Graco 230-963 User Manual
INSTRUCTIONS/PARTS LIST
This
manual contains
WARNINGS
READ
AND
RETAIN
IMPORTANT
and
INSTRUCTIONS
FOR
REFERENCE
e
ORACO
507-671
Rev
D
SUPERSEDES
and
PCN
B
A
ULTRA@
400
Hazard
Never use l,l,l-tnchloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
I
such solvents in this
.sion, which could cause death, serious bodily injury and/or substantial property damage.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc
of
Using Fluids Containing Halogenated Hydrocarbons
eauimnent. Such use could result in a serious chemical reaction, with the possibility
of
parts.
explo-
I
INDEX
WARNINGS
INTRODUCTION
SETUP
OPERATION;
SHUTDOWN 8 CARE
FLUSHING GUIDELINES
TROUBLESHOOTING GUIDE
Motor Won't Operate
Low output
No
Excessive Pressure Fluctuations
Motor
Electrical Short
Spin Test
Bridge Test
REPAIR SECTION
General Repair Notes
List of Tools
Power Supply Cord Replacement
Filter Replacement
ON/OFF Switch Replacement
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Output
...............................................
Is
Hot and Runs Intermittently
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...................................... 17
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:
.......
.......................
...........................
2
.
6. 7
9-11
12
12. 13
13
13
14
15
16
17
18
18
19
3
4
5
7
8
Microswitch Replacement
Bridge Rectifier Replacement
Choke Replacement
Varistor Replacement
Circuit Board Replacement
Pressure Control Replacement
Stall Pressure Calibration
Connecting Rod. Drive Housing or Crankshaft
Replacement
Motor Brush Replacement
Motor Capacitor Replacement
Motor Replacement
PARTS LISTS 8 DRAWINGS
Sprayer
Pressure Control
How To Order Replacement Parts
TECHNICAL DATA Back Cover
NOTE:
............................................
..................................................
.......................................
...............................
See manual
displacement pump repair instructions and
parts list
.
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307.793.
supplied. for the
19
20
21
21
22
23
24
25. 26
27
28
29.
30
32.
33
34.
35
33
307-671
1
Read
HIGH
and
understand
PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
FOR
PROFESSIONAL
all
instruction
USE
ONLY.
manuals,
OBSERVE
tags,
and
ALL
warnings
WARNINGS.
before
operating
equipment.
FLUID INJECTION
General Safety
This equipment generates very high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid
through your skin and into your body and cause extremely
serious bodily injury, including the need for amputation. Also,
fluid injected or splashed into the eyes or onto the skin can
cause serious damage.
NEVER point the spray gun at anyone or 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
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
Be sure equipment safety devices are operating properly
before each use.
Medical Alert
If any fluid appears to penetrate your skin, get
MEDICAL CARE AT ONCE.
SIMPLE CUT.
Note
to
Physician: injection
jury.
as possible.
Toxicity
directly into the blood stream. Consultation with a plastic
surgeon or reconstructive hand surgeon may be advisable.
important
It
Is
is
tip
-
Airless
Tell the doctor exactly what fluid was injected.
to
Do
not delay treatment to research toxiciry.
a
concern
HAZARD
guard in place on the spray gun when
~.
~~ ~
with
your hand or body.
Spray
treat the
with
Wounds
DO
in
the skin is a traumatic
injury surgically as
some exotic coatings injected
EMERGENCY
NOT TREAT AS A
in-
soon
Spray Gun Safety
Be sure
each use. Do not remove or
can cause
Safety
Whenever you stop spraying, even for a moment, always set
the gun safety latch in the closed or “safe” position, making
the gun inoperative. Failure to set the safety latch can result
accidental triggering of the gun.
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
injection when the tip is not installed. Check diffuser operation
regularly. Follow the Pressure Relief Procedure, below,
then remove the spray tip. Aim the gun into
holding the gun firmly to the pail. Using the lowest possible
pressure, trigger the gun. If the fluid emitted is not diffused
to an irregular stream, replace
Tip
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 accidental
ly placing your fingers or any part of your body close to the
spray tip.
Spray
Use extreme caution when cleaning or changing spray tips.
the spray tip clogs while spraying, engage the gun safety latch
immediately. ALWAYS follow the Pressure Relief Pro
cedure and then remove the spray tip to clean
NEVER wipe
fully relieved
all
gun safety devices are operating properly before
a
malfunction and result
Latch
Guard
Tip
Safety
off
and the gun safety
Devices
modify
any part of the gun; this
in
serious bodily injury.
the diffuser immediately.
build-up around the spray tip
latch is engaged.
a
it.
until
in
metal
pail,
in-
pressure is
-
If
-
~~
Pressure
To reduce the risk of serious bodily injury, including fluid injection, injury from splashing fluid or solvent
skin, moving parts or electric shock, always follow this procedure whenever you shut
ing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying.
the gun safety latch.
