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

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

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

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

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

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

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

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

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

Output

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

Is

Hot and Runs Intermittently

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

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

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

...................................... 17

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

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

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

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

:

.......

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

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

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

.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

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.

(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

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

~~

TYPE

OF

PROBLEM

LOW OUTPUT

WHAT

If

1. Check for worn spray tip.

2. Check tinue released. Plug in and turn on sprayer.

Prime with paint. Trigger gun momen tarily, then release and engage safety latch. Relieve pressure, turn unplug sprayer.

3. Check electrical supply with volt meter. Meter should read

4. Check extension cord size and length;

must be at least 12 gauge wire and no longer than 15.2 m

5.

Check G1 and G2 leads from bridge

WX)

or loose wires or connectors. Refer page

6.

Check stall pressure. Refer

Procedure on page 24.

TO

check is

to

CHECK

OK.

go to next check

to

see

that

stroke when gun trigger is

pump does not con

190-250

(150

to

circuit board

22.

off

Volts.

ft).

1340)

for damage

to

Calibration

and

to

WHAT

If

1. Follow Pressure Relief Procedure Warning then replace

separate gun or tip manual.

-

2.

Service pump. See manual 307-793.

-

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

try

4. Replace with a correct, grounded exten

sion cord.

5.

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

6.

Calibrate pressure control. See page 24.

TO

is

DO

NOT

check

another outlet.

OK

refer to this column

tip.

See your

-

ter-

7.

Check bridge terminals sulation and terminals for signs of overheating. See page

8.

Check for loose motor brush leads and terminals. See page

9.

Check for worn motor brushes which should be 14 mm

pBge

27.

10.Check for broken and misaligned motor

brush springs. Rolled portion of spring must rest squarely on top of brush.

11.Check motor brushes for binding

brush holders. See page 27.

12.Check circuit board

with a good circuit board. See page

13.Check motor armature for shorn by us

ing an armature tester (growler) or per form spin

14.Check bridge

a good bridge or by performing the bridge test. See page 16 or CAUTION: until armature is determined A bad armature out

a

good bridge.

(308)

+

to

motor. Inspect

and - leads and

20.

27.

(9/16) minimum. See

1340)

test.

See

page 15.

(308)

by substituting with

Do

not perform this check

will

immediately burn

wiring

in

-

in

by substituting

22.

20.

to

be good.

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

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

8.

Tighten terminal screws. Replace

brushes if leads are damaged. See page

blades are

27.

9.

Replace brushes. See page

10.Replace spring if broken. Realign spring

with brush. See page

11 .Clean brush holders, remove carbon

dust with small cleaning brush. Align brush lead with

assure free vertical brush movement.

12.Replace circuit board. See page

-

13.Replace motor.

-

14.Repiace bridge. See page

27.

slot

in brush holder

See

page

29.

20.

27.

to

22.

NO OUTPUT

Motor runs and pump stroke:

307-671

1.

Check paint supply.

2. Check for clogged intake strainer.

3. Check for loose suction tube or fittings.

1. Refill and reprime pump.

2.

Remove and clean, then reinstall.

3. Tighten; use thread sealant or sealing

tape on threads if

necessary.

TYPE OF PROBLEM

NO OUTPUT

(Continued)

WHAT TO CHECK

If

check is

,

Check to see piston ball are seating properly. manual 307-793.

.

Check for leaking around throat packing nut which may indicate worn or damag ed packings.See manual 307-793.

OK,

go

to next check

if

intake valve ball and

See

-

WHAT TO

If

check

,.

Remove intake valve and clean. Check balls and seats for nicks; replace if necessary. See manual

#.

Replace packings. See manual 307-793. Also check piston valve seat for harden

ed

paint or nicks and replace

necessarv.

is

DO

NOT

OK

refer to this column

307-793.

if

-

Motor runs but pump does not stroke

EXCESSIVE PRESSURE FLUCTUATIONS

Spray panern variations.

.

Check displacement pump connecting

pin.

See

rod

,

Check connecting rod assembly for damage. See page 25.

.

Be sure crank

plug

in

to check. Turn

See

page 25.

.

Be sure both G1 and G2 leads from bridge

firmly

'.

Check stall pressure. Refer to Calibration procedure on page 24.

i.

Check bourdon tube flag and detector position. Turn pressure sening to max imum; flag should not drag or bind optical detector slot of circuit board.

page 26.

in

sprayer and turn on momentarily

1308)

connected. See

drive housing rotates;

off

and unplug sprayer.

to circuit

board

page

r

CIRCU'TBoARD

22.

13401

are

"

in

.

Replace pin if missing. Be sure retainer spring is fully in groove connecting rod. See page 26.

!.

Replace connecting rod assembly. See page 25.

i.

Check drive housino assemblv for damage and page

25.

.

Reconnect securely. See page

I.

Calibrate pressure control. See page 24.

I.

Carefully bend flag into alignment with

-

detector slot to see if that corrects pro

blem.

If not, replace bare pressure control assembly trol after reassembly.

replac; if necessary.

(3011'. Calibrate pressure con-

a11 around

See

22.

-

MOTOR IS HOT

e

RUNS INTERMllTENTLY

OPTICAL

OPTICAL DETECTOR

DETECTOR

FLAG

VIEW

OF OPTICAL DETECTOR AND FLAG

I.

Check circuit board with a good board. See page

i.

Check

LOW

12.

.

Check to operating at high pressure with small tips, which causes low motor RPM and results

I.

Check to where sprayer is located is more than

32%

direct sun.

!.

Check to stalled condition [sprayer turned on, pressurized, but not operating) for long periods of

see

in

excessive heat build up.

see

(90°F)

or

see

time.

(3401

by substituting

22.

OUTPUT section on page

if

sprayer has been

if ambient temperature

if

sprayer

if

sprayer has been left in a

is

located

I.

Replace circuit board. See page

I.

Decrease pressure sening or increase

size.

!.

Move sprayer

in

possible.

1.

