . , . . , . . . . . . . . . . . . . . . . . . . . . . l/4 npsm

Wetted Parts:

Displacement Pump . . . . . . . Stainless steel, Carbon steel,

Aluminum, Polyethylene, DelrinB, Leather

Filter . . . . . . . . . . .

NOTE: PTFE

Aluminum, Steel, PTFE and Delrin are trademarks of the tainless steel

Company.

Dimensions

Weight (dry w/o packaging) ................

Height ................................

Length ................................

Width .................................

37 lb (17 kg)

19 in. (483 mm)

15in. (381 mm)

14 in. (356 mm)

DANGER LABELS

The English language DANGER label shown on page 1 is also

on your sprayer. If you have paint-

ers who do not read English, order one of the following labels to apply to your these labels for good visibility. sprayer. The drawing below shows the best placement of

Order the labels directly from Grace, free of charge: l-800-328-021 1 App,y other

French 185-956

Spanish 165-961

German 186-041

Greek 186-045

Korean 186-049

English 185-953

The Grace Warranty and Disclaimers

WARRANTY

Grace warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Grace distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Grace will, for a pe- riod of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box on EM and GM sprayers or power train on EH and GH sprayers, which will be repaired or replaced for twenty-four months from the date of sale for Gas-Hydraulic (GH) and Gas-Mechanical (GM) sprayers and for thirty-six months from the date of sale for Electric-

Mechanical (EM), Electric-Hydraulic (EH), 39Ost and 490st sprayers, This warranty applies only when the equipment is installed, operated and maintained in accordance with Grace’s written recommendations.

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

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

DISCLAIMERS AND LIMITATIONS

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

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Grace makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Grace. These items sold, but not manufactured by Grace (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Grace will provide purchaser with reasonable assis- tance in making any claim for breach of these warranties.

36 308-248

Sales Offices:

Foreign Offices:

Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan

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

PRINTED IN U.S.A. November, 1992; Revised December, 1994

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