(51
Hold a metal pan
gun safety latch.
you are ready to spray again.
If
you
steps above, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then
completely. Now clear the
ENGAGE SAFETY
IATCH
Relief
suspect that the spray
Procedure
(21
Turn the ON/OFF switch to OFF.
of
the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.
17)
Open the drain valve, having a container ready to catch the drainage.
tip
tip
or hose
or hose.
TURN
UNPLUG
(31
Unplug the power supply cord.
is
completely clogged, or that pressure has not been
SWITCH
TO OFF
CORD
DISENGAGE SAFETX
ANDTRIGGERQUN:
ENGAGE SAFETY AGAIN
in
off
the sprayer, when checking or servic
(4)
Disengage the gun safety latch.
181
Leave the drain valve open until
fully
relieved after following the
the eyes or on the
(1
(61
Engage the
OPEN DRAIN VALVE
1
-
Engage
loosen
I
I
2
307-671
EQUIPMENT MISUSE HAZARD
FIRE
OR
EXPLOSION HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible
chemicals and fluids, or using
cause them to rupture and result
serious bodily injury, fire, explosion or property damage.
NEVER alter or modify any part of this equipment; doing
could cause
CHECK
worn or damaged parts immediately.
Read and follow the fluid and solvent manufacturer's literature
regarding the use of protective clothing and equipment.
System Pressure
This sprayer can develop
WORKING
accessories are rated to withstand the maximum working
pressure
ing pressure of any component or accessory used in the
system.
Fluid Compatibility
BE SURE that
patible with the wetted parts shown
the back cover.
turer's literature before using them in this sprayer.
it
to malfunction.
all
spray equipment regularly and repair or replace
PRESSURE.
of
this sprayer. DO NOT exceed the maximum work
a11 fluids and solvents used are chemically com
Always read the fluid and solvent manufac
worn or damaged parts, can
in
fluid injection or other
so
,
192
bar
(2750
Be sure that all spray equipment and
psi) MAXIMUM
in
the Technical Data on
HOSE SAFETY
High pressure fluid
hose develops
damage or misuse, the high pressure spray emitted from
cause a fluid injection injury or other serious bodily injury or
property damage.
ALL FLUID HOSES MUST HAVE SPRING GUARDS ON
BOTH
ENDS1 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
pressure fluid can dislodge
pressure spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the
tire hose for cuts, leaks, abrasion, bulging cover, or damage or
movement of the hose couplings.
exist, replace the hose immediately.
high pressure hose or mend
repaired hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULLY. Do
hoses to
are not
DO NOT expose Graco hose to temperatures above
1180°F) or below -4OOC (-4OOF).
Hose
Proper hose grounding continuity is essential to maintaining a
grounded spray system. Check the electrical resistance of your
air and
have a tag on
resistance, contact the hose supplier ormanufacturer for the
maximum resistance limits. Use a resistance meter in the ap
propriate range for your hose to check the resistance. If the
resistance exceeds the
mediately. An ungrounded or poorly grounded hose can make
your system hazardous. Also read FIRE
HAZARD.
move equipment.
comoatible with the inner tube and cover of the hose.
Grounding
fluid
in
the hoses can be very dangerous.' If the
a
leak, split or rupture due to any kind of wear,
connections.securely before each use. High
a
loose coupling or allow high
If
any of these conditions
DO
it
with tape or any other device.
Do
not use fluids or solvents which
NOT try to recouple
not
it
can
en-
pull on
820C
Continuity
hoses at least once a week. If your hose does not
it
which specifies the maximum electrical
recommended limits, replace
OR
EXPLOSION
it
im-
-
A
Static electricity is created by the flow of fluid through the
pump and hose.
properly grounded, sparking may occur, and the system may
become hazardous. Sparking
in or unplugging a power supply cord. Sparks can ignite fumes
from solvents and the fluid being sprayed, dust particles and
other flammable substances. whether you are spraying in
doors or outdoors, and can cause a fire or explosion and
serious bodily injury and property damage. Always plug the
sprayer into an outlet at least
sprayer and the spray area. Do not plug in or unplug any
power supply cords in the spray area when there is any chance
of igniting fumes still in the air.