Turn

off

spraying for

pressure.

to shaded, coolel ' area if

sprayer whenever you stop

awhile and relieve fluid

22.

tip

307-671

13

TYPE

OF

PROBLEM

ELECTRICAL SHORT

Buildino circuit breaker ooens as

sooi

turned on.

as sprayer switch

is

CAUTION

Any short in any part of motor power circuit, which connected to the output sidc of the bridge, will cause bridge to burn out immediate

ly. Correctly diagnose anc

repair all shorts before ing and

replacing

thf

check,

bridge

WHAT TO CHECK

If

check

is

OK,

go

to

next check

Check all electrical wiring for damaged

insulation, and all terminals for loose or damage. Be sure to check wires ween pressure control and motor which are encased in conduit

141

I.

29.

i$

,

Check for missing inspection plate

gasket

(see page

or other metal to metal contact points which could cause a short.

Check motor armature for shorts by us

ing an armature tester (growler) or per

form spin test. See page

windings for bums.

,

Check bridge

a good bridge

test.

See page

27).

bent terminal forks

15.

(3081

by substituting with

or

by performing bridge

16.

bet-

See page

Inspect

WHAT TO DO

If

check

Is

NOT

OK

umn

refer to this

1.

Repair or replace any damaged wiring or

fit

-

terminals. Securelv reconnect all wires.

2.

Correct faulty conditions.

3.

Replace motor. See page

4.

Replace bridge. See page

29.

20.

col

-

Building circuit breaker opens

as soon as sprayer is plugged

into outlet and sprayer is

turned on.

NO1

CAUTION:

until armature is determined to be

A bad armature will immediately burn

out a good bridge.

Check 'Basic Electrical Problems' on

page

Check ON/OFF switch

19.

Be

Disconnect wires from switch and check switch with ohm meter. The ohm meter should read switch OFF, and zero with the switch

ON.

CAUTION:

will burn the bridge out immediately, which in turn usually causes the ONlOFF switch

Do

not perform this check

9.

sure

the

sprayer

infinity

with the ONlOFF

A short

to

fail in the closed mode.

in

good.

1302)

See page

is

unplugged!

the motor circuit

2.

Replace ON/OFF switch. See page

19.

14

307-671

~_____~

~

SPIN

TEST

WARNING

Before doing this procedure, follow the Pressure

Relief

the risk of in the eyes or on the skin, injury from moving Darts. or electric shock.

~~~ ~~

For checking armature, motor winding and brush elec

trical continuity.

Setup Remove the drive housing from the sprayer as des cribed in Steps

Remove the pressure control cover and screws, !he motor cover, the fan cover (F), and the inspectton covers

Disconnect the

(308).

Armature Quickly turn the motor fan by hand.

shorts,

before coming to a complete stop. If the motor does not spin freely and resists rotation, the

armature See page

Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity)

Connect the lead.

Turn the motor fan by hand per second.

If there following: leads;

e)

Repair parts as needed. See page If there

the motor. See page

Procedure Warning on page

a

fluid injection injury, splashing fluids

17

to reduce

1

1-9,

page

25.

IJ).

See Fig

See

Fig

Short

the motor will coast

is

shorted and the motor must be replaced.

29.

two

is

uneven or no turning resistance, check the

a)

c) loose brush terminal screws; d) worn brushes;

broken motor leads;

is

still uneven or no turning resistance, replace

9.

two

leads from the motor to the bridge

10.

Circuit Test

If

there are

two

or three revolutions

black motor leads together with a test

at

about

two

revolutions

broken brush springs;

f)

loose

b)

broken brush

motor lead termlnals.

27.

29.

no

-

Fig

9

307-671

15

BRIDGE

TEST

Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional. See Bridge Rectifier Replacement, page continuity tester, such ohms scale

Eight individual checks, or tests, must be performed. the bridge fails even one test,

Fig

11

ing the chart dicated by the black dots for each test, then check the continuity.

In Tests 1,

In Tests indicated, check continuity, connections and check continuity again. get

NO

other way.

In Tests 7 and

by

the black dots. Touch the indicated meter wire, and then the other. tinuity one way, and

(

n

shows the position of the wires on the bridge.

at

the right, connect the meter wires

2

and

4, 5 and

continuity one way, and

6,

8.

as

multi-meter set on the X1

).

it

must be replaced.

3,

there should be

connect the + and - meter wires

then.switch the meter wire

NO

YES

connect the meter wires

You

YES

continuity the other way.

should get

20.

Use

as in-

continuity.

You

continuity the

"G"

should

as

indicated

wire to one

NO

If

Us

as

con

a

BRIDGE

WIRES

-

Fig

11

16

307-671

GENERAL

REPAIR

NOTES

WARNING

Pressure Relief Procedure

To'reduce the risk of serious bodily injury,

cluding fluid injection, splashing fluid in the eyes or on the skin, or injury from moving parts or elec tric 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.

1 .Engage the gun safety latch.

2 .Turn the

3

4 .Disengage the gun safety latch.

5

6

7 .Open the drain valve, having a container ready

8

If

pletely clogged, or that pressure has not been fully relieved after following the steps above, VERY

SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the

Tool

The following tools are needed when repairing this sprayer.

Phillips screwdriver

Small flatblade screwdriver

Needle nose pliers Plastic mallet

Adjustable wrench

2

"

adjustable, open-end wrench

Torque wrench

114"

3/16

518"

318"

112''

314"

718"

High quality motor oil Bearing grease

For calibration procedure only:

318

0.015'

High pressure, oil

5

gallon pail Clean water Mineral spirits NEW

Part

Before repairing any part of the sprayer, read the ing

general repair notes and the repair procedure. Be

sure you have the necessary tools and parts available.

off

the sprayer, when checking or servic:

ONIOFF switch to OFF.

.Unplug the power supply cord.

.Hold a metal part of the gun firmly to the side of

a grounded metal pail, and trigger the

relieve pressure.

.Engage the gun safe& latch.

to catch the drainage.

.Leave the drain valve open until you are ready

to spray again.

you suspect that the spray

List

hex key wrench

"

hex key wrench socket wrench open end wrench

end wrench

open

end wrench

open open end wrench

ignition wrench

spray tip

207

bar

No.

-

(3oM)

214-915.

filled test gauge, Part No. 102-814

psi) high pressure spray hose,

tip

or hose

tip

in

gun

to

is

com

or hose.

follow-

-

1.

When disconnecting wires assembly, use needle nose pliers to separate mating

connectors.

When reconnecting the wires, be sure the flat blade

of the insulated male connector is centered

-

around blade of the female connector when

wrap the connection is made.

in

the pressure control

CAUTION

tion, be sure to properly mate connectors, and never pull on a wire to disconnect wire could loosen the connector from the wire.

2.

Route wires in the pressure control assembly carefully through the legs of the U tube, where appropriate, to avoid interfering with the bourdon tube which moves as the pressure set ting changes and to avoid pinching the wires be tween the pressure control box and cover.

it.

Pulling on a

-

shaped bourdon

CAUTION

Improper wire routing can result performance or damage to the pressure control.

3.

Keep

all trical fittings removed during repair procedures. These parts are not normally provided with replace ment assemblies.

4.

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

If the sprayer does not operate properly, review the

repair procedure again to verify that everything was done correctly. If necessary, refer to the Troubleshooting Guide, pages other possible problems and solutions.

To reduce the risk of serious bodily injury, in cluding electric shock, DO NOT touch any moving parts or electrical parts with your fingers or a tool while

Shut

complete the inspection.

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

FWARNlNGl

screws, nuts, washers, gaskets, and elec

inspecting.the repair.

off

the sprayer and unplug

in

poor sprayer

9-16,

to help identify

it

as soon as you

CAUTION

Do not run the sprayer dry for more than

seconds to avoid damaging the pump packings.

5.

Reinstall the motor cover before regular operation of the sprayer and replace cover directs cooling air around the motor to help

prevent overheating. fire or explosion; see the WARNING, below.

it

if

it

is damaged. The

It

can also help prevent burns,

WARNING

During operation, the motor becomes very hot

and could burn your skin if touched. Flammable

materials spilled on the hot, bare motor could cause a fire or explosion. Always have the motor cover in place during regular operation to reduce

the risk of burns, fire or explosion.

in

the

-

30

307-671

17

POWER SUPPLY CORD REPLACEMENT

WARNING

Relief Procedure Warning on page 17 to reduce the risk of eyes or on the skin, injury from moving parts, or electric shock.

a

fluid injection injury, splashing in the

follow the Pressure

(See

Fig 12

Et

131

1. Use the

(337)

2.

Use screws (651 holding the pressure control to the frame.

3. Remove the pressure control mounting bracket using a Phillips screwdriver.

4.

Disconnect the power supply cord wires from the

control box terminal strip

5. Install the new power supply cord reverse order of disassembly.

Install

sure,to follow olua to use.

.I

FILTER REPLACEMENT

19

mm open end wrench to remove the nut

from the filter stud (310).

the

13 mm socket wrench to remove the

(336) using a screwdriver.

a

new plug on the other end

all

local codes regarding the type of

(See Fig 12)

of

(3111 in the

the cord. Be Fig

WARNING

Before doing this procedure, follow the Pressure

Relief

Procedure Warning on page 17 to reduce

a

the risk of eyes or on the skin, injury from moving parts, or

fluid injection injury, splashing in the

two

(50)

12

1. Remove the pressure control cover and screws.

2.

Use

a

needle nose pliers to remove the four wires

from the filter (3101.

3.

Use the lockwashers pressure control box.

4.

Remove the old filter and install a new one in the reverse order of disassembly.

M8

wrench to remove the lower nut and

(337,

338)

on the outside of the

Fig

13

18

307-671

ON/OFF SWITCH REPLACEMENT

(See Figs 14

WARNING

Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce

a

the risk of eyes or on the skin, injury from moving parts, or

electric

1. Remove the pressure control cover and screws.

2. Remove the wires attached to the switch

TPl and TP2, using a screwdriver. See page