If you experience any static sparking or even a slight shock
while using this equipment, STOP SPRAYING IMMEDI
ATELY. Check the entire system for proper grounding. Do not
use the system again until the problem has been identified and
corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and
all other spray equipment used or located
CHECK your local electrical code for detailed grounding
-
-
structions for your area and type of equipment, BE SURE to
ground all of this spray equipment:
1.
Sprayer: plug the power supply cord, or extension cord,
each equipped with an undamaged three
a properly grounded outlet. Do not use an adapter. All ex
tension cords must have three wires and be rated for
amps.
2.
Fluid
hoses: use only grounded hoses with a maximum of
500
feet
ing continuity. Refer to Hose Grounding Continuity.
3.
Spray
properly grounded fluid hose and sprayer.
4.
Fluid
supply container: according to local code.
5.
Object being
6.
All solvent pails used when flushing, according to local
code. Use only metalpails, which are conductive. Do not
place the pail on a non
or cardboard, which interrupts the grounding continuity.
7.
To
maintain grounding continuity when flushing orreliev-
ingpressure, always hold a metal part of the gun firmly to
the side of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce the risk of fluid injection injury, static sparking, or
splashing by following the specific flushing procedure given
on page
cedure on page
Hold a metal
and use the
0
If
every pan of the spray equipment is not
may also occur when plugging
6
m
I20
feet) away from the
in
the spray area.
-
prong plug, into
1150
m) combined hose length to ensure ground
gun:
obtain grounding through connection to a
Sprayed: according to local code.
-
conductive surface, such aspaper
of this manual. Follow the Pressure Relief Pro
2,
and remove the spray
part of the gun
lowest possible fluid pressure
firmly to the
tip
before flushing.
side of
a metal pail
during flushing.
in-
-
-
-
15
-
-
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. Unplug the sprayer, and follow the
Pressure Relief Procedure on page
ting accidentally.
2
to prevent
it
from star
-
United States Government safety standards
ticularly the General Standards, Part
1910,
IMPORTANT
have been adopted under the Occupational Safety and Health Act. These
and the Construction Standards, Pan 1926-should be consulted.
standards-par-
307-671
3
Your new Ultra
differently than other airless paint sprayers. This section
will
help
operating
Pressure Control
The pressure control includes an
sprayer, the pressure adjusting control knob, and
pressure sensing device.
motor speed
fluid pressure
Motor
The DC motor has sealed bearings and replaceable
motor brushes.
pump
volume
Working together, the pressure control and motor
cause
pressure demand. When the pump is cycling, the motor
sounds like an automobile starter cranking. When the
pump is not cycling, the motor
until the fluid pressure stabilizes, then the motor will
shut itself off. However, there will
sprayer and
voltage or voltage fluctuations than an AC motor, and
an extension cord of up to
at
at
the pump to cycle whenever there is fluid or
unless you manually shut
Because the motor
"
400
Sprayer functions and operates
you
become familiar with the sprayer before
it.
ONlOFF
Its
function is to control the
so
that the sprayer maintains constant
at
the pump outlet.
Its
function
the rate needed to supply sufficient .paint
the selected pressure.
it
will stay pressurized and ready to use
is
is
to drive the displacement
may hum intermittently
it
off
and relieve pressure.
DC,
it
is less sensitive to low
45
m
(150
switch for the
still
be power to the
feet) can be used.
a
Displacement Pump
The positive displacement, volume
vides equal fluid delivery'on both the up and down
pump strokes. The pump has a wet-cup which, when
filled with Graco Throat Seal Liquid, helps prevent
damage to the throat packings and piston rod.
Fluid Filter
The fluid filter provides the final paint straining to help
avoid clogs in the hose and spray tip. The filter includes
a
reusable element and a drain valve for relieving fluid
pressure when shutting
Hoses
Two grounded, nylon spray hoses with spring guards
are included with the sprayer. The
has
a
114
hose allows flexible gun movement. The nylon hose
material acts
pressure fluctuations.
Spray Gun
Guard
The spray gun includes
prevents accidental triggering when
the WARNING on page
prevents accidental triggering if the gun is dropped. The
Reverse
fluid to remove clogs from the spray tip without remov
ing
it
helps reduce the risk of fluid injection injury.
in. ID. The
as a
&
Reverse-A-CleanTM IV DripLessTM Tip
-A-
Clean
from the gun.
off
0.9
m
pulsation dampener to absorb
a
2)
IV
SwitchTipTM uses high pressure
It
includes a safety tip guard which
-
balanced pump pro
the sprayer.