21.

3.

Use a 16 mm socket wrench to loosen and remove

the nut and rubber boot

pressure control box. Remove the switch guard

(304).

4. Remove the ONIOFF switch.

5. Remove the wires attached to the switch TP4 and TP3 using a screwdriver. See page

6. Attach the wires to TP4 and TP3 of the new switch.

7. Install the new switch

rotation ring

in

the threads of the switch, and the external tab engages trol box.

8.

Install the switch guard (304). aligning the internal

tab with the groove

9. Powder the inside of the rubber boot talcum, then shake excess out of boot.

10. Install the nut and rubber boot and tighten.

11. Reconnect the wires to

12. Reinstall the pressure control cover and screws.

fluid injection injury, splashing

shock.

(303)

so

the internal tab of the anti-

(W)

engages with the vertical groove

with

the blind hole

in

(D)

the threads.

TP1 and TP2.

from the top of the

of the pressure con-

22,

Fig 21.

in

the

(302) at

22,

(303)

Fig

with

Et

15)

Fig

14

MICROSWITCH REPLACEMENT

Before doing this procedure, follow the Pressure

Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing eyes or on the skin, injury from moving parts, or

1. Remove the pressure control cover and screws.

2. Disconnect both wires from the microswitch

3. Use the socket wrench to remove the nuts from the microswitch.

4. Check to see if the flag

the

fluid

pressure is 0 bar two 6 mm hex nuts behind the microswitch. Adjust the distance from the top of the flat to top inside the pressure control box to 40.79k 0.254 mm

(1.606*

the dimension. Refer to Fig 1.

5. Perform the on page 24 before regular operation of the sprayer.

6. Reinstall the cover

0.010

in.).

STALL

(X)

is loose. If

(0

Tighten the screwsand recheck

PRESSURE

and

screws.

(See Fig 15)

in

the

(3061.

it

psi), then loosen the

is, be sure

of

CALIBRATION

Fig

15

307-671

19

BRIDGE RECTIFIER REPLACEMENT

(See

Fig 161

WARNING

Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce

in

at the ap

(50).

nut

(332).

the

1

Then

/N

the risk of a fluid injection injury, splashing eyes or on the skin, injury from moving parts or electric shock.

~ ~~~ ~~ ~~

1.

Remove the pressure control cover and screws.

2.

Disconnect all wires from the bridge propriate terminals.

~~

3. Outside the pressure control box on the right side are

two

screws screw near the back mounting plate loosen and remove the front screw. Slide the bridge out.

4.

Slide the new bridge

the lockwasher

FRONT

5.

Install the front screw, lockwasher and

(331).

Loosen,

(333)

of the bridge. Refer to the Detail in Fig 16.

on the rear screw (331) is

but don't remove the

(308)

into the box being sure

(3081

.

The lockwashers bridge to avoid overheating which bridge failure. Refer to the Detail

6. Make sure the bridge is flush with the side of the box and tighten the screws securely.

7. Connect all wires. Carefully route the wires.

-

I-

Be sure the flat blade of the insulated male nector is centered in the wrap

female connector when the connections are made. Improper connections may cause the sprayer to malfunction.

Ro'ute all wires carefully to avoid interference with

the movement of the bourdon tube, circuit board, or control box cover which could cause a

8.

Reinstall the pressure control cover and screws.

CAUTION

(333)

must be in front

CAUTION

of

will

in

Fig 16.

-

around blade of the

the

result

con-

malfunc-

in

Fig

20

16

307-671

BRIDCE

INSTALLATION

DETAIL

CHOKE REPLACEMENT

1. Remove the pressure control cover and screws.

2. Remove the grounding screw lead. Loosen the appropriate screw on the terminal

strip (336) and

lead.

Use

3.

4.

the M8 wrench lockwasher pressure control box.

Remove the old choke (309) and install a new one in

the reverse order of disassembly.

discornect the yellow/green choke

(337,

(See

Fig 17)

(312) and remove the

to

remove the upper nut and

US)

on the outside of the

Fig

17

VARISTOR

Relief Procedure

the risk of a fluid injection injury, splashing in the

eyes

1.

Remove the control box screws and cover. Remove the

'

2. harnesses ONlOFF switch

Trim the leads on the new varistor

3.

(1-118 in.). Turn each lead outward to form a loop

that through.

Place

4.

loop

the screws into the switch.

5.

Wrap the varistor under the switch.

REPLACEMENT

WARNING

Warning on page 17 to reduce

or on the skin, injury from moving parts, or

two

screws

(318, 319) and the old varistor from the

(See

Figs 18 8 19)

(A$).

(302).

(339)

is

large enough for the screws

a

wiring harness on each screw, then place

of

the varistor leads on each screw and thread

(A,

the wiring

to 28.5 mm

8) to pass

a

n

FRONTVIEW

n

SIDEVIEW

307-671

21

CIRCUIT BOARD REPLACEMENT

(See

WARNING

Before doing this procedure, follow the Pressure Relief Procedure Warning on page

the risk of a fluid injection injury, splashing

eyes or on the skin, injury from moving parts, or electric shock.

1.

Remove the pressure control cover and screws.

2.

Turn the pressure control knob all the way counter

clockwise to the minimum setting to release spring tension on the board. three or four threads shaft are exposed below the pressure adjustment nut

(SI.

Be sure

Back down the nut, if necessary.

to

unolua

Also

check to be sure only

of

the pressure control knob

17

to reduce

rhe soraverl

20.

Step 2 is essential to reduce the risk of damaging

the circuit board while removing

IcAuTloNl

3.

Disconnect

two

heavy black wires. Pay close attention

connections are made.

4. To

5.

6.

remove the board from the box, pull out the

-

black plastic-tipped pin the circuit board toward the wall of the box and carefully slide the board out.

Install the board was removed.

Reconnect all wires. Refer to the wiring diagram Fig

21.

ALL

wires from the board, including the

See

(330).

in

the box at the Same angle as

or

Fig

21.

Push the

installing

.

bottom

Figs

in

See

it.

to

20

the

Fig

where

of

in

8

21)

rClRCUlT

-

Fig

P

BOARD

r

PRESSURE CONTROL

KNOB

CAUTION

Be sure the flat blade of the insulated male con- nector is centered exactly blade of the female connector when connections are made.

it

Route all wires carefully to avoid interference the circuit board, bourdon tube and pressure con trol cover.

These precautions are essential to reduce the risk of malfunction.

in

the wrap-around

with

-

7.

Perform the on page

STALL

24

if you installed a new board.

PRESSURE

CALIBRATION

Fig

22

21

307-671

TP8

TP7

PLUQ

PRESSURE CONTROL REPLACEMENT

the risk of a fluid injection injury, splashing in the

1. Disconnect the main fluid hose (72) and the secon

dary fluid hose, if used, from the sprayer.

(23)

2. Disconnect the fluid hose displacement pump outlet nipple control inlet elbow

3.

Loosen the filter bracket nut using a 19

4.

Hold the pressure control adapter (315) firmly with

a

19

wrench to loosen the swivel union

remove the fluid filter

5. Remove the pressure control cover and screws, and disconnect the four motor leads at the appropriate

terminals.

6. Refer page

7.

Remove the conduit (41

8.

Use

remove the pressure control mounting screws 165) and washers trol box. Remove the box.

9. Install the new pressure control assembly reverse order of disassembly.

mm

open end wrench.

to

CIRCUIT BOARD REPLACEMENT

22,

remove the circuit board and retain.

a

13 mm open end wrench to loosen and

(314).

open end wrench.

(53).

1.

(64)

located below the pressure con

from between the

(22)

and pressure

(63)

and washer

Use

an adjustable

(52).

in

(62)

then

on

the

CAUTION

-

Fig

22

-

stalling the new pressure control assembly. Turn

ing

it

can damage the sensitive bourdon tube.

with

Hold the adapter firmly

10.

Perform the starting on page 24, before regular operation of the sprayer.

STALL PRESSURE CALIBRATION

a 19 mm open end

-

307-671

23

~ ~~

STALL

I

Calibration Setup

1. Follow the Pressure Relief Procedure Warning

2. Remove the pressure control screws and cover.

3. Remove the plug from the top of the

4. Place the pump suction tube

PRESSURE

USE EXTREME CAUTION

fluid injection injury or other serious bodily injury which can result from splashing, component rupture, electric

shock, fire, explosion, or moving parts.

This procedure sets the sprayer to 192 bar (2750 psi)

MAXIMUM WORKING PRESSURE. This procedure

must be performed whenever a

board, or pressure control assembly is removed and reinstalled or replaced, to be sure the sprayer is pro perly calibrated.

Improper pressurize

explosion. taining the maximum working pressure which would result in poor sprayer performance.

on page 17. Remove the spray hose and gun. Install a

new

outlet.

install the test gauge

clean water.

calibration can

and result

It

may also prevent the sprayer from ob

0.015' spray tip in the gun. Connect the gun

test hose and connect the hose to the sprayer

CALIBRATION

WHEN PERFORMING

cause the sprayer to

in

component

(See

Fig

23

and 24)

(W).

new

or

used circuit

rupture, fire or

fluid

filter, and

in

a 5 gallon pail of

WA

RNlNG

THIS CALIBRATION PROCEDURE

NEVER attempt to increase the fluid outlet pressure by performing this calibration in any other way.

NEVER EXCEED 192 bar (2750 psi) MAXIMUM WORKING PRESSURE. Normal operation sprayer at higher pressures could result in compo

nent rupture, fire or explosion.

AVOID assembly with your fingers or

box cover is removed to reduce the risk of electric

shock.

touching.the wires

over-

to

-

a

to

reduce the risk of a

in

the pressure control

tools

when the control

of

the

-

5.

Be sure the gun safety latch is engaged.

6. Use a 9 mm pressure adjustment nut about

two

7. With the pressure control knob

setting, turn the sprayer switch ON.

THE SPRAYER SHOULD NOT

If

it

does start,

disengage the a grounded waste container until pressure is reliev ed. Engage the gun safety latch. Turn the pressure

adjustment Turn the sprayer on to be sure

8.

Slowly

to the maximum setting and hold 9 pressure adjustment gauge reads EXACTLY 192 bar

h

Follow the Pressure Relief Procedure Warning on page

I

turn the pressure control knob

mm

(3/8') ignition wrench to slowly turn the

(3/8') ignition wrench to turn the

full turns. See Fig 24.

shut the. sprayer switch OFF,

gun

safety latch, trigger

nut

(S)

a

little further counterclockwise.

nut

(SI

(S)

clockwise

counterclockwise

(B) at

the

STARTI

it

does nor

(81

it

(2750

WARNING

17.

minimum

the

gun

start.

clockwise

there. Use a

until

the

psi).

CAUTION

To

prevent pump corrosion,

the pump, hose and

sure to close the drain valve, first. pressure necessary to flush. Follow the Pressure Relief Procedure Warning

the mineral spirits you are ready to spray again.

9.

Remove the'test gauge assembly and reinstall the plug. Flush out water

in

flush the water out of

gun

with mineral spirits. Be

Use

the lowest

on

page

the pump to protect

with

mineral spirits.

17.

Leave

it

into

test

until

-

1

Fig

23

24

307-671

CONNECTING ROD, DRIVE HOUSING,

or

CRANKSHAFT REPLACEMENT

(See

Fig

25)

WARNING

Before doing

Relief Procedure Warning on page the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or

NOTE:

1.

Remove the front cover and screws

2.

Unscrew the suction tube holding a wrench on the pump intake valve to keep

the pump from loosening.

3.

Disconnect the pump outlet hose

pump outlet nipple

4.

Use

a screwdriver

(21)

at the top of the pump. Push the pin

the rear.

5.

Loosen the jam nut Unscrew and remove the displacement pump

6.

Remove the connecting rod damage, and replace if needed.

7.

Use a 5 mm three screws and lockwashers of the drive housing

8.

Remove the four short screws screws shield

9.

Use a 4 mm.(5/32") hex key wrench to remove the

two

screws and lockwashers

rear of the front end bell (L).

10.

Lightly tap the lower rear of the drive housing with a plastic mallet

bell. Then pull the housing

this

procedure, follow the Pressure

17

to reduce

Stop the sprayer at the bottom of its stroke to get the crank the crank must be lowered manually, carefully rotate the blades of the fan with a screwdriver.

(3/16)

(1121

and spacers

(1).

Remove the shield.

to

(81)

in

its lowest position. If

(11.13).

(14)

from the pump,

(23)

(22).

to

push aside the retaining spring

(86)

with an adjustable wrench.

(9).

inspect for wear or

hex key wrench to remove the

(8.7)

from the recess

(6).

(110)

and

(1111

from the motor

loosen

(78, 79)

it

from the motor front end

off.

from the top

811

from the

(20)

out

(19).

two

long

CAUTION

DO

NOT allow the gear cluster removing the drive housing ed if dropped.

(6).

(26)

to fall when

It

is

easiiy

damag

-

r-

DO

NOT lose the thrust balls end of the gear cluster between gears. The ball, which is heavily covered with grease, usually stays but could be dislodged. If caught between gears and not removed, the balls the drive housing. If the balls are not bearings will wear prematurely.

11.

Inspect the drive housing for wear or damage and replace if needed.

12.

Pull the Crankshaft damage and replace, if needed. Be sure the bear ings

i81a

crankshaft assembly.

13.

Evenly lubricate the inside of the bronze bearing

the drive housing with high quality motor oil.

Liberally pack the roller bearings and gears

bearing grease.

14.

Install the crankshaft, meshing the gears.

15.

Clean the mating surfaces of the drive housing and

front end bell.

16.

Carefully align the drive housing and front end bell with the locating pins, then push the drive housing

onto the front end bell or tap

plastic mallet.

17.

Reinstall the motor shield

screws

18.

Install the screws and lockwashers

tighten evenly.

DO

align or seat the housing, which would cause

ICAUTION1

DroDer alionment and Dremature bearina wear.

and

(112)

and spacers

(110).

NOT use the drive housing screws to

81b)

(81)

are

(24)

located

(26)

or allow them to fall

in

the shaft recesses,

will

seriously damage

out. Inspect for wear or

in

place on either side of the

it

(1)

using the two long

(111)

and the four short

at

each

in

place, the

into place with a

(8,

7)

try

-

in

with

and

to

im-

Fig

25

..

w

86

I

24

307-671

25

19. Install

20.

the

connecting rod (9).

Screw the displacement pump about 3/4 of the

(6).

way into the bearing housing

up to the pin hole in the connecting rod assembly

(9) and continue screwing in the pump until the pin

slides easily into the hole. Back the top threads of the pump cylinder are flush with the face of the bearing housing and the outlet nip-

ple

(22)

is

facing back. Push the retaining spring

(21)

into the groove ing rod. Tighten the jam nut

ft-lb)-very tight to prevent

will damage the bearing housing. and

26.

all

the way around the connect

Hold the pin

off

the pump until

(86)

to

See

94

Figures

it

from loosening which

N.m

(20)

-

(70

25

Be sure the retaining spring

groove of the connecting rod,

IwARN'NG1

io

prevent the pin

vibration. See Fig

(20)

26.

(21)

is firmly in the

all

from working

the

way

loose

around,

I

If the pin works

off

due to the force of parts could be projected through the air and result in serious bodily injury or property damage, in cluding damage to the pump, connecting rod or bearing housing.

21.

Reinstall the front cover and screws Reconnect the suction tube hose

(23).

loose,

it

or other parts could

the pumping action.

(14) and pump outlet

due

break

These

(11,

to

-

13).

I

Fig

26

307-671

MOTOR

BRUSH

REPLACEMENT

(See Figs

27

8

28)

NOTE:

Before doing this procedure, follow the Pressure

Relief Procedure Warning on page the risk of fluid injection injury, splashing eyes or on the skin, injury from moving parts or electric shock.

1.

Remove the four short screws long screws (112) and spacers shield

2. Remove the screws gaskets

3.

Loosen

the lead.

4.

.Push down on the spring clip slightly then pull the

clip away from and out

Fig 28. Keep the spring clip.

5.

Remove and discard the brush.

6.

Inspect the commutator for excessive pitting, burn ing or gouging.

NOTE:

New motor brushes are included with each

Packing Repair Kit. Replace them when screws. Reinstall the motor shield and screws. replacing the packings, and/or when they have been worn to a minimum of the longest side.

Be sure

(1).

Remove the shield. See Fig 27.

(K) on each side of the motor. See Fig 27.

the brush lead terminal screw and remove

A black color on the commutator is normal.

to

unplug the sprayer1

(110)

(111)

(HI,

inspection covers

of

the brush holder. Refer to

9/16

17

to

reduce

in

and the

from the motor

the

(JI

on

two

and

11.

Reinstall the brush inspection covers, gaskets,

J.K

Fig

n

-

SPRING CLIP

107-398

and

Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to be wearing too fast.

7.

Place a new brush edges are as shown in the first part of Fig