15.2
m (50foot) hose
(3
foot),
3/16
in. ID whip
trigger safety latch which
and a trigger guard which
it
is engaged (see
-
-
Drive Assembly
The sealed drive assembly transfers power from the
motor to the displacement pump.
4
307-671
DC
SETUP
1.
Connect
Hose
and Gun (Refer
to
Fig
1.)
NOTE:
To avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautlons:
IcAUTioNl
1.
2.
3.
4.
~~
2.
When tightening fittings at the pressure control, hold one wrench firmly on the hex of
the pressure control fitting
rotating. Use another wrench
mating fitting.
a. Remove the plastic cap plug from the filter
outlet nipple and tightly screw the
fluid hose onto the nipple.
b. Tightly connect the whip hose between the
fluid hose and the gun inlet connection.
c. Don't use thread sealant on swivel couplings.
The sealant can prevent the swivel from
rotating freely.
d. Don't install the spray tip
Always use nylon spray hose
m
(50
ft)
Never use a wire braid hose as it
to act
Never install any shutoff device between
the filter and the main hose. See
Always use the main filter outlet for one-
gun operation. Never plug this outlet.
Fill Packing Nutiwet-Cup
Fill
the packing nut/wet-cup
Throat Seal Liquid (TSL), supplied.
long.
as a pulsation dampener.
to
keep
to
15.2
yet1
at
least
is
too rigid
Flg
(See
Fig
1/3
full with Graco
it
from
tighten the
m
(50
ft)
15.2
1.
2.)
3.
Check Electrical Service
a.
Be
sure the electrical service is properly rated
for your sprayer and that the outlet you use
properly grounded.
b. Attach an appropriate plug to the power supply
cord, according
c. Use an extension cord which has
minimum
45
m
(150
sprayer performance.
4.
Plug
in
a.
the Sprayer
Be sure the ONlOFF switch
Fig
3.
Then plug the cord into a grounded elec
trical outlet
spray area.
to
your local electrical codes.
3
12
gauge size, and a maximum of
ft)
long. Longer lengths may affect
at
least 6 m
(20
ft)
wires of
is
OFF. 'Refer
away from the
WARNING
Proper electrical grounding is essential
the risk of fire or explosion which can result in
serious
to the warning section
HAZARD
instructlons.
5.
bodily.injury and property damage. Refer
FIRE
on page 3 for more detailed grounding
Flush the pump to remove the lightweight oil
which was left in to protect pump parts after fac-
tory
testing.
a. Before using water-base paint, flush with
mineral spirits followed by soapy water, and
then
a
clean water flush.
OR
to
EXPLOSION
reduce
Is
a
to
b. Before using oil
spirits only.
c.
See
"
Flushing Guidalines" on page 8 for
flushing procedure.
6.
Prepare the paint according
recommendations.
a.
Remove any skin that may have formed.
b.
Stir the paint
c. Strain the paint through
(available
ticks that could clog the filter or spray tip. This
is probably the
trouble-free spray painting,
-
base painr, flush with mineral
to
the manufacturer's
to
dissolve hard pigments.
5
fine nylon mesh
at
most paint dealers)
mosr
importanr step toward
to
bag
remove par-
307-671
6
~ ~~
OPERATION
Pressure Relief Procedure
WARNING
To reduce the risk of serious bodily injury, in
cluding fluid injection, injury from splashing fluid
or solvent in the eyes or on the skin, moving parts
or electric shock, always follow this procedure
off
whenever you shut
ing or servicing any part of the spray system,
when installing, cleaning or changing spray tips,
and whenever you stop spraying.
1.
Engage the gun safety latch.
2.
Turn the ON/OFF switch to OFF.
3.
Unplug the power supply cord.
4.
Disengage the gun safety latch.
5.
Hold a metal part of the gun firmly to the
side of a grounded metal pail, and trigger
the gun to relieve pressure.
6.
Engage the gun safety latch.
7.
Open the filter drain valve, having a container ready to catch the drainage.
8.
Leave the drain valve open until you are
ready to operate the sprayer again.
Prime the Sprayer
a.
Close the filter drain valve.
b. Don't install the spray tip
c. Put the suction tube into the paint container.
d. Turn the pressure adjusting knob all the way
counterclockwise to the lowest pressure set
ting.
e.
Disengage the gun safety latch.
a
f. Hold
aimed into
Squeeze the trigger and hold
ON/OFF switch to ON, and slowly increase the
pressure setting until the sprayer starts. Keep
the gun triggered until
system and the paint flows freely from the gun.