the brush lead is routed as shown

of Fig 28.

8.

Slowly

the brush holder until the clip tab engages in the

holder rests squarely on the brush.

9.

Route the brush lead to the terminal and tighten the terminal screws. Be sure the brush lead does not touch any part of the armature or motor housing.

10.

Test the brushes: a.

b. Turn the

c.

push.the tabbed end of the spring clip into

and

the rolled portion of the tension spring

With the ON/OFF switch OFF, turn the pressure control knob all the way wise to minimum pressure. Plug

crease the pressure until the motor comes up to

full speed.

Inspect the brush and commutator contact area

for excessive arcing. Arcs should not

circle around the commutator surface.

in

the holder

ON/OFF switch ON and slowly

so

the beveled

in

the second part

counterclock-

in

the sprayer.

WARNING

Do

not touch the brushes, leads, springs or brush holders while the sprayer is plugged in electric shock and possible serious bodily injury.

to

28,

"

trail" or

avoid

and

in

COMMUTATOR COMMUTATOR

SIDEVIEW

CAPACITOR

OFMOTOR BRUSH INSTALLATION

I

TERMINALSCREW

-

BRUSH LEAD

SPRING CLIP

BRUSH HOLDER

MOTOR END BELL

-BRUSH

CAUTION

Do

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

~

30

Fig

28

DETAIL OF MOTOR BRUSH

SHOWN WITH MOTOR LEAD

FACING BACK OF MOTOR

307-671

27

MOTOR CAPACITOR REPLACEMENT

(See

WARNING

Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or

(48).

1. Remove the control box cover motor leads.

2.

Remove the fan cover IF) and screws

See

Fig

rear of the motor.

3.

Use a screwdriver to motor shaft groove and remove the fan

4.

Remove the inspection cover

(K)

gasket

from each side

29.

gently

lift the fan tab out of the

of

the motor

Disconnect the

(G)

(J),

screws

from the

(El.

(H),

(2).

See

and

29.

5.

Push down slightly on the spring clip and pull the

clip out of the brush holder. See Fig

6. Gently push the brushes out of the brush holder and inspect. Replace if necessary.

30.

See

page 27.

Figs

Fig

29

&

30)

7. Make

8.

9.

10.

11. Position the rear end

12. Position the

13.

a

matchmark between the front end

and the motor housing and the rear end bell (M)

and the motor housing to use as alignment marks during reassembly.

of the motor housing. Refer to Fig

Use

a

11

mm (7/16) socket wrench to remove the

nuts from the rear end bell

Gently plastic mallet to loosen

Do

washers that fall

To

minal screws insulation plate of the rear end bell. Install capacitor capacitor clearance'between the capacitor and any grounded metal parts. Always replace both capacitors at the same time.

push marks carefully and install the lockwashers and nuts.

into place, making sure the fan motor shaft groove.

tap

alternate ears of the rear end bell with

not

pull the motor armature out.

replace

the

(X),

is

not cracked. Maintain

it

onto the motor housing. Align the metch-

fan

Install the fan cover and screws.

Also

make

a

mark on the

29.

(MI.

it,

then

pull

it

straight

Retain any

out

when the bell is

capacitor, remove the brush lead ter-

(Y)

and the screw

making sure the ceramic case

bell

(MI over the

(E)

over the motor shaft and push

removed.

(Z)

going into the

a

3

mm

tie

tabs

engage

bolts and

bell

front

off.

a

new

of

the

(1/8")

in

the

(L)

a

it

Fig

29

1

BRUSH

HOLDER

'4

Ll

DETAIL

SHOWN WITH MOTOR LEAD

OF

MOTOR

FACING BACK

OF

BRUSH

MOTOR

I

14.

Reconnect the motor leads in the pressure control box and reinstall the conduit

(105)

into conduit elbow, around the motor lead. Reinstall the pressure control cover

(51).

28

307-671

(41).Push conduit seal

(48)

and screws

Fig

30

MOTOR

Before doing this procedure, follow the Pressure Relief Procedure Warning on page the risk of eyes or on the skin, injury from moving parts, or electric shock.

1

1. Disconnect the pump outlet hose

2.

3.

4.

5.

REPLACEMENT

WARNING

a

fluid injection injury, splashmg in the

Be

sure

displacement pump outlet nipple Remove the screws

(48)

and disconnect the four motor leads.

Use

an adjustable wrench to loosen the conduit connector nut assembly

Swing the conduit control elbow (313).

Pull the motor leads through the elbow, one time.

(401.

(313)

(See Fig 31

to

unplug

(51)

and pressure control cover

at

the pressure control

(41)

away from the pressure

the

(22).

8

17to

sprayer!

(23)

32)

reduce

from the

at

a

6.

Loosen the connector nut (39) at the motor and pull the conduit leads through the conduit, one

31.

7.

Unscrew the elbow

8.

Pull the wires through the elbow,

Remove the front cover and screws

9.

Use

10.

11.

12.

a

two

screws

the drive housing.

Remove the four short screws screws shield

Use

a 4 mm (5/32”) hex key wrench to remove the

two

screws

the motor front end bell

(41

away from the motor, then pull the

at

a

time. See Fig

139)

from the motor.

one

at

(11.13).

5

mm (3/16) hex key wrench to remove the

(8)

and washers

(112)

and spacers

(1).

Remove the shield.

(78)

and washers

(L).

(7)

from the recess

(110)

and

(111)

from the motor

.

(79)

from the rear of

a

time.

two

of

long

Fig

31

13.

Use a plastic mallet to gently tap the displacement

(19)

from

the

pump

(6)

from the front end bell. Then pull the drive hous-

ing away from the front end bell.

DO

NOT allow the gear cluster removing the drive housing ed if dropped. The cluster may stay engaged in either the front end bell or the drive housing.

DO

NOT lose the thrust balls end of the gear cluster between gears. The ball, which is heavily covered with grease, usually stays in the gear recesses, but could be dislodged.

not removed, the balls will seriously damage the

drive housing. If the balls are not in place, the

bearings will wear prematurely.

14.

Use

a 6 mm two screws underside

support

of

the motor to keep the sprayer from

rear to loosen the drive housing

CAUTION

(261

If

caught between gears and

(114")

hex key wrench to remove the

(35)

and lockwashers

the motor mounting frame. Be

~

(26)

to fall when

(6).

It

is easily damag-

(24)

located

or allow them to fall

at

(34)

from the

each

sure

to

tlppmg.

15.

Lift the motor assembly

16.

Place the new motor assembly on the frame and align

-

with the frame mounting holes. Install the

screws

17.

Liberally grease the gear cluster gear end bell. Check to be sure the thrust balls place.

18.

Be sure the bronze-colored bearing (81a1 and the silver the crank shaft

19.

Align the gears and push the drive housing straight onto the front end bell and locating pins.

20.

Starting at Step

tinue to reassemble the sprayer.

NOTE:

20.

Reinstall the motor shield and pressure control cover.

(351

and lockwashers

(0)

and pack

-

colored bearing (81b) are properly placed on

(81).

13

Use

a

turning motion on the conduit when

feeding wires through

off

the frame.

(34)

tightly.

(26)

all

bearings in the motor front

and pinion

(24)

and working backwards, con-

it.

are in

(6)

Fig

32

PART DRAWINGS

AND

PARTS LISTS

307-671

31

PARTS

Model Includes

230-963

11

DRAWING

Ultra

items

1-112

"

400.

Series

D

Includes

REF

PART

NO.

1

2

3 4 5

6

7

8

9 11 13

14 19

x)

21

22

23

24 26

27

'178-934

33

34 35

39

40

218-353

41 42

43

44 45

48

218-326

50

51

52

53

214-no

items

181-612

218-415

107-267

-

264

107

107-219

220-270

105-510

107445

218-359 218-363

107-209

180-192

220-647

176-818 176-817

162-453

218-083

100-069 218-364

218-361

104-008

107-212

102-932

065-099

106062

176884

101-242 104-81 1

179-936 1 OE-075

155-665

1-112

DESCRIPTION

SHIELD, motor MOTOR, electric:

Includesitems

and one of item

.

TERMINAL. insulated

.

TERMINAL; insulated

.

BUSHING

~~

HOUSING, drive LOCKWASHER; SCREW, cap, socket-head;

1/4-23

x CONNECTING ROD ASSEMBLY COVER, drive housing SCREW, machine,

1

"

TUBE, siphon PUMP, displacement

Refer to

PIN, straight, headless SPRING, retaining NIPPLE; HOSE; grounded, nylon;

29"

both ends BALL; GEAR CLUSTER LABEL, warning CART FRAME LOCKWASHER; SCREW, cap, socket-head;

<

,^..

IIL

CONNECTOR, conduit PRESSURECONTROLASSY:

see

CONDUIT, electrical WHEEL WASHER, back

RING, retaining

CAP

-. . . , . .

COVER, pressure control

BRACKET, mounting SCREW, thread

1

I?"

UiION, adapter;

npsm FILTER, Refer to

1

307-793

114

(736

mml

1/4";

separate parts list on page

huh

"

If1

swivel

fluid

307-273

1/2"

npsm x

long;

SST

..

112

3.4. 5,

27

~~~~~~

114

"

fil.

for parts

1/4

spring guard

5/16

-

up

-

forming;

318

for

parts

HP

one of item

head;

8-32

npt

114

"

5\16-18

7.5'1109.5mm1

10-24

npt

(m)

x

ID;

34

x

318

QTY

1

24

1

i

1

3

1 1

x

4

1

1 1 1 1

1

2

1

2

1

2

x

-

z

1

REF

PART

NO. NO.

54

210-657

59

+178-034

60

100-509

61

179-945

62

100-322

63

150-513

64

100-214

65

100-001

71

181-073

72

210-541

73

214

74

220-955

78

107-423

79

100-028

81

218-242

81a

180

81

b

107-434

86

176-762

105

107-447

108

178483

110

108-865

111

108-663

112

108-709

-

701

-

131

DESCRIPTION

VALVE;1/4 npt Imbe)

BALL Refer to

TAG, warning

PLUG, pipe ADAPTER, elbow; x WASHER;

NUT, jam. hex;

LOCKWASHER; SCREW, cap, hex; STRAINER HOSE, grounded,

50

ends HOSE, grounded. nylon;

3

ends GUN, airless, contractor; See SCREW, cap, button head;

306.861

for parts

7/16

114

npt(m) x

114

npt

7/16

5/16'

5/16-18 x 518

ft

115

m) long; spring guard both

ft

(0.9

ml

307-614

nyion;

long; spring guard both

for parts

unflml

1fl

"

114

3/16'

114.23 x 5/8"

81a.