Release the trigger and engage the safety.
metal part of the gun firmly against and
a
the sprayer, when check-
with
Paint.
yet1
metal waste container.. See Fig
it
open, turn the
all
air is forced out of the
-
Fig
4
3.
Adjusting the Spray Pattern
a.
Increase the pressure adjusting knob setting
is
completely
a
larger tip
4.
just until spray from the gun
atomized.
fogging, and to decrease tip wear and extend
the life of the sprayer, always use the lowest
possible pressure needed to get the desired
results.
b. If more coverage is needed, use
rather than increasing the pressure.
-
c. Test the spray pattern.
of the spray pattern, engage the gun safety and
loosen the retaining nut. Position the tip guard
horizontally for
a
for
nut.
To
avoid excessive overspray and
To
adjust the direction
a
vertical pattern. Then tighten the retaining
horizontal pattern or vertically
is
NOTE: If the pump
4.
2.
Install the Spray Tip and
a.
b. Install the spray tip. If using the RAC
6
307-671
tainer under the drain valve and open the
drain valve. When fluid comes from the
valve, close
safety and proceed
Check
found, follow the Pressure Relief Procedure
Warning, above, before tightening connec
tions.
Be
to manual
installation instructions.
all
fluid connections for leaks. If any are
sure the gun safety latch
307-848,
hard to prime, place a con-
it.
Then disengage the gun
as
Tip
supplied with the gun, for
in Step If, above.
Guard
is
engaged.
IV,
refer
-
4.
Cleaning a Clogged Tip
WARNING
a
To avoid
your hand, body, or
when cleaning or checking
point the gun toward
container when checking to see if the
DO
NOT try to "blow back" paint; this is NOT an
air spray sprayer.
a. Clean the front of the tip frequently during the
b. If the spray tip does clog, release the gun trig-
fluid injection injury,
a
rag in front of the spray tip
a
.the ground or into a waste
day's operation.
Relief Procedure Warning on page
use a solvent-soaked brush to keep fluid from
building up and clogging the tip.
ger, engage the gun safety, and rotate the
RAC
IV
handle
First,
180°.
See Fig
DO
NOT hold
clogged tip. Always
tup
I
S
follow the Pressure
5.
clear.
6.
Then
Fig
5
ENGAGETHE
TRIGGER SAFETY
LATCH
LATCH
TO
BY
TURNING
PERPENDICUI
QUN
BODY
AR
c. Disengage the gun safety and trigger the gun
d., Return the handle to the original position,
e.
SHUTDOWN
1.
Check the packing nutlwet-cup daily. First
follow the Pressure Relief Procedure Warning
on page
all
rod and premature wear of packings. The packing
nut should be tight enough to stop leakage, but no
tighter. Overtightening may cause binding and
cessive packing wear.
hammer to adjust the nut. See Fig
2.
Clean the fluid filter often and whenever the
sprayer is stored. First follow the Pressure Relief
Procedure Warning on page
307-273,
3.
Lubricate the bearing housing after every
hours of operation. Fill the cavity
housing with SAE
4.
Flush the sprayer at the end
and fill
corrosion and freezing.
on page
a
waste container. Engage the gun safety
into
again.
disengage the gun safety, and resume spray-
ing.
if
the tip is stili dogged,
shutoff and unplug the sprayer, and open the
drain valve to relieve pressure. Clean the spray
tip as shown in manual
the RAC
times to help prevent fluid buildup on the piston
IV
DripLess tip guard.
AND
CARE
6.
Be sure the wet-cup is
engage the gun safety,
307-848,
Use
a
screwdriver and light
supplied with
113
full of TSL
6.
6.
Refer to manual
supplied, for the cleaning procedure.
of
10
nondetergent oil.
of
it
with mineral spirits to help prevent pump
See
"
Flushing Guidelines
the bearing
each work day
0.
ex
100
at
-
"
Fig
6
6.
Coil the hose and hang
storing
hose from kinking, abrasion, coupling damage,
Refer to the warning section
page
damaged hoses.
rWARNiNG1
it,
even for overnight, to help protect the
3
for information on the hazard of using
it
on the hose rack when
HOSE
SAFETY on
etc.
chance of fluid freezing in the pump or pressure
control in cold weather, never leave water or any
type of paint in the sprayer when it is not in use.
Freezing can seriously damage the sprayer and
result in loss of pressure or stalling.
5.
For vary short shutoff periods, leave the suction
tube in the paint, follow the Pressure Relief Pro-
cedure Warning on page
tip.
6,
and clean the spray
307-671
7
FLUSHING
When to Flush
1.
New Sprayer. Your new UltraQ
factory tested in lightweight motor'oil which was
left
Before using water-base paint, flush with mineral
spirits, followed by soapy water, and then
water flush.
Before using oil
spirits only. and unplug the sprayer, open the drain valve to
2.
Changing Colors. Flush with*a compatible solvent
such as mineral spirits or water.
3.
Changing from water-base
Flush with soapy water, then
4.
Changing from oil-base to water-base paint.
Flush with mineral spirits, followed by soapy water, spirits with the fluid to be sprayed and the sprayer is
then
How to Flush
1.
Follow the Pressure Relief Procedure Warning
on page
2.
Remove the filter bowl and screen; see manual
307-273
install the bowl without the screen.
GUIDELINES
400
Sprayer was
in to protect pump parts. spirits and leave the pump, hose and gun filled with
a
clean
-
base pain!, flush with mineral
to
oil-base paint.
minera1,spirits.
a
clean water flush. ready to use.
6.
'
supplied. Clean the screen separately and
5.
Storage.
Water
-
base paint: flush with water, then mineral
mineral spirits. Shutoff and unplug the sprayer,
open the drain valve to relieve pressure and leave
open.
Oil-base paint: flush with mineral spirits. Shutoff
relieve pressure and leave open.
6.
Startup after storage.
Before using water
spirits with soapy water and then a clean water
flush.
When using oil
-
base paint, flush out mineral
-
base paint, flush out the mineral
FILTER
BOWL
SCREEN
FILTER
SUPPORT
DRAIN VALVE
SHOWN OPEN
4
Fig
7
3.
Close the filter drain valve.
4.
Pour 2 liters
bare metal pail. Put the suction tube in the pail.
Always remove the spray tip from the gun before
flushing to reduce the risk of a fluid injection in-
IWARNING1
5.
Disengage the gun safety latch.
6.
Point the spray gun into a grounded metal waste
container and with a metal part of the gun firmly
touching the metal container, squeeze the gun trig-
ger.
This procedure helps avoid static sparking
which can cause fire or explosion and splashing.
With the gun triggered, turn the ONIOFF switch to
ON
and slowly
clockwise
gun triggered until clean solvent comes from the
nozzle. Release the trigger and engage the gun
safety latch.
(112
just
gal.) of compatible solvent into a
turn
the pressure adjusting knob
until
the sprayer starts. Keep the
MAINTAIN FIRM
METAL TO METAL
CONTACT WHEN
Fig
8
7.
Check
follow the Pressure Relief Procedure Warning
on page
sprayer, and recheck the connections for leaks.
8.
Remove the suction tube from the pail. Disengage
the gun safety and trigger the gun to force solvent
from the hose.
more than
pressure control. Then turn ON/OFF switch
OFF and engage the gun safety latch.
9.
Unplug the power supply cord. Open the drain
valve and leave open until you
sprayer again. Unscrew the filter bowl and reinstall
the clean screen. Reinstall the bowl, hand tight
only.
10.
If
ing to use a water-base paint, flush with soapy
water followed by
Step
all
fluid connections for leaks. If any leak,
6.
Now tighten the connections, start the
Do
30
not let the pump
seconds to avoid damaging the
are
you have flushed with mineral spirits and are go-
a
clean water flush. Then repeat
run
ready to use the
1.
dry for
to
8
307-671
TROUBLESHOOTING GUIDE
Pressure
To reduce the risk of serious .bodilv
cluding fluid injection, splashing fluid in ihe eyes
or on the skin, or injury from moving parts or elec
tric shock, always follow this procedure whenever
you shut
ing
cleaning or changing spray tips, and whenever
you stop spraying.
1.
Engage the gun safety latch.
2.
Turn
3.
Unplug
4.
Disengage the gun safety latch.
5.
Hold a metal part of the gun firmly to the side of
a grounded metal pail,
relieve pressure.
Relief
off
any part of the spray system, when Installing,
the
Procedure
injury.
the sprayer, when checkingor servic-
ON/OFF switch to
the
power supply cord. then loosen comphely. Nowciearthe tip or hosb:
OFF.
and3rigger the gun to
-
TYPE
OF
PROBLEM
WHAT TO CHECK
If
check is
-
WARNING
in-
OK,
go
6.
Engage the gun safety latch.
7.
Ooen the drain valve. havina a container readv
-
to next check
to
8.
Leave the drain valve open until you are ready
to spray again.
If
you suspect that the spray
pletely clogged, or thatpressure has not been fully
relieved after following the steps above, VERY
SLOWLY loosen the
hose end
~~
catch the drainage.
couolina and relieve oressure araduallv.
WHAT.TO
If
tip
check is
I
tip
or hose
guard retaining nut or
DO
NOT
OK
refer to this column
is
com-
I~~~~
MOTOR
Basic Fluid Pressure Problems
WONT
OPERATE
-
Basic Mechanical Problems
-
Basic Electrical Problems
1.
Check the pressure control knob sening.
The motor
minimum sening (fully
counterclockwise).
2.
Check for a clogged spray tip. Refer
your separate gun or tip instruction
manual.
1.
Check for frozen or hardened paint
the pump (19) andlor pressure control
bourdon tube. Using a screwdriver,
carefully try to rotate fan
motor.
2.
Check displacement pump connecting
rod pin
pushed into connecting rod
spring retainer
groove of connecting rod. See page
3.
Check for motor damage. Remove drive
housing assembly
to
rotate fan bv hand.
1.
Check electrical supply with volt meter.
Meter should read 190-250
will
not run if
See
page
(m).
It
must be completely
(21)
it
is at the
at
15.
should be firmly in
(6).
back of
(91 and
See page
Volts.
25.
in
Try
1. Slowly increase the pressure setting to
see
if
the motor starts.
2.
to
Relieve pressure, refer
gun or tip instruction manual for tip
cleaning.
1.
Thaw'.
Slowly increase pressure setting
motor starts. If
displacement pump packings
manual
pressure control box (3011'. See page
Plug
in
307-793)
to
sprayer
it
doesn't, replace the
andlor replace the bare
23.
2.
Push pin into place and secure with the
spring retainer.
26.
3.
Replace motor I1 1 if
1.
Reset building circuit breaker; replace
building fuse. Try another electrical
outlet.
fan won't turn.
your separate
and
turn
on.
to
(see
see
if
2.
Check extension cord for visible
damage. Use a volt meter or
m
extension cord outlet
3. Check sprayer power supply cord
for visible damage such
sulation or wires.
4.
Check motor brush leads, terminals and
brush length. Brush length should be
14
i
'Thaw the sprayer if water or water-based paint has frozen in
it,
due
to
warm area.
completely. If the bourdon tube was not damaged by the
freezing, the pump should operate. If paint hardened (dried1 in
the sprayer. the pump packings and/or bare pressure control
mum be replaced.
exposure
Do
to low temperatures, by placing
not try to start the sprayer until
See
page
1
23
or manual
mm minimum. See
it
it
307-793.
has thawed
in
to
as
DaQe
a
2.
test
lamp
check.
(311)
broken in
-
Replace extension cord.
3. Replace power supply cord.
See page 18.
4.
lighten terminal screws; replace
brushes. See page
27.
28.
'When replacing the bare pressure control box (item
remove the ONlOFF switch, bridge, circuit board and elec
trical hardware and reinstall these parts in the bare box.
Troubleshooting continued on next page.
307-671
301).
-
9
TYPE
OF
PROBLEM
~~~~~~
WHAT TO CHECK
If
check
Is
OK,
go
to
next check
WHAT TO DO
If
check is
NOT
OK
refer to this column
MOTOR
Diagnosing circuit board
dicator lamps. The normal
condition is red lamp on,
clear lamp
telling
Follow
cedure
gun from hose. Remove
pressure control cover and
check for faulty condition of
circuit board lamps.
Condition A both lamps on;
pump won't operate and
motor is not running
WON7
pump
Pressure Relief
Warning. Remove
OPERATE
on
when board
to
run.
in
Pro-
-
is
I.
Check leads from bridge 1308) to motor
to be sure they are securely fastened
and properly mated.
1.
Check G1 and G2 connections between
circuit board
damage or loose terminals.
3.
Check for loose motor brush lead con
nections and terminals. See page 27.
4.
Check brush length which should be 14
mm minimum.
NOTE also
at the same rate on both sides of the
motor.
5.
Check for broken or misaligned motor
brush springs. Rolled portion of spring
must rest squarely on top of brush. See
page
6.
Check motor brus'hes for binding
brush holders. See page
7.
Check motor armature commutator for
burn spots, gouges and axtreme
rouohness. Remove motor cover and
brush inspection plates to check.
page
27.
27.
(3401
and bridge
See
that
page 27.
the brushes do not wear
27.
1308)
for
in
See
1.
Replace any loose terminals and crimp
to leads. Be sure male terminal blades
are straight and firmly connected to
mating part.
2.
Clean circuit board male terminals.
Replace loose or damaged terminals.
Securely reconnect leads.
3.
-
Tighten terminal screws. Replace
brushes if leads are damaged.
See page 27.
4.
Replace brushes. See page 27.
5. Replace spring
with brush. See page
6.
Clean brush holders. Remove carbon
with small cleaning brush. Align brush
lead with slot in brush holder to assure
free vertical brush movement.
7. Remove motor and have motor shop
resurface commutator if possible. See
page 27.
if
broken. Realign spring
27.
Condition B
Both lamps
off
6.
Check motor armature for shorts using
armature tester (growler) or perform spin
test.
See
page 15.
9.
Check bridge
a good bridge or performing bridge test.
See
page 16.
CAUTION: D
until
armature is determined to be good.
A bad armature will immediately burn
out
a
good bridge.
1. Check electrical supply. Connect
voltmeter to electrical outlet. Meter
should read
2.
Check power supply to circuit board
with sprayer turned ON. Measure
voltage at
read 190
1308)
by substituting with
O
not perform this check
190.250 Volts.
TPl and TP2. Meter should
-
250
Volts.
See page
7.2.
8.
Replace motor. See page
9.
Replace bridge. See page
1. Reset circuit breaker or replace outlet
fuse.
If
to
2. Unplug sprayer. Check continuity of
both poles of ONlOFF switch
TPl to TPZ, and TP2 to TP3.
switch
Check continuity of
TP4 to TP6 and TP3 to TP5. Replace
filter if faulty.
Check
tinuity
Replace cord if faulty.
circuit breaker or fuse continues
open, see "Electrical Short", page 14.
if
faulty.
power supply cord (3111 for
from TP5 to TP7 and TP6 to
29.
20.
(302) from
Replace
RFI
filter (3101 from
con
TP8.
-
10
307-671
3.
Check a11 terminals and wires fog
damage or loose fit.
4.
Check motor thermal cutout switch.
Unplug sprayer. Allow motor to cool.
Disconnect motor thermal switch leads
at
TP9 to TPlO. Use ohmmeter to check
continuity. Switch should
when motor is cool.
be closed
3. Replace damaged terminals and recon
nect securely.
4.
Replace electric motor
close when motor is cool. See page
if
switch does not
-
29.
YPE
OF
PROBLEM
Condition
B
(continued)
Condition
Red
Unplug
C
lamp on, clear lamp
sprayer1
off
WHAT TO CHECK
f
check is
i.
Check microswitch
pressure in the pressure control discon
nect wires TP18 and TP19. Check con
tinuity across switch terminals with an
ohmmeter. Switch contact should be
closed. Depress actuator
audible
have opened. Ohmmeter should read in
finity.
i.
Check circuit board
with a good board. See page
Check circuit board
.
from box
sea
OK,
go
to
next
check
1306).
With no fluid
"click" indicates the contacts
page
wirhout
22
disconnecting wires;
for removal procedure.
bunon. An
(3401
by substituting
(3401
by removing
22.
WHAT TO
If
check
5.
-
-
Replace microswitch. See page 19.
-
3,
Replace circuit board. See page
I.
Replace circuit board.
is
DO
NOT
OK
refer
Sea
to
this colurn
22.
page
22.
WARNING:
while still wired over
detector which could cause the sprayer
.
to over-pressurize, if the microswitch
does not function properly. Tum the
sprayer on
lamp condition, then shut
ly.
WARNING:
tric shock, handle board by edges only1
Do
not allow any metal objects to come
in
contacl with the boardl
Plug in and turn on sprayer. Clear lamp
should be
board over
Turn
!.
Check bourdon tube flag and detector
position. Reinstall circuit board
22.
Turn pressure setting to maximum;
flag should extend
optical detector slot from the bonom.
DETECTOR
Removing the circuit board
-
rides the optical
ONLY
long enough to check
To reduce the risk of elec
on
now - removing the circuit
-
rides the optical detector.
off
and unplug sprayer.
less
than half way into
off
immediate
(see
-
page
-
2.
Calibrate pressure control to
corrects problem.
If
not, replace bare pressure control box
13011'.
See
page
23.
See
page
sea
24.
if
that
'When replacing
circuit
board
and
VIEW
the
bare pressire control box 13011.
elecbical
hardware and
reinstall
C
I
R
C
U
I
T
-
BOARD
OF
OPTICAL DETECTOR AND
remow
the
in
the
ON/OFFswitch,
new bare box.
FLAG
bridge,
Tmubleshooting continued on next
307-671
page.
11
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