1/4"

81b

LOCKWASHER; CRANKSHAFT ASSEMBLY Includes items

.

BEARING

.

BEARING

NUT. hex

"

ID;

1

ID;

1

2 2

1 1 1 1

1 1

4 2

2

306

e

307

manuals.

'Warning labels and tags supplied at no charge.

HOW

1.

To be sure you receive the correct replacement parts, kit or accessories, always give all of the information requested in the chart below.

2.

Check the parts list

3.

Order all parts from your nearest Graco distributor.

numbers

TO ORDER REPLACEMENT PARTS

use

the

ref.

in

descriptions refer

to

no.

identih, the correct part number;

when,ordering.

to

separate instruction

do

not

6

digit

PART

NUMBER

PART

DESCRIPTION

307-671

33

Ref

No.

PRESSURE

Includes items

40

CONTROL ASSEMBLY

301

to

340

PARTS

REF PART NO.

LIST

NO.

301 218-351

302

107-437

303

105659

304

107-255

306

107-435

3B

218-400

309

218-366

310 107427 311

065-140

312

100-035

DESCRIPTION

BARE

PRESSURE Includes items

.ON/OFF SWITCH

.BOOT, ONIOFF switch .GUARD, locking

.MICROSWITCH

BRIDGE, rectifier, SCR CHOKE

FII

TEE)

.

...

,

..,.

CORDSET, power supply; no plug

SCREW,

No.8

.

. . .

CONNECTOR, conduit ELBOW. street; ADAPTER, NIPPLE.

HARNESS

HARNESS, wire HARNESS, wire

HARNESS, HARNESS, HARNESS,

mach; slotted pan head;

x

5/16

.

114

, wire

"

3/8

nDt

wire wire wire

CONTROL

302

to

1/4

npth x fl

npttrn)

306

x

1/4

BOX

nptlm)

313

ON

1 1 1 1 1

1

'1

1

1 1

1

1 1 1 1 1 1 1

REF PART DESCRIPTION

NO.

324 107-438

325

326

327

328 329

330

331

332

333

100-975

101.792

157-021 108295

107-258

180-041 101-273

100-179

100-718

334

335

336

337

338

339

340

**Extra Warning labels and tags supplied at

107-436 105329 100-109

1080%

218-355

SCREW. machine. x

518

"

long

NUT, hex, machine,

LOCKWASHER, external,

shakeproof; No.

LOCKWASHER, No. BUSHING, strain relief TIP, pin, black plastic

Dlhl

I I,"

SCREW, machine, flat head;

No.

10-24 x 518

NUT, hex, mscr, No.

LOCKWASHER, internal, shakeproof; No.

10

LABEL. WARNING

LABEL, WARNING TERMINAL STRIP NUT, hex,

LOCKWASHER, external, shakeproof; VARISTOR CIRCUIT BOARD

M8 x

5

"

1.25

5/16

fil

No.

long

head: No.

8,

10-24

.

5

internal

thd

no

charge.

QTY

5-40

2

1

1 1 1

2

1

1 1

2

1 1

34

307-671

See

'How

To

Order Replacement

Pam"

on page

3.

WIRING DIAGRAM

THESE WIRES ARE CONNECTED

TO

TWO

TERMINALS ON THE OTHER

SIDE

OF

THE

ONlOFF

SWITCH

SERVICE

INFORMATION

Listed below by the assembly changed are

NEW

parts.

ASSEMBLY PART

CHANGED STATUS

OLD

Sprayer,

Series

NEW

OLD

NEW

OLD

NEW

OLD

NEW

OLD

NEW

OLD

NEW

REF PART NO. NO. NAME

218-618

14

1 181-612

16 217-593

74

220-955

39

218-215

19 220-647

47

214-638

23

218-083

58

178-392

44

101-242

135

102-952

71

181

Motor Cover Motor Shield

Gun

Displ. DisDl.

Hose Hose Pin

Ring

Strainer

-

073

Strainer

OLD

Pump

PUmD

and

NOTE:

This manual now includes complete service

procedures. The parts list has new reference numbers.

Other major changes to the sprayer are the upright cart

(33)

and changes to the suction tube

DISCONTINUED MODEL

NOTE:

(14).

Model

230-964

is

obsolete and has been deleted from the manual.

307-671

35

ULTRA@

PTFE

400

TECHNICAL

DATA

Power Requirements

Operating Range

CyclesILiter (gallon)

Power Cord

Inlet Paint Strainer

:

: : :

230

0-192 124

2.5

VAC,

(470)

mm 0 (13

16

mesh,

bar

Stainless Steel Screen, reusable

:

60

Outlet Paint Filter

mesh,

Stainless Steel screen, reusable

Pump Inlet Size

Fluid Outlet Size

Weight

:

314

npt w/30° I.D. chamfer

:

114

npsm from fluid filter

:

36

Kg

(80

Wetted Parts : Aluminum, Delrin@ , Nitralloy, Nylon, Ultra-High

Molecular Weight Polyethylene, Polyurethane, Rubber impregnated leather, Stainless Steel, Tungsten Carbide, Zinc

Dimensions : Width:

546.1 mm (21.5

Height: Handle extended:

Handle down:

Length: Handle extended:

Handle down:

Delrin' and are registered trademarks

50

Hz,

1

(0-2750

ga.), 3 wire,

1190

micron,

250

micron,

Phase,

psi)

3.7

6 m (20

Ib) approximately

-

plated steel in.)

939.8

723.9

660.4

609.6

of

the Du Pont Company.

AMP minimum

ft)

long

mm

(37

mm

(28.5

rnrn

(24

in.)

(26

in.)

,

Subsidby

GRACO

Factory

and

Ernnc~.Atlente.

ARlbte

INC.

Canpanles:Canada; England;

P.

0.

Box

PRINTED

Dallas,

1441

IN

U.S.A.

Datrolt.

Loa

Angala.

Switzerland

Wat

France; Germany;

MINNEAPOLIS, MN

307811 1-84

ReViSed

7-87

Csldwall

55440-1444

lN.J.1

Hong

Kong; Japan

Graco 230-963 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual