Graco 231-032 A Series, 231-041, 220-409 B Series Instructions And Parts List

INSTRUCTIONS/ PARTS

LIST

Rev

307-758

B

SUPERSEDES

A

This

manual

contains

IMPORTANT

WARNINGS

and

INSTRUCTIONS

READ

AND

RETAIN

FOR

REFERENCE

120

VAC,

15

Amp

ULTRA"500 AIRLESS PAINT SPRAYER

2750

psi

(1%

bad

MAXIMUM

WORKING

PRESSURE

Model

231432,

Series A

Basic, without hose, gun, spray tip kit or tip

Model

231-041

Includes Sprayer Model 231-034. hose, gun, RAC

111

spray tip kit, and spray tip

of

choice.

Model

22049,

Series

B

Same

as

231-041 except is CSA certified

PATENT

NO.

4.r)7.610

PATENTED

1963.

CANADA

BREVETE

1984

FOREIGN

PATENTS PENDING

INDEX

Warnings

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

2,

3

Avertissement

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

4.

5

Advertencia

......

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

6,

7

Introduction

.........

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

8

Operation

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

10

Shutdown

&

Care

......

...

. . .

...

. .

....

. .

.11

Flushing Guidelines

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

12

Troubleshooting Guide

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

13-20

Spin Test

...... . . .

..

. . .

...

. . . . . . .

.....

. .

.19

Bridge Test

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

20

Repair Section Index

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

21

Parts List

Et

Drawings

Sprayer

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

32,

33

How

To Order Replacement Parts.33

Pressure Control

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

34

Circuit Board

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

35

Technical

Data

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

Back Cover

Warranty

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

Back Cover

setup.

..

. .

. . . .

. . . . .

. .

. . .

. .

. . . .

. , . . . .

.9

WARNING

Never use 1,l.l-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing

such solvents in this equipment. Such use could result in

a

serious chemical reaction, with the possibility

of

explo-

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 parts.

GRACO INC.

P.O.

BOX

1441

MINNEAPOLIS,

MN

55440-1444

@COPYRIGHT

1986

GRACO

INC.

WA

RPJING

HIGH

PRESSURE SPRAY CAN CAUSE SERIOUS INJURV.

FOR

PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.

Read and understand

all

instruction manuals before operating equipment.

FLUID INJECTION HAZARD

General Safety

This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin end into your body and cause extremely

serious

bodily injury, including the

need

for amputation. Also,

fluid injected or splashed into

the

eyes

or

on

the

skin

can

cause serious damage. NEVER point the spray gun

at

anyone or

at

any part of the

try to "blow back" paint; this is NOT an air spray system.

body. NEVER put hand or fingers over the spray tip: NEVER

ALWAYS have the tip guard in place

on

the spray gun when

spraying.

before cleaning or removing the spray tip or servicing any

ALWAYS .follow

the

Pressure Rellef Procedure. below, system equipment. NEVER try to stop or deflect leaks with your hand or body.

before each use.

Be sure equipment safety devices are operating properly

Medical Alert-Airless Spray

Wounds

If

any fluid appears to penetrate your skin, get EMERGENCY

MEDICAL CARE AT ONCE.

DO

NOT TREAT AS A

SIMPLE CUT. Tell the doctor exactly

what

fluid was injected.

Note

to

Physlclan:

Injection

in

the

skin

is a traumatic

in-

jury.

It

Is

Important

to

treat the injury surgically

ns

soon

es

posslble.

Do

not delay treatment

to

rasearch

toxicity.

direct& into the blood

stream.

Consultation with e plastic

Toxicily

is

e concern

wi?h

some

exotic

coatings injected

surgeon or reconstructive hand surgeon may be advisable.

Spray

Gun Safety Devices

Be

sure

a11

gun safety devices are operating properly before

each

us8.

Do

not remove or modify any part of the gun; this

can cause

a

malfunction and result in serious bodily injury.

Safety

Latch

Whenever you stop spraying, even for a moment, always

set

the gun safety latch in the closed or "safe" position, making

the gun inoperative. Failure to

set

the safety latch can result in

accidental triggering of the gun.

Diffuser

The gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed. Check diffuser operation regularly. Follow the Pressure Rellef Procedure. below, then remove the spray tip. Aim the gun into

a

metal pail,

holding the

gun

firmly to the pail. Using the lowest possible

to an irregular stream. replace the diffuser immediately.

pressure, trigger the gun. If the fluid emitted

is

not diffused in-

Tip

Guard

spraying. The tip guard alerts you to the fluid injection hazard

ALWAYS have the tip guard in place

on

the spray gun while

and helps reduce, but does not prevent, the risk of accidentally placing your fingers

or

any part of your body close to the

spray tip.

Trigger

Guard

Always have the trigger guard in place

on

the gun when spray-

ing to reduce the risk of accidentally triggering the gun if

it

is

dropped or bumped.

Spray

Tip

Safety

the spray tip clogs while spraying, engage

the

gun safety latch

Use extreme caution when cleaning or changing spray tips. If immediately. ALWAYS follow the. Pressure Rellef Pro-

cedure and then remove the spray tip to clean

it.

fully relieved and the gun safety

latch is engaged.

NEVER wipe

off

build-up around the spray tip until pressure is

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection, splashing fluid or solvent in the eyes or

on

the

skin,

or injury

from moving parts or electric shock, always follow this procedure whenever you shut

off

the sprayer, when checkin or servic-

ing any part

of

the qxay system, when installing, cleaning

or

changing spray tips, and whenever you stop spraying.(fl) Engage

the gun safety latch.

(21

Turn the ON/OFF switch to

OFF.

131

Unplug the power supply cord.

(4)

Disengage the gun safay 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.

161

Engage the

gun safety latch.

(71

Open the pressure relief valve, having a container ready to catch the drainage. (8) Leave the pressure relief

valve open until you are ready to spray again.

If

you

suspect rhat

the

spray

tip

or

hose

is

complete+ dogged, or fhat pressure has nor

been

fulty

relieved after following the

stepsabove, VERY SLOWLY

loosen

the tip guard retaining nut

or

hose end coupling and relieve pressure gradually, then loosen

completely. Now clear the tip

or

hose.

/

,'

*'

TURN

SWITCH

TO

OFF

LATCH

UNPLUG

CORD

OPEN PRESSURE RELIEF VALVE

2

307-768

>

>,.

. .. .. .

.

..

EQUIPMENT MISUSE HAZARD

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

NEVER alter or modify any part of this equipment: doing

so

could cause

it

to malfunction.

CHECK

all

spray equipmant regularly and repair or replace

worn or damaged parts immediately. Always wear protective eyewear, gloves and clothing as

recommended by the fluid and solvent manufacturer. System Pressure

This

sprayer can develop

2750

psi

/795

bar)

MAXlMUM

WORKING

PRESSURE.

Be sure that

all

sorav muioment and accessorik are~rited to withstand the'maximum working pressure of this sprayer.

DO

NOT exceed the maximum work-

svstem.

ing pressure of any component or accessory used in the

Fluid and Solvent Compatibllity Always read the fluid and solvent menufecturer's literature

More

using them in this sprayer.

~ ~ ~~~

HOSE SAFETY

High pressure

fluid

in

the

hoses

can be very dangerous. If the

hose develops

a

leak, split or rupture due

to

any kind of wear,

damage or misuse, the high pressure spray emitted from

it

can

cause

a

fluid injection injury or other serious bodily injury or

property damage. ALL FLUID HOSES MUST HAVE SPRING GUARDS

ON

BOTH ENDS1 The spring guards help protect the hose from kinks or bends et or close to the coupling which can result

in

hose rupture. TIGHTEN all fluid connections securely before each use. High

pressure fluid can dislodge

a

loose coupling or allow high

pressure spray to be emitted from the coupling.

tire hose for cuts. leaks, abrasion, bulging cover. or damage or

NEVER

use

a

damaged hose. Before each

use,

check the en-

exist. replace the hose immediately.

DO

NOT try to recouple

movement of the hose couplings. If any of these conditions high pressure hose or mend

it

with tape or any other device. A

repaired hose cannot contain the high pressure fluid.

hoses to move equipment.

Do

not usefluidsor solvents which

HANDLE AND ROUTE HOSES CAREFULLY.

Do

not pull on

are not compatible with the inner tube and cover of the hose.

DO

NOT expose Graco hose to temperatures above

lWF

(82"CI or below -40°F

(40O"Cl.

Hose

Groundin

Continuity

Proper hose grounkg continuity is wntial to maintaining a

rounded spray system. Check the electrical resistance of your

tag on

it

which specifies

the maximum

electrical

resistance,

uid hoses et least once

a

week. If your

hose

does

not have a

contact the hose supplier or manufacturer for the maximum resistance limits. Use

a

resistance meter in the appropriate range for your hose to check the resistance. If the resistance exceeds the recommended limits, replace

it

immediately. An ungrounded or poorly grounded hose can make your system hazardous.

Also

read FIRE

OR

EXPLOSION HAZARD.

w

FIRE

OR

EXPLOSION HAZARD

through the pump

end hose. If every part of the

spray equip-

Static electricity is

created by the high velocity

flow of fluid

ment

is

not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or unplugging

e

power supply cord. Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying indoors or outdoors, and can cause

a

fire or explosion and serious bodily injury and property damage. Always plug the.sprayer into an outlet at leest

20

feet

I6

m)

away from the sprayer and the spray area.

Do

not plug in or

any chance

of igniting fumes still in the air.

unplug any power supply cords in

the spray area when there is

If you experience any static sparking or even a

sli

ht shock while using this equipment, STOP SPRAYING IMMEDIATELY. Check the entire system for proper grounding.

Do

not

use

the system again until the problem has been identified and

corrected.

Grounding

To reduce the risk of static sparking, ground the sprayer and

all

other spray equipment used or located in the spray area.

structions for your area and type of equipment.

BE

SURE to

CHECK your local electrical code for detailed grounding in-

ground

all

of this spray equipment:

1.

2.

3.

4;

5.

6.

7.

Sprayer: plug the power supply cord, or extension cord, each equipped with an undamaged three-prong plug, into

a

properly grounded outlet.

Do

not

use

en adepter. All ex-

tension cords must have three wires and

be

rated for 15

amps.

Fluid

hoses:

use

only grounded hoses with a maximum of

5M)feet

(150

m) combined hose length to ensure ground-

ing continuity. Refer to

Hose

Groundlng Continulty.

Spray

gun:

obtain grounding through connection to

a

properly grounded fluid hose and sprayer. Object being sprayed: according to

lml

code.

fluid supply container: according

to

local

code.

AI1

solvent pails used when flushing, according to local

code. Use only metelpails, which are conductive.

Do

not

place the pail

on

a

non-conductive surface, such as paper

or cardboard, which interrupts the grounding continuity.

ing

pnrssura, always

hold

a metal part of the gun

firmly

to

To

maintain grounding continuiry when flushing or reliev-

the side

of

a grounded metal pail, then trigger the gun.

Flushing

Safety

Reduce the risk of injection injury, static sparking, or splashing

of

this menuel. Pollow the Pressure Rellef Procedure

on

by fqllowing the specific flushing procedure given on page 12 page

4,

and remove the spray

tip

before flushing. Hold a metal

part

of

the

gun

firmly

to

the side

of

a

metal

pail

and

use

the

lowest

possible fluid pressure during flushing.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers or other

body

parts. KEEP CLEAR of moving parts when starting or

operating the sprayer. Unplug the sprayer. and follow the

Pressure Rellef Procedure on page

2,

before checking or

servicing any part of the sprayer to prevent

it

from starting

accidentally.

IMPORTANT

ticularly the General Standards, Part 1910,

and the Construction Standards,

Part

1926-should be consulted.

United States Government safety standards

have been adopted under the Occupational Safety and Health Act. These standards-par-

307-758

3

A

VER

TIS

La

pulvdrisation A haute

pression

peu

blessures

trhs

graves.

RBserv6

exclusivement

A

I'usage

professionnel.

Observer

toutes

les

consignes

de

s6curit6.

Bien

lira

et

bien

comprendre

tous

les

manuals

d'instructlons

avant

d'utiliser

le

matbriel.

RlSQUES

D'INJECTION

Consignes gBnBrales de sBcuritB

Cet

appareil produit un fluide B trb haute pression.

Le

fluide

fuites

ou

de ruptures peut phetrer

sous

la

peau

ou

B

I'interieur

pulv4risb par

le

pistolet

ou

le

fluide

sous

pression provenant de

du corps

et

entrainer des blessures trh graves, voir

m6me

une

amputation. Meme

sans

&re

sous

pression,

le

fluide Bclabous-

ant

ou

entrant dens

Ias

yeux

peut aussi entrainer des

Massurea graves. NE JAMAIS pointer

le

pistolet vers quelqu'un

ou

vers une par-

tie

quelconque du corps. NE JAMAIS mettre

la

main ou

188

doigts sur I'ajutage du pulv6risateur. NE JAMAIS essayer de "refouler"

la

peinture.

Cet

appareil Nest PAS un compreSSBur

pneurnatique. TOUJOURS garder

la

protection de

I'ajutage

en

place sur

le

pistolet pendant

la

pulv6risation.

TOUJOURS obsenrer

la

March

B

Sulvra

pour

DBtendre

la

Pression donnee plus loin, avant de nettoyer

ou

d'enlever

I'ejutage

du pulverisateur,

ou

d'effectuer un travail quelcon-

que sur une partie de I'appareil.

NE JAMAIS essayer

d'arr&er

ou de d4viir

les

fuites

avec

la

main

ou

le

corps.

Avant chaque utilisation, bien s'assurer que

Ies

dispositifs de

s4curit4 fonctionnent correctemant.

Soins

m4dicaux

En

cas

de penetration de fluide sous

le

paau: DEMANDER

IMMEDIATEMENT DES

SOINS

MEDICAUX D'URGENCE. NE PAS SOIGNER CETTE ELESSURE COMME UNE SIMPLE COUPURE.

Avls

au

madecln:

La

pdndtration des fluides

sous

la

paeu

esr

un

traumarisme.

II

est

Important de traltar

chlrurglcalement

cette

blesaure Imm4dlatament. Ne

pas

retarder

le

treitement pour

effectuer

das recherches sur

la

mx".

Certeins

revdtements

exotiques

sont dengereuse-

sang.

I1

est

souhaitable

de

consulter

un

chirurgien esthdtique

menr toxiques quend is sont injectds directement dens

le

ou

un

chirurgien spdcielisd dans

la

reconstruction des

mains.

Dispositifs

de

sBcurit6

du

pistolat

enlever ni modifier une partie quelconque du pistolet; ceci risquerait d'entralner un mauvais fonctionnement

et

des

blessures graves.

Verrou

de

securitd

A chaque fois que

I'on

s'arr8te de pulvbriser,

mbme

s'il

s'agit

d'un court instant, toujours mettre

le

verrou de sewrite du

pistolet sur

le

position "fermk"

ou

"sbcurit4"

1"safe")

pour

empkher

le

pistolet de fonctionner. Si

le

verrou de &curite

n'est

pas mis,

le

pistolet peut

se

d4clencher accidentellement.

Voir la Fig.

3.

Diffuser

ques d'injection accidentelle quand I'aiutage

n'est

pas en

Le

diffuseur du pistolet

sert

B

diviser

le

jet

et

13

reduire

189

ris-

place. Vbrifier

la

fonctionnement du diffuseur rbgulibrement.

Pour

cette

v&ification, detendre

la

pression

en

ObseNant

19

loin puis enlever I'ajutage du pulv6risateur. Pointer

le

pistolet

Marche

A

Suivre pour DBtendre

la

Pression donnb plus

dens un seeu

en

metal,

en

le

maintenant fermement contre

le

wau. Puis, en utilisant

la

pression

la

plus feible possible, ep-

puyer sur

le

gachette du pistolet. Si

le

fluide projete n'estpas

diffuse

sous

forme de jet irrbgulier, remplacer imm4diatement

le

diffuseur.

Protection

de

/%jute

e

TOUJOURS maintenir

B

e

protection de

I'ajUtage

en place Sur

le

tion de I'ajutage anire I'anention

sur

18s

risques dhjection

et

pistolet du pulverisateur pendant

la

pulv6risation.

La

PrOteC-

contribue

B

reduire, mais n'4vite pas

le

risque, que

Ies

doigts

ou

une partie quelconque du corps ne passent accidentelle-

ment B proximite immediate de I'ajutage du pulv4risateur. Consignes de

skurite

concarnant I'ajutaga

du

pulv4risateur remplacement des ajutages du puhrbrisateur.

Si

I'ajutage

sa

Faire ear8mement attention B I'occasion du nettoyage

ou

du

bouche pendant

la

pulv6risation, mettre immediatement

le

verrou de skurite du pistolet. TOUJOURS bien observer

la

Marche

B

Suivre

pour DBtendre

la

Pression puis BnleVBr

I'ajutage

du pulverisateur pour

le

nettoyer.

NE

JAMAIS essuyer ca qui

s'est

accumul6 autour de I'ajUta9e

tomb&

et

que

le

verrou de securitb du pistolet ne soit engage,

du pulv4risateur avant que

la

pression ne soit completement

Avant cheque utilisation, bien

s'assure

que tous

Ies

dispositik

de

&curite du pistolet fonctionnent correctemant. Ne pas

,

\

Marche

A

Suivre

pour

DBtendre

la

Pression

Pour reduire

Ies

riGues de blessurea graves,

y

compris

Ies

blessures par injection de fluiie

ou

celles

tau+

per des

Bclaboussures dens

Ies

yeux

ou

sur

la

peau, des pieces en mouvement

ou

par Blectrocution. toujours bien obsenrer.cette marche

B

suivre B chaque fois que l'on arrete

le

pulv6risateur. B I'occasion de

la

verification ou de

la

reparation d'une piece de I'appareil

de pulv6risation.

B

I'ocasion de I'installation. du nettoyage

ou

du remplacement des

ejutagea

et

d'une maniere gendrala

B

cha-

que arr8t.

1)

Engager

le

verrou de skurite du pistolet.

21

Mettre I'interrupteur Marche-Arrbt

sur

ARRET

1"OFF").

3)

Debrancher

le

cordon d'alimentation.

4)

DBsengager

le

vermu de &curite du pistolet.

5)

En maintenant une partie m4tallique du pistolet

ferment appuyb contre

le

c6t4 d'un seau

en

m4tal.

appuyet sur

la

gachene du pistolet pour lib4rer

la

pression.

61

Engager

le

verrou de skurite du pistolet.

7)

Ouvrir

la

soupape de s4curite en prenant soin d'avoir un recipient pr8t B rkupbrer

le

liquide.

8)

hisser

la

soupape ouvena

jusqu'h

ce

que

!a

pulverisateur soit de nouveau pret

B

&re

utilis6.

SiI'on soupmnne

qua

I'ejutage

du

pulv&iseteur

ou

/a

ruvau

est mmplbtement

bouchd,

ou

qua

la pression n'e pas

Btd

complbte-

men?

libdnh,

aprds avoirproddd

aux

ophtions ci-dessus, desserrer

TRES

LENTEMENT I'Bcrou de retenue de

la

protectlon de

,

l'ajutege

w

le

raccord du bout du tuysu et lib4rer progressivement

le

pression,

puis

terminer le desserrage. On peut maintenant

deboucher I'a'uta

e

ou

le

tuyeu.

I

1

2

3

4.5.6

7

4

307-758

RISQUES

EN

CAS DE MAUVAISE UTlLlSATlON DU MATERIEL

Cansignes g4nBraies

de

s4curit4 Pression

Toute utilisation anormale de I'appareil de pulvdrisation ou des

accessoires comme, par exemple, la mise

sous

una pression

Ce pulvbrisateur peut produire un PRESSIONMAXIMUM

DE

TRAVAIL

195

bar

(2750

lb/po.

2

1.

S'assurer que tous

Ies

excessive,

Ies

modifications de pibces, I'utilisation de produits

chimiques et de matibres incompatibles et I'utilisation de

Blbments du pulv4risateur et

ses

accessoires sont concus pour

resister

B

la pression maximum de travail de ce pulvbrisateur.

pieces

us&

ou abimbs peut causer des &gats B I'appareil

ou

'

NE PAS depesser la pression maximum de travail d'aucun des des ruptures de pibces et entrainer une injection de liquide ou d'autres blessures sbrieuses, un incendie, une explosion ou

Compatib[llt& ,.himique

des

corps

Bl6ments ou accessoires utilisBs avec cet appareil.. d'autres dbgats.

NE JAMAIS alt6rer ou modifier une piece de cet apparail; ceci

Toujours lire soigneusement

1%

documents et brochures du

fabricant des fluides et solvants utilis6s avant de s'en servir risquerait d'entrainer

son

mauvais fonctionnement. dans ce pulv4risateur.

VERIFIER regulibrement tout I'appareil de pulvdrisation

et'ses

Bquipements et r6parer ou remplacer immediatament

185

MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXlBLES

pieces us& ou abimks.

Le fluide

B

haute pression circulant dans

Ies

tuyaux peut &e MANIPULER LES TUYAUX AVEC PRECAUTION ET

trbs dangereux. En cas de fuite sur

le

tuyau. de fissure, CHOlSlR SOIGNEUSEMENT LEUR CHEMIN. Ne pas deplacer

dBchirure ou rupture

B

la suite de I'usure, da d@&s ou d'une

mauvaise utilisation,

les

projections de fluide haute pression

le

fluide en tirant sur

le

tuyau.

Ne

pas m'liser de fluides

ou

de

solvants qui ne sont pas compatibles avec I'enveioppe in-

qui

en

proviennent peuvent entrainer des blessures graves par tbrieure ou extbieure du tuyau. NE PAS exposer

le

tuyau

B

penetration sous la peau ou par contact, ainsi que des dBgets des temperatures suphrieures

B

82'C I1Bo"F) ou infbrieures

B

met4riels. -40°C I-4O"FI. TOUS LES TUYAUX FLEXIBLES DOIVENT

AVOlR

DES

Continuit4 de

la

mise

A

la

terre

des

tUyaUX

RESSORTS SPIRALE DE PROTECTION AUX 2 BOUTS1 Les spirales de protection contribuent

&

Bviter la formation de

Une bonne continuit6 de la mise

B

la terre des tuyaux

est

hentielle pour maintenir la mise A la terre de I'ensemble de pliures, de.boucles ou de noeuds sur 18s tuyaux qui pourraient entralner la rupture

du

tuyeu B I'endroit

du

reccord ou B son

vaporisation. VBrifiez

la

resistance Blectrique de vos tuyaux

B

voisinag.4.

fluides et B air, au moins una fois par ssrnaine. Si votre tuyeu

S~R~ER

FERMEMEN~

leS

raccords

avant

chaque

UtiliSa.

que maximum. prenez contact avec

10

fournisseur de waux

ne compone pas d'etiquene qui precise la resistance Blectri-

tion,

Le

fluide

sous

pression

peut

faire

sauter

un

raccord

ou la fabricant pour avoir

tes

limites de resistance maximum.

dessed ou produire un jet

B

haute pression s'6chappant par

10

vOtre

tuyau

et

vBrifiez

rBsinance,

si

ceIIe-ci

depasse

Ies

Utilisez

un

metre de resistance de

la

gamme approprib pour

raccord.

limites recommandBas, remplacez

le

tuyau imm6diatement.

utilisation, verifier entibrement chaque tuyau pour d4celer

les

recte

peut entrainer des risqus pour votre

systbme.

Lisez

NE JAMAIS utiliser

un

tuyau endommag& Avant chaque Un tuyau sans mise

B

la terre ou avec une mise B la terre incor-

coupures, fuites, abrasions, bourwuflures de I'enveloppe ou aussi LES RISQUES D'INCENDIE OU D'EXPLOSION citoute autre deterioration ou jeu des raccords. Si l'on constate rune de ces dbteriorations,

il

taut remplacer

le

tuyau im-

dessus. m6diatement. NE PAS essayer de refaire la raccord

d'un

tuyau

.haute pression

ni

de reparer

le

tuyau avec du ruban adhBsif ou

oar tout autre moven. Un tuvau rBoar4

ne

Deut Das resister au

fluide sous pression.

RISQUES D'INCENDIE OU D'EXPLOSION

Da I'BlectricitB statique est produite' par

le

passage du fluide

B

grande vitesse dans la pompe et dans

Ies

tuyaux. Si toutes

Ies

pieces de I'appareil de pulv6risation ne sont pas convenablement reliks

B

la masse ou

la

terre, des Btincelles peuvent

se

produire et I'appareil risque d'btre dangereux. Des Btincelles

peuvent egalement

se

produire B l'occasion du branchement

ou

du

debranchemant

du

cordon d'aiimentation.

Les

Btincelles

sont suffisantes pour allumer

185

vapeurs de solvants et

le

fluide pulv6risB.

Ies

fines panicules de poussibre ainsi que

d'autres substances inflammables, quand on pulverise

I'in-

tBrieur ou B I'extdrieur,

et

elles

peuvent causer un incendie ou

una explosion, einsi que des blessures graves et des degats trouvant

B

au moins

6

m

120 pieds) de I'appareil

et

de I'endroit

mat6riels. Toujours branchar

le

pulv4risateur dans une prise

se

cordon d'alimentation que1 qu'il soit dans la

zone

ob

se

fait la

ob

se

fait la puiverisation. Ne pas brancher ou debrancher un

pulv6risation quand

il

y

a

le

moindre risque que des vapeurs

encore presentes dans I'air prennent feu.

..

S'il

se

produit des Btincelles d'6lectricit6 statique, ou si vous

ressentez la moindre d6charge. ARRETU IMMEDIATEMENT

LA

PULVERISATION. VBrifiez que

le

svstbme entier est bien

mis

B

la

terre.

Ne

vous

serw)z

pai

du

sysieme avant qua la pro-

blbme soit identifie et corrig4.

Mise

A

la

term ou

a

la

masse

Pour reduire

18s

risques de production d'etincelles d'Blectricit6

statique,

le

pulvhrisateur

et

tous

Ies

Bquipements utilisbs ou

se

tmuvant dans la

zone

de

pulveisation doivent &re relib B la terre ou B la masse. Pour connaltre la detail des instructions de mise

A

la terre dans la region et

le

type

paniculier d'Bquipe-

ment. CONSULTER

le

code ou

les

reglementationp Blectriques

locales. S'ASSURER que tous

les

Bquipements de pulv6risa-

tion suivents sont bien relies

B

la terre:

1.

Pulv.4risateur: Erancher

le

cordon d'alimentation ou. la

rallonge qui doivent &re Bquipk d'une prise

B

3

fiches en bon

&at, dans une prise de courant convenablement mise

B

la

terre. Ne pas utiliser d'adaptateur. Toutes

les

railonges doivent

avoir

3

fils

et

Atre prbues

pour

15

ampbres.

2.

Tuyeux flexibles: Afin d'assurer la continuit6 de la mise

B

la

terre, n'utiliser que des tuyaux cornportant une mise B la terre

et

ayant une longueur maximum combink de 150

m

(15CO

pieds). Sa

reponer

&dement au paragraphe "Con-

tlnult6

du

circuit de

mlse

B

la

terra

des

tuysux".

3.

Pistolet: RBaliser la'mise B la terre en

le

raccordant B un

tuyau flexible et

B

un pulvbrisateur deja convenablement relib

B

le terre.

4.

Recipient d'alimentation: observer

IB

code

ou

Ies

reelemen-

tations locales.

5.

Objefs, matdriel

ou

surfaces recevant la pulvdrisation:

observer

le

code ou

Ies

r@lementations locales.

6.

Tous les seaux de solvants

utili&

pour

le

rincage: observer

le

code ou

Ies

reglementations locales. Nutiliser que des seaux mdtalliques conducteurs de I'6lectricite. Ne pas mettre le seau sur une suriaace non conductrice

comme

sur du papier ou du

7.

hur

conserver

/a

continuitd

de

la

mise

d

kt

tern

quand

on

canon car cela interromprait

la

continuit6

le

la mise

B

la

terre.

rinca le matdriel

ou

wend

on

libdm

la

pression, toujours maintenir une panie mbtallique du pistolet fermement appuyb contre

le

c6t6 d'un seau en mdtal puis appuyer sur la detente

du pistolet.

Mesures

de

SBeuritB concernant

le

Rincege

Pour reduire

185

risques de blessures par p(ln4tration de

la

peau et

les

risques diis aux Btincelles d'6lectncltB statique ou

aux Bclaboussures, observer

la

rnarche B suiwe pour

le

rincage

donnk

B

la page 12 de ce manuel. Observer

la

"Merche

B

Suivrs

pour

DBtendre

la

Pression"

donnee

B

la

page 4 en

enlever lsjutage

du

pulvdrisateur evant le rincage. Maintenir

une panie metallique du pistolet fermement appuy6e contre

le

cbt6 d'un seau en m&al et utitiser la pression

la

plus faible

possible pendent

le

rincage.

307-758

5

EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES.

SOLO

PARA

US0

PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.

Lea

y

entienda

todo

el

manual

de

instrucciones

antes

de

manejar

el

equipo.

PELIGRO

DE

INYECCION

DE

FLUID0

Seguridad general

Este equipo genera un fluido a una presi6n muy aka.

El

rociado de la pistola,

10s

escapes de fluido o roturas de

10s

componentes pueden inyectar fluido en

le

piel y e1

cuerpo

y

Causar lesiones enrernadamente graves, incluyendo a veces la salpicado en

10s

ojos puede causar graves daKos.

necesidad de amputaci6n. Tambibn,

e1

fluido inyectado

o

cuerpo. NUNCA colocar la mano o 10s

dedos encima de

la

bo-

NUNCA apuntar la pistola hacia alguien

o

alguna pane del

quilla. NUNCA tretar de "hacer retornar

la

pintura";

este

NO

es

un sisterna de rociado de aire.

pistola mientras

se

est6 pulverizando.

SIEMPRE tener colocado

e1

protector de la boquilla en la

dado

m6s

abjo,

antes

de lirnpiar o sacar la boquilla o de dar

SIEMPRE seguir

el

procedimiento de descarga de presibn,

servicio a cualiquier equipo del sistema. NUNCA tratar de parar

o

desviar

10s

escapes con la mano

o

el

cuerpo. estBn funcionando bien antes de cada uso.

hurar que todos

10s

aparatos de seguridad del equipo

Tratamienta

medica

Aviso

al

medico:

Sise

llega a inyectareste fluido en lapiel

se

causa

una lesidn traumdtica.

Es

imponanre tratar

qulrhgicamante

la

lesi6n

a

le

brevedad posible.

No

demorar

el

tratamiento para investigar

la

toxicidad.

La

tox-

icidad es algo de

sum8

importancia en elgunas pinturas

exdticas cuando se inyactan directamente

al

torrente

sanguineo. Sir4 conveniente consultar

a

un especiaiista en

citugia pldstica

o

reconstructive de

las

menos.

Asqurar que todos

10s

aparatos protectores de la pistole

Aparatos

de

seguridad

de

la

pistola pulverizadora

esthn funcionando bien antes de cada uso. No sacar

ni

malfuncionamiento de la misma con Ias consiguientes lesiones

rnodificar ninguna pieza de la pistole pues podria causar

e1

penonales.

Pestillo de seguridad

Cada vez que

se

deje de pulverizar, aunque sea por un breve

momento, siempre colocar

e1

pestillo de seguridad en la

posici6n "cerrada",

lo

que deja la pistola inoperante.

El

no

hacerlo puede llevar al disparo imprevisto de la pistole.

Difusor

e1

riesgo

de inyecci6n cuando no

est4

instaiada la boquilla.

El

difusor de la pistola dispersa

e1

chorro pulverizado y reduce

Revisar con regularidad

el

funcionamiento del difusor. Seguir

y

despu6s sacar la boquilla. Apuntar la pistola

a

un balde

el

procedimiento de descarga de presi6n. dado

rnhs

abajo,

methlico, sosteniendola bien firme contra

81.

Utilizando la

presi6n

m4s

bajo posible, disparar la pistola. Si

el

fluido

emitido

no sale disperso

en un chorro irregular, reernplazar de

inmediato

e1

difusor.

Rotector de

10

boquilla

SIEMPRE tener

el

protector de la boquilla colocado en la

pistola mientras

se

est6

pulverizando. kte protector llama la

atenci6n contra el peligro de inyeccidn

y

ayuda a reducir, per0

no evita, la colocaci6n accidental de

10s

dedos o cualquier otra

pane del cuerpo cerca de la boquilla.

Seguridad

de

la boquilla pulverizadora

Tener mucho cuidado al lirnpiar

o

cambiar Ias boquillas. Si

pestillo de la pistoia de inmedieto. SIEMPRE seguir

e1

pro-

llegare a obstruirse mientras

esth

pulverizando, enganchar

e1

cadimianto de descarga de presi6n y despu6s sacar la boquilla para limpjarla.

quiila antes de que

se

haya descargado por completo la

NUNCA limpia8la acumulaci6n de pinture alrededor de la bo-

presi6n

y

e1

pestillo est6 enganchado.

.. . .

Marche

B

Suivre

pour

DBtendre

la

Pression

Pour reduire

Ies

risques de blessures graves,

y

compris

Ies

blessures par injection de fluide ou ceiles caus.& par des

Bclaboussures dans

18s

yeux ou sur la peau, des pieces en mouvernent ou par Blectrocution, toujours bien observer cene marche

8

suivre B chaque fois que I'on arrete

le

pulv6risateur. B l'occasion de la verification ou de la reparation d'une piece de I'appareil

de pulvbrisation,

B

I'occasion de I'installgtion, du nettoyage ou du remplacement des ajutages

et

d'une maniere gBn6rale B cha-

que err&.

11

Engager

le

verrou de sBcurit6 du pistolet.

21

Mettre I'interrupteur Marche-ArrBt sur ARRET

I"OFF"1.

31

Debrancher

ferrnement appuyh contre

le

c8t6 d'un

seau

en metal, appuyer sur la gachene du pistolet pour liberer la pression.

6)

Engager

le

cordon d'alimentation.

4)

Ddsengager

le

verrou de skurite du pistolet.

5)

En maintenant une panie metallique du pistolet

81

hisser

la

soupape ouvene jusqu'i ce que

!e

pulvbrisateur soit de nouveau pr& B &re

utili&.

verrou de sbcuritb du pistolet.

7)

Ouvrir la soupape de sBcurite en prenant soin d'avoir un recipient prbt B rBcup4rer

le

liquide.

Sil'on soupconne

que

/'aiutage dupulvdrisateur

ou

le

tuvau

est

compldtement

bouchd.

ou

quela

pression n'epas

dtd

compldte

ment libdrde aprhs awirprocddd

aux

op6rations ci-dessus.

desserrer TRES LENTEMENT I'krou de retenue de

la

protection de

I'ajutage ou

le

raccord du bout du tuyau et libher progressivement la pression, puis terminer le desserrage. On peut maintenant

dbbouchec I'a'uta

e

ou

le

tuyau.

1

2

3

7

6

307-758

PELIGRO

POR

MAL

US0

DEL

EQUIP0

Cualquier mal

us0

dd

equipo pulverizador o 10s

accesorios, tal

Segurided general

wmo

sobrepresurizaci6n. modificaci6n de piezhs,

us0

de

materiales

y

produnoe quimicos incompatibles, o utilizaci6n

de piezas dafladas

o

desgastadas, puede hacen que

se

rompan

y

causen la inyecci6n de fluido u otras lesiones corporales

,

graves, incendio, explosi6n o daRon a la propiedad. NUNCA alterar

o

modificar ninguna pieza de

este

equipo;

e1

hacerlo podrla causar una averla. REVISAR con regularidad

e1

equipo pulverizador y reparar

o

reemplazar de inmediato Ias piezas dafladas o desgastadas.

Esta

pulvarizadora puede desarrollar

1%

barias

(2750

psi1 de

Presi6n del sistema

PRESION

DE

TRABAJO MAXIMA. Asegurar que todo

e1

equipo pulverizador

y

sus

accesorios tienen

la

capacidad para

aguantar la presidn

maxima

de trabajo de

esta

pulverizadora. NO exceder la presi6n maxima de trabajo de ningdn componente

o

accesorio de

este

sistema.

solvente antes de usarlos en esta

pulverizadora.

Siempre

leer

18s instrucciones del fabricante del fluido

y

SEGURIDAD EN EL

US0

DE

LAS MANGUERAS

Ei

fluido que escapa a aka presi6n por 18s mangueras puede

ser

muy

peligroso. Si en la manguera

se

desarrolla un escape,

una rotura

o

rajadura debido a cualquier tip0 de desgaste,

daflo

o

maltrato.

e1

chorro a aka oresi6n emitido oor all1 ouede

.~

~~ ~

&mar una lesibn

por

inyeccidn u otras lesiones corporales

graves

o

daflos a la

propiedad.

.~

QUE TENER GUARDAS DE RESORTE EN AMBOS EX-

lTODAS

US

MANGUERAS

PARA FLUIDOS TIENEN

TREMOSl Estas protegen Ias mangueras contra dobleces

o

retorceduras

en

10s

acoplamientos o cerca de

ellos.

10s

que

podrlan traducirse en roturas de la manguera. Antes de usarlas, APRETAR bien firmes todas 18s conexiones.

Ei

Ruido a alta presi6n puede desalojar

un

acoplamiento suelto

o

dejar que por

41

escape un chorro a aka presi6n.

NUNCA usar una manguera

que

est6 daRada. Siempre,

abultada,

0

acoplamientos sueltos o daflados. Si llegara a en-

revisarla en busca de cortaduras, escapes, abrasi6n. cubierta contrarse cualquiera de estas condiciones, reemplazar de

in-

mediato

la

manguera. NO intentar reacoplar una manguera de

similar. Una menguera que ha sido remendada no aguante

e1

aka presi6n o enmendarla con cinta adhesive

u

otro

material

Ruido a alta presibn. MANEJAR

Y

PASAR CUIDADOSAMENTE LAS

MANGUERAS.

No

tirar de 18s mangueras para mover

e1

eauipo. No usBr fluidos o solventes aue Sean incomoatibles con

el

tubo interno y la cubierta dela manguera. NO exponer

las

mangueras a temperatures

sobre

82°C

1180°F)

o

bajo

-4OT

I-40°F).

Contlnuidad del circuito de puesta

a

tierra de la

manguera

esencial para mantener conectado a tierra

e1

sistema

La

continuidad del circuito de puesta a tierra apropiado

es

pulverizador.

Es

indispensable revisar la resistencia el4ctrica

maxima de

las

mangueras de aire y de fluido por

lo

menos una

vez

a la semana. Si la manguera no tiene una etiqueta en la

cual

se

especifica la resistencia elktrica maxima, ponerse en

confano con

e1

proveedor o fabricante de

le

manguera para

la

informaci6n sobre

10s

limites de resistencia. Usar un metro de

resistencia

en

la gama apropiade

Dara

cornprobar la resisten-

PELIGRO DE INCENDIO 0 EXPLOSION

manguera crea electricldad sstAtica. Si todas

les

partes

dal

Ei

flujo a alta velocidad del fluido

a1

pasar por la bomba

y

equip0 pulverizador no tienen buena tierra, pueden ocurrir chispas. convirtiendo al sistema en algo peligroso. Tambibn, pueden producirse chispas al enchufar

o

desenchufar

el

cor-

d6n el6ctrico. Estas chispas pueden inflamar

10s

vapores de

10s

solventes

y

el

chorro de fluido pulverizado, particulas de

polvo

y

otras sustancias inflamables. sea al aire libre o baio

techo,

Io

que podria causar una explosi6n o incendio y graves

lesiones corporales

y

daflos a

la

propiedad. Enchufar siempre

la pulverizadora

a

un tomacorriente que

se

encuentre a por

lo

menos

6

m

(20

pies) de

la

m4quina y del area que

se

va a

e1

lugar donde

se

est& rociando cuando todavia exista

la

rociar. No enchufar o desenchufar ningdn cordbn electric0 en posibilidad de

que

queden vapores inflamables

en

el

aire.

choque'el4ctrico

mientras

se

us8

el

equipo, DWAR

DE

Si ocurre una chispa de electricidad esthtica o incluso un ligero

busca de una tierra apropiada. No usar de nuevo

el

sistema

PULVERIZAR DE INMEDIATO. Revisar todo

e1

sistema en

hasta haber identificado

y

solucionado

e1

problema.

Puesta a tierra

Para reducir

el

riesgo de chispas estdticas, conectar a tierra la

se

encuentre en

el

lugar que

se

va a rociar. CONSULTAR

el

pulverizadora y todo

el

otro equipo de pulverizar que

se

use

o

c6digo elbctrico de

la

localidad para las instrucciones sobre las

conexiones a tierra exigidas para la zona

y

tipo

de equipo. ASEGURAR de conectar a tierra todo este equipo pulverizador:

1.

Pulverizadora: enchufar

el

cordbn el4ctrico. o cable exten-

sor, cada uno con

un

enchuf de tres patas

en

buen estado, a un tomacorriente con puesta a tierra apropiado. No usar un adaptador. Totos

10s

cables extensores tienen

que

tener tres

hilos y una capacidad de

15

amperios.

2.

Mangoeras para fluidos: usar solamente mangueras con

puesta a tierra de una longitud combinada de

150

m

tambih al pdrrafo sobre continuidad a tlerra de

la

1500

pies), para asegurar buena continuidad a tierra. Referirse

manguera.

3.

pistola: hacer la puesta a tierra conecthndola a una

manguera de fluido

y

pulverizadora bien conectadas a tierra.

4.

Suministrar

un

recf'piente: de acuerdo al c6digo de la

localidad.

5.

Objeto qua

se

estd rociando: de conformidad con

e1

c6digo

local.

6.

Todos

10s

baldes de solvente usados durante

el

lavado, de

conformidad con

el

c6digo local. Usar solamente baldes de

metal, que

Sean

conductivos. No colocar ei balde en una

superficie no conductiva, como papel

o

cart6n. que inter-

rumpe

la

continuidad a tierra.

7.

Para mantener

la

continuidad a tierra durante

el

lavado

o

descarga de presidn, siempre apoyar una parte metalica de la

pistola bien firme contra

el

costado del

balde

de

metal,

despu6s apretar

el

gatillo.

Seguridad durante

el

lavado

Para reducir

el

riesgo de que

se

inyecte o salpique fluido en la

piel,

o

que ocurra una descarga

de

electricidad estBtica. siem-

pre seguir las INSTRUCCIONES PARA EL LAVADO, dadas

en

la pagina 12. Seguir

el

procedlmlento de descerga de

presl6n

en la phgna

6,

y

quitar la boquiila rociadora antes

de

Iavar.

Apoyar una parte methlica

de

la pistola

bien

firrne

contra

el

costado de un balde de metal y usar ie presi6n

mas

baja

posible de fluid0 durante

e1

lavado.

cia; si excede

10s

limites recomendados, rwmplazarla de

in-

mediato.

Es

muy arriesgado tener una manguera sin puesta a

PELIGRO

DE

LAS PlEZAS MOVILES

tierra 0 con la puesta a tierra en malas condiciones. Leer

tam-

bi4n la informaci6n sobre RIESGO DE INCENDIO 0 EXPLO- otras panes del cuerpo. MANTENERSE ALEJADO de Ias

as

piezas en movimiento pueden pinchar o amputar dedos

u

SION.

mds

arriba. piezas en movimiento durante

e1

arranque 0 funcionamiento

de la pulverizadora. Desenchufar la pulverizadora

y

descargar

la presi6n antes

de

revisar o dar servicio, a cualquier parte de

pulverizadora, para irnpedir que arranque inesperadamente.

IMPORTANT

Se

han adoptado las normas de seguridad del gobierno de

10s

Estados Unidos de Norteambrica bajo

e1

Acta de Seguridad

y

Salud Ocupacional. DeberAn consultarse estas normas. en especial las Generales, Parte

1910,

y

las Normas de

Construe-

cibn, Parte

1926.

*"-I

7=0

7

~~~

INTRODUCTION

Model

231441

ahown

ULTRAm

WO

BAS1

PRESSURE

CONTROL

KNOB

ELECTRIC

MOTOR

CIRCUIT

BREAKER

RESET

BUTTON

DRIVEASSEMBLY

PAILHANQER

ONIOFFSWITCH

PRESSURE

RELIEFVALVE

MAIN

FLUID

HOSE

WHIP

HOSE

Your new UltraTM

500

Sprayer functions and operates

differently than other airless paint sprayers. This section

will

help you become familiar with the sprayer before

operating

it.

The pressure control includes an

ON/OFF

switch for the

Pressure Control sprayer, the pressure adjusting control knob, a pressure

sensing device, and a current overload circuit breaker

with a manual reset bunon.

Its

function is to control the

motor

speed

so that the sprayer maintains constant

fluid pressure

at

the pump outlet.

Motor

The

DC motor has sealed bearings and replaceable

motor brushes.

Its

function is to drive the displacement

pump et the rate needed to supply sufficient paint

volume st the selected pressure. Working together, the pressure control and motor

cause the pump to cycle whenever there is fluid or

pressure demand. When the pump is cycling, the motor

sounds like an automobile starter cranking. When the

pump is not cycling, the motor hums, hums intermit-

tently, or appears

to

have shut

'tself

off.

However, there

will

still

be power to the sprayer and

it

will stay

off

and

relieve pressure.

pressurized and ready to use unless you manually shut

it

Because the motor is DC,

it

is

less

sensitive to low

voltage or voltage fluctuations than an AC motor, and a

heavy gsuge.extension cord of up to

150

feet

145

m)

can be used.

The

sealed drive assembly transfers power from the DC

Drive Assembly

motor to the displacement pump.

Displacement Pump

The

positive displacement, volume-balanced pump pro-

vides

equal

fluid delivery on both the up and down

filled

with

Graco Throat Seal Liquid, helps prevent

pump strokes. The pump has e wet-cup which, when

damage to the throat packings and piston rod.

Ruld

Fllter

The fluid filter provides the final paint straining to help

avoid

c!qs

in

the hose and spray

tip.

The filter ,includes

a reusable element and a pressure relief valve for reliev-

ing fluid pressure when shutting

off

the sprayer.

The

grounded, nylon spray hoses have spring guards on

Hoses both ends. The

50

foot

(15.2

m) hose has a 1/4

in.

ID.

The

3

foot

(0.9

m),

3/16

in.

ID

whip hose allows

flexi-

ble gun movement.

The

nylon hose material ects as

a

pulsation dampener to absorb pressure fluctuations. Spray Gun

8

Reverse-A-Clean

111

Spray Tip

which prevents accidental triggering when

it

is engaged

Graco high pressure spray guns have

s

trigger safety

(see

below). The Reverse-A-Clean

111

spray tip uses high pressure fluid to remove clogs from the spray tup without removing

it

from the gun.

It

includes a safety tip

guard which helps reduce the risk of injection injury.

1.

Connect

Hose

and Gun (Rafer to Fig

1.1

a.

Remove the plastic cap plug from the filter

fluid hose onto the nipple.

outlet nipple and screw the

50

ft

(15.2

ml main

b. Connect the whip hose between the fluid hose

and the gun inlet connection.

c. Don't

usa

thread sealant, and don't install the

spray tip yatl

WARNING

If

you

are supplying your own hoses and spray

gun, be sura they are electrically grounded and

ratad for at least

2750

psi

1195

bar) Working

Ressure,

and that the gun has a tip guard. This is

to reduce the risk of serious bodily injury caused

by static sparking and fluid injection or overpressurizing end rupturing the equipment.

-

TCAUT'ON1

To avoid damaging the pressure control, which

may result in poor equipment performance and component damage, follow these precautions:

1.

Always

usa

nylon spray hose of

at

least

50

ft

(15.2

m) long.

2.

Never

use

a

wire braid hose

as

it

is

too rigid

3.

Never install any shutoff device between

to act

as

a

pulsation dampener.

4.

Always

usa

the main filter outlet for one-

the filter and the main hose.

See

Fig

2.

gun operation. Never plug this outlet.

I

2.

Fill

Packing NutlWet-Cup

(See

Fig

2.)

Throat

Seal

Liquid (TSL), supplied.

Fill the packing nut/wet-cup

113

full with Graco

3.

Check Electrical Service

a.

Be

sure the electrical service

is

120

V,

60

HzAC,

15

Amp (minimum) and that the

outlet

you

use

is properly grounded.

b.

Use

an extension cord which has 3 wires of

a

minimum

12

gauge

size,

and a maximum of

150

ft

145

m) long. Longer lengths may

affect

sprayer performance.

a.

b.

c.

4.

Plug

In

the Sprayer

Be

sure the ON/OFF switch

is

OFF. Refer

to

Fig

3.

Plug

the power supply cord into a grounded

from tha spray area to reduce the chance of

a

electrical outlet that is at

least

20

R

(6

m)

away

spark igniting the spray vapors.

supply cord plug, which is the grounding

Do

not remove the third prong

of

the power

prong, and do not

usa

an adapter.

5.

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

then

s

clean water flush.

mineral spirits followed by soapy water, and

b.

Before using oil-base paint,

flush

with

mineral

spirits only.

ANY

SHUTOFF

m

3

c.

See

FLUSHING GUIDELINES on page

12

for

flushing procedure.

6.

Prepare the paint according to the manufacturer's recommendations.

a.

Remove any skin that may have formed. b. Stir the paint to dissolve pigments. c. Strain the paint through

a

fine nylon mesh

bag

(available at most paint

dealers)

to remove par-

is

probably the most important step toward

tides that could clog the filter or spray tip.

This

trouble-free spray painting.

307-758

9

Pressure Relief Procedure

WARNING

To

reduce the risk of serious bodily injury, in-

cluding fluid injection or splashing

in

the eyes or on the skin, or injury from moving parts or electric shock, always follow this procedure whenever you shut

off

the sprayer, when checking or servicing any pert of the spray system, when installing, cleaning or changing spray

tips,

and whenever you

stop spraying.

2.

Turn the ONlOFF switch to OFF.

1. Engage the gun safety latch.

3.

Unplug the power supply cord.

4.

Disengage the gun safety latch.

5.

Hold e metal part of the gun firmly to the side of

a

metal pail, and trigger the gun to relieve

pressure.

8.

Engage the gun safety latch.

7:Open the pressure relief valve, having

e

con-

8.

Leave the pressure relief valve open until you

tainer ready to catch the drainage.

ere

reedy to operate the sprayer again.

plate& clogged,

or

that

pressure

has

not been fully

If

you

suspect

that the spray tip

or

hose

is

com-

relieved after following the steps above,

VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually.

Then loosen the nut completely. Now clear the tip

or hose obstruction.

1. Prime the Sprayer

with

Paint.

a.

Close

the filter's pressure relief valve.

See

Fig 1. b. Don't install the spray tip yet1 c. Put the suction tube into the paint container. d. Turn the pressure adjusting knob

all

the way

counterclockwise to lower the pressure setting.

e.

Disengage the gun safety latch.

f.

Hold a metal part

of

the gun firmly against end

aimed into

a

metal waste container. See Fig

4.

ONIOFF switch to ON, and slowly increase the

Squeeze the trigger and hold

it

open, turn the

pressure setting until the sprayer

starts.

This procedure reduces the risk of static electric discharge and splashing. Keep the gun triggered until

all

air

is

forced out

of

the system and

the paint flows freely from the gun. Release the

trigger and engage the safety.

NOTE:

If

the pump is herd to prime, place a con-

tainer under the pressure relief valve and open

it.

When fluid comes from the valve,

close

it.

Then disengage the gun safety

latch and proceed

as

in Step

If,

above.

g. Check

ell

fluid connections for leeks.

If

any

are

found, follow the Pressure Relief Procedure Warnlng, above, then tighten connections.

2.

Instail the Spray

Tip

and Tip Guard

a.

Be sure the gun safety latch

is

engaged.

(Refer to Fig

6.)

b.

Unscrew the tip guard retaining nut from the gun.

Fig

4

BE

SURE

GUN

SAFETY

LATCH

IS

ENGAGE01

Fig

5

c.

Install the Reverse-A-CleanTM

111

spray housing

with tip installed. See the RAC

111

packaging

label for instructions.

d. Tighten the retaining nut by hand until snug.

e.

Use a wrench to tighten the retaining nut about 118 to 1/6 turn.

Overtightening the retaining nut

will

damage the

CAUTION

seat gasket end result in leakage.

3.

Adjusting the Spray Pattern

a.

Increase the pressure adjusting knob setting

just until spray from the gun is completely

atomized. To avoid excessive ovenpray and the life of the sprayer, always use the lowest

fogging, and

to

decrease tip wear and extend

possible pressure needed

to

get the desired

results.

b.

If

more coverage is needed, use e larger tip

rather than increasing the pressure.

c. Test the spray penern. To adjust the direction

of the spray pattern, engage the gun safety latch end loosen the retaining nut. Position the tip

so

the groove

is

horizontal for e horizontal pattern or vertical for e vertical pattern. Then tighten the retaining nut.

4.

5.

Operatlng Tips. These suggestions will help prevent the motor from running too hot or operating intermittently.

a.

Decrease the pressure when using a small tip.

b. Keep the sprayer in

e

shaded area when spray-

ing outdoors.

c. Turn

off

the sprayer and relieve pressure

whenever vou stoo soravina.

-ARNING

To reduce the

risk

of serious bodily injury from fluid injection or splashing in the.eyes or on the skin, use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately, then follow the procedure in Steps

%-5e,

below.

Cleaning

e

Clogged

Tip

I

NEVER

wipe

off

build up around the spray tip until pressure is fully relieved and the gun safety latch is engaged.

a.

Clean the front of the tip frequently during the

day's

operation.

First,

follow the Pressure

use

a

solvent-soaked brush to keep paint from

Relief Procedure Warning on page

10.

Then

building up and clogging the tip.

spray tip handle

180°.

See

Fig

6.

ger, engage the gun safety, and rotate the

c. Disengage the gun safety latch and trigger

the

gun into

a

waste

container. Engage the gun

safety latch again.

b. If the spray tip does clog, release the gun trig

d. Return the handle to the original position,

disengage the gun safety, and resume spraying.

8.

If

the

tip is

still

clogged,

engage the gun safety

latch,

shut

off

end unplug the sprayer,

and

open the pressure relief valve to relieve pressure. Clem the spray tip.

1.

2.

3.

SHUTDOWN AND

CARE

Check the packing nut/wet-cup dally. First

follow the Pressure Rellef Procedure Warning at

all

times to help prevent paint buildup on the

on page

10.

Be

sure the wet-cup is

1/3

full of

TSL

piston rod and premature wear of packings.

The

pecking nut should be tight enough to stop leakage, but no tighter. Overtightening may cause bindina and excessive Dackina weer.

Use

a

screw-

driver and light hammer to idjust the nut.

See

Fig

7.

sprayer is stored. First follow the Pressure

Relief

Clean the fluid fllter often and whenever the Procedure Warning on page

10.

Refer

to

manual

307-273,

supplied, for the cleaning procedure.

and

fill

it

with mineral spirits to help prevent pump

Flush the sprayer at the end

of

each work

day

corrosion end freezing.

See

"Flushing Guidelines"

on page

12.

CAUTION

Never leave water or any paint in the sprayer overnight to:

(1)

prevent pump corrosion;

(2)

to

pre-

vent the paint or water from freezing

in

the pump

and pressure control which can cause

loss

of

Always use mineral spirits for the final flush.

pressure, stalling or serious sprayer damage. Relieve pressure. This leaves

a

protective coating

of

mineral spirits in the sprayer.

4.

For

very

short shutoff periods, leave the suction tube in the paint, follow the Pressure Rellef Procedure Warning on page

10,

and clean the spray

tip.

5.

Coil

the hose and hang

it

on the hose rack when

storing

it,

even for overnight, to help protect the

hose

from kinking, abrasion, coupling damage, etc.

Fl9

7

Wt7.7M

11

FLUSHING GUIDELINES

When to Flush

5.

Storage.

1.

New Sprayer. Your new UltraTM

500

Sprayer was

factory tested in lightweight oil which was

left

in to

Water-base pelnt

flush with water, then mineral

spirits and leave the pump, hose and gun filled with

Before

using

water-base pelnt,

flush with mineral

protect pump parts. mineral spirits. Shut

off

and unplug the sprayer,

spirits. followed by soapy weter, and then

e

clean

open the pressure relief valve to relieve pressure and

leave

open.

water

flush.^

Oll-base palnt:

flush with mineral spirits. Shut

off

Before

uslng

oil-base palnt,

flush with mineral and unplug the sprayer, open the pressure relief

spirits only. valve to relieve pressure and leave open. such

as

mineral spirits or water.

Flush with soapy water, than mineral spirits.

then

a

clean water flush.

Flush with mineral spirits, followed by soapy water, is ready to use.

2.

Changing Colors. Flush with a compatible solvent

6.

Startup after storage. Before

uslng

water-base palnt,

flush out mineral

3.

Changing from water-base to oil-base paint.

spirits with soapy water and then

a

clean water

flush.

When.uslng

off-base

paint,

flush out the mineral

4.

Changing from oil-base to water-base paint. spirii with the paint to be sprayed and

the

sprayer

How

to

Flush

1.

Follow the Pre.esure Relief Procedure Warning

on page

2

or

10.

2.

Remove the filter bowl and screen;

see

manual

307-273

supplied. Clean the screen separately and

install the bowl without the screen to flush

it.

See

Fig

8.

3.

Close the filter pressure relief valve.

4.

Pour one-half gallon

(2

liters) of compatible solvent

into

a

bare metal pail. Put the suction tube in the

pail.

5.

Remove the spray tip from the gun.

WARNING

splashing, always remove the spray tip from the gun, and hold

a

metal part of the gun firmly to the

side of and aimed into

a

grounded metel pail when

flushing.

8.

Disengage the gun safety latch. Point the spray gun

of the gun firmly touching the metal container,

into

e

metal

wasta

container and with e metal pert

squeeze the gun trigger.

Sea

Fig

9.

Thls

pre

and splashlng.

With the gun triggered, turn the

cedure helps reduce the rlsk

of

statlc sparklng

ON/OFF switch to ON and slowly turn the pressure adjusting knob clockwise

lust untll

the sprayer

starts.

Keep the gun triggered until clean solvent

comes from the nozzle.

Release

the trigger and

engage the gun safety latch.

12

307-753

METALTO METAL

MAINTAIN FIRM

GUN AND CONTAINER

CONTACT BETWEEN

Fig

9

7.

Check

all

fluid connections for

leaks.

If

any leak,

first follow the Pressure Relief Procedure Warn-

start

the sprayer, and recheck the connections for

ing on page

2

or

10.

Now

tighten the connections,

leaks.

8.

Remove the suction tube from the pail. Disengage the gun

safety

and trigger the gun

to force

dvant

from the hose.

Do,

not let the pump run dry

for

more than

30

seconds to wold damaglng the

pump packlngsf

Then turn ON/OFF switch to OFF

and engage the gun safety.

9.

Unplug the power supply cord. Open the pressure the sprayer again. Unscrew the filter bowl and

relief valve and leave open until you are ready to

use

reinstall the clean screen. Reinstall the bowl, hand

tight only.

10.

If you have flushed with mineral spirits end are go-

water followed by

a

clean water flush. Then repeat

ing to

use

e

water-base paint, flush with soapy

Step

1.

TROUBLESHOOTING GUIDE

Pressure

Relief

Procedure

WARNING

To

reduce the risk

of

serious bodily injury, including fluid injection, splashing

fluid

in

the eyes or

on

the skin, or

in-

jury from

moving

parts

or electric

shock,

always

follow

this procedure whenever you shut

off

the sprayer, when

checking or servicing any part

of

the

spray system, when installing, cleaning or changing spray tips, and whenever

you stop spraying.

2.

Turn

the

ONlOFF

switch to

OFF.

1.

Engage

the gun

safety

latch.

3.

Unplug

the

power supply cord.

4.

Disengage

the

gun

safety

latch.

5.

Hold a metal part

of

the gun firmly to the side

of

a

metal pail,

and

trigger the gun to relieve pressure.

6.

Engage

the

gun

safety

latch.

7.

Open the pressure relief

valva.

8.

Leave

the

pressure

relief

valve open until you are ready to spray again.

If

you

suspect that the spray tip or hose is completely clogged, or 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 tip or hose.

PE OF PROBLEM

ITOR

WON'T

OPERATE

iic

Fluid Pressure Problems

;ic Mechanical Problems

iic Electrical Problems

WHAT

TO

CHECK

If check

Is

OK,

go

to

next check

I

When

check

la

not

OK

refer

to

thls

cdum~

WHAT TO

DO

1.

Check the pressure control knob setting. The

1.

Slowly increase the pressure setting to see

ii

motor

will

not run if

it

is

at

the minimum set-

ting (fully counterclockwise).

the motor starts.

2.

Check for a clogged spray tip. Refer to your

or tip instruction manual for tip cleaning. separate gun or tip instruction manual.

2.

Relive pressure, refer to your separate gun

1.

Check for frozen or hardened paint in the

tube. Using

a

screwdriver, carefully try to

1.

Thaw'. Plug in sprayer and turn on. Slowly

page

19.

starts.

If

it

doesn't. replace the displacemeni

increase pressure setting to see

if

motor

pump

(39)

andlor pressure control bourdon

rotate fan

at

back of motor by hand. See

pump packings

(see

manual

307-7931

andlor

replace the bare pressure control box

(301)'.

sea

page

26.

2.

Check displacement pump connecting rod

2.

Push pin into place and secure with the

(20).

It

must be completely pushed into

connecting rod

(3)

and spring retainer

(35)

spring retainer.

should be firmly in groove of connecting rod.

see

page

28.

3.

Check for motor damage. Remove drive

2.

Replace motor

(1)

if fan won't turn.

housing assembly

(2).

See page

29.

Try to

rotate fan by hand.

be sure

it

has not popped up. circuit breaker continues to open,

see

"Elec.

1.

Check sprayer circuit breaker

(309)

button to

1.

Depress circuit breaker button to reset. If

trical

Short", page

16.

2.

Check electrical supply with volt meter.

Meter should read

105

to 125

VAC.

3.

Check extension cord for visible damage.

cord outlet to check.

Use

a

volt meter or

teat

lamp

at

extension

4.

Check sprayer power supply cord

(311)

for visible damage such as broken insulation or wires.

5.

Check motor brush leads, terminals and brush length. Brush length should be

112"

minimum.

See

Dane

22.

2.

Reset building circuit breaker: replace building fuse. Try another electrical outlet.

3.

Replace extension cord.

4.

Replace power supply cord. See page

23.

5.

lighten terminal screws; replace brushes.

See page

22.

'Thaw the sprayer if water or water-based paint has frozen in When replacing the bare pressure control box (item

301).

it,

due to exposure to

low

temperatures, by placing

it

in

a

warm

area.

Do

not try to start the sprayer

until

it

has thawed

remove the circuit breaker, ONlOFF switch, bridge, circuit board and electrical hardware and reinstall these parts

in

the

freezing, the pump should operate.

If

paint hardened (dried) in

Mmpletely. If the bourdon tube was not damaged by the bare box.

the

sprayer, the pump packings andlor bare prossure control

must be replaced.

See

page

26

or manual

307-793.

Troubleshooting continuedon nextpage.

307-758

13

fPE

OF

PROBLEM

OTOR WONT OPERATE

gnosing

circuit board

in-

ator lamps. The normal ndition

is

red

lamp

on,

1ar lamp on when board

is

ring

pump

to

run.

~llow Pressure Relief Produre. Remove gun from

lee.

Remove pressure con-

)I

cover and check for faulty

nps.

ndition

of

circuit board

mdition A both lamps

on:

Imp won't operate and >tor is not running

ondkion

B

0th lamps

off

WHAT

TO

CHECK

It

check Is

OK,

to to next check

.

Check leads from bridae

(3081

to motor to

be

sure thei are securelyiastened and properly mated.

:.

Check G1 and G2 connections between circuit board

123)

and bridge

WS)

for damage

or

10088

terminals.

,,

Check for

loose

motor brush lead connec-

tions and terminals. See page

22.

..

Check brush length which should be

1/2"

minimum. See page

22.

the same rate

on

both sides of the motor.

NOTE also that the brushes do not wear

at

i.

Check for broken or misaligned motor brush

springs. Rolled portion of spring must rest squarely

on

top of brush. See page

22.

i.

Check motor brushes for binding in brush holders. See page

22.

1.

Check motor armature commutator for burn

spots, gouges and extreme roughness.

Remove motor cover and brush inspection plates to check.

See

page

22.

mature tester (growler) or perform spin test.

See

page 19.

good bridge or performlng brldge

teat.

See

page

20.

CAUTION:

Do

not perform this check until armature is determined to be good. A bad armature will immediately burn out

a

good

bridge.

I.

Check motor armature for shorts using ar-

j.

Check bridge

(308)

by sybstituting with a

2.

Check sprayer power supply cord (3111. Disconnect TP6 female and TP1 female and

sprayer. Meter should read 105 to 125 VAC.

connem

volt meter

to

these leads. Plug

in

Unplug sprayer. Reconnect TP1.

3.

Check ONlOFF switch

(303).

Disconnect TP:

and connect volt meter

to

TPB female and

TP2 male. Plug

in

sprayer and turn

on.

Mete

should read 105 to 125 VAC. Turn

off

and

unplug sprayer. Reconnect TP2.

I.

Check jumper wire

(5%).

Disconnect TP3

and

connect

volt meter to TP6 female and

TP3

female. Plug in sprayer and turn

on.

Meter

should read

105

to 125 VAC. Turn

off

and unplug sprayer. Reconnect TP3.

5. Check circuit

breaker

1309).

Connect

volt

meter to TP6 female and TP4. Plug in sprayer and turn

on.

Meter should reed 105

to 125 VAC. Turn

off

and unplug sprayer.

77

-

1.

2.

3.

4.

5.

6.

7.

8.

9.

"

1.

2.

2

r

3.

4.

5.

WHAT TO

DO

When check is

not

OK

refer to this columr

Replace any l&e terminals

and

crimp to

leads.

Be

sure male terminal blades are

straight and firmly connected to mating part.

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

Tighten terminal screws. Replace brushes if

leads are damaged.

See

page

22.

Replace brushes.

See

page

22.

Replace spring if broken. Realign spring witb brush. See page

22.

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

Remove motor and have motor shop resur-

face commutator if possible. See page

30.

Replace motor.

See

page

30.

Replace bridge. See page 24.

Depress circuit breaker button to reset. if cil trical Short", page 16.

cuit breaker continues to open, see "Elec-

Replace power supply cord. See page

23.

Replace ON/OFF switch. See page

23.

Replace jumper wire.

See

page

25.

Replace circuit

breaker.

See

page

24.

(Continued)

Troubleshooting continued

on

YPE

OF

PROBLEM

ondition

B

bntinued)

ondition

C

"

hen replacing the

bars

prssaure

wntml

box

C301l.

remove

the circun breaker.

dge,

circuit board and

alenrical

hardware

and

reiMtall

in the

new

bars

box.

hen

WHAT TO

CHECK

If

check

Is

OK,

go

to

6.

Check motor thermal cutout switch. Connect volt meter to TP6 female and TP9

female. Plug in and turn

on

sprayer. Meter

should read 105 to 125 VAC. Turn

off

and

unplug sprayer.

7.

Check microswitch

(3021.

Reconnect TP6

connectors. Connect volt mater

to

TP15 male and TP4. Meter should read 50-125 VAC.

8.

Visually inspect microswitch

13021

button.

Adjustment stud

(Q)

should not depress the microswitch button when fluid pressure is zero. Manually check by depressing button with small screwdriver; an audible click indicates microswitch is in normal position.

9.

Check microswitch

1302)

continuity with ohm

meter. Be

sure

sprayer is unplugged1 Mater

should read zero ohms with

no

fluid pressure

in the sprayer.

10.Check all terminals for damage or loose fit. Reconnect TP6 connectors.

11.Check circuit board

(23)

by substituting with

a

good board.

See

page 25.

1. Check circuit board

(23)

by removing from

25

for removal procedure.

box without disconnecting wires;

see

page

while

still

wired over-rides the optical detec-

WARNING: Removing the circuit board tor which could cause the sprayer to overtion properly. Turn the sprayer on

OML

Y

pressurize, if the microswitch does not func-

shut

off

immediately.

long enough to check lamp condition, than

WARNING:To reduce the risk of electric shock, handle board by

edges

only1

Do

not allow any metal objects to come in contact with the boardl

Plug

in

and turn

on

sprayer. Clear lamp

should

be

on

now - removing the circuit

board over-rides the optical detector. Turn

off

and unplug sprayer.

2. Check bourdon tube flag and detector position. Reinstall circuit board

(see

page

251.

Turn pressure setting

to

maximum; flag

should extend

less

than haif way into optical

detector slot from the bottom.

VIEW

OF

OPTICAL DETECTOR

AND

FLAG

and

reiMtall

in the

new

bars

box.

box

C301l.

remove

the circun breaker.

WHAT TO

DO

When check le not

OK

refer

to

thls column

i.

Allow motor to cool. Correct cause of overheating. If switch remains open etter motor

cools,

check continuity between TP9 female

and TPlO with ohmmeter. If

open,

replace

motor.

'.

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

I.

Microswitch is faulty. Return sprayer for repair.

I.

Microswitch is faulty. Return sprayer for repair.

0.Replace damaged terminals and reconnect

1 .Replace circuit board.

See

page 25.

securely.

.

Replace circuit board.

See

page 25.

!.

Calibrate pressure control to see

if

chat cor-

rects problem.

See

page

27.

If

not, replace bare pressure control box

(3011'. See page

26.

Troubleshooting continued on nextpage

YPE

OF

PROBLEM

DW

OUTPUT

0

OUTPUT

lotor run8 and pump stroke!

WHAT TO CHECK

If check is

OK,

go

to

I.

Check for worn spray tip.

2.

Check to sae that pump does not continue

to

stroke when gun trigger is released. Plug

in and turn

on

sprayer. Prima with paint. Trigger gun momentarily, then release and engage safety latch. Relieve pressure, turn

off

and unplug sprayer.

3.

Check electrical supply with volt meter. Meter should read

105

to 125 VAC.

4.

Check extension cord size and length:

must

be

at

least 12 gauge wire and

no

longer thar

1Wft

(15.2

m).

5.

Check

G1

and

G2

leads from bridge

(308)

to

circuit board

(23)

for damage or

lwae

wires

or connectors. Refer to page

25.

Procedure

on

page

27.

5.

Check staii pressure. Refer to Calibration

7.

Check bridge

(308)

+

and - iaads and

ter-

minals to motor.

InsDect

wiring insulation

and terminals for signs of overheating.

See

page

,20.

3.

Check for

loose

motor brush leads and tar-

mimls. See page

22.

8.

Check for worn motor brushes which should be 1

/2"

minimum.

See

page

22.

I0.Check for broken and misaligned motor

brush springs. Rolled portion of spring

must

rest

squarely

on

top of brush.

I1 .Check motor brushes for binding

in

brush

holders. Sea page

22.

12.Check circuit board

(23)

by substituting with

a good circuit board.

See

page

25.

13.Check motor armature for shorts by using

81

armature tester (growler) or perform spin

test.

See

page

20.

14.Check bridge

1308)

by substituting with

a

gwd bridge or by performing the bridge test. See page

19.

CAUTION:

Do

not perform this check

until

armature is determined

to

be good. A bad

armature will immediately burn

out

a

good

bridge.

1.

Check paint supply.

2.

Check for clogged intake strainer.

See

page

29.

3.

Check for

loose

suction tube or fittings.

See

page

29.

WHAT TO DO

When check

Is

not

OK

refer

to

this

colum

1.

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

2. Selvice pump.

See

manual

307-793.

3.

Reset

building circuit breaker; replace

building fuse. Repair electrical outlet or try

another outlet.

4.

Replace with a correct, grounded extension cord.

5.

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

6.

Calibrate pressure control.

See

page

27.

7.

Be sure male terminal blades are centered

and firmly connected to female terminals.

Replace

any

loose

terminal or damaged wir-

ing. Securely reconnect

wires

to bridge.

8.

lighten terminal screws. Replace brushes if

9.

Replace brushes.

See

page

22.

leads are damaged. See page

22.

10.Raplace spring if broken. Realign spring

wit1

brush.

See

page

Y2.

1l.Claan brush holders, remove

carbon

dust with small cleaning brush. Align brush lead with

slot

in brush holder to assure free ver-

tical brush movement.

12.Replaca circuit board. See page

25.

13.Raplace motor.

See

page

30.

14.Replace bridge.

See

page 24.

1.

Refill and reprime pump.

2. Remove and clean, then reinstall.

3.

Tighten:

use

thread sealant or sealing tape

on

threads

if

necessary.

Tmubleshooting

continued

on

TYPE

OF

PROBLEM

NO OUTPUT

(Continued)

not stroke

Motor

NnS

but pump does

-

EXCESSIVE PRESSURE FLUCTUATIONS

Spray pattern variations.

h

R

1

WHAT TO CHECK

If

check

Is

OK,

go

to

next check

ball are seating properly. See manual

m-793.

i.

Check

to

sea

if intake valve ball and piston

i.

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

307-793.

.

Check displacement pump connecting rod

pin.

See page

28.

!.

Check connecting rod assembly for damage.

I.

Be sure crank

in

drive housing rotates; plug

in

sprayer and

turn

on

momentarily

to

check.

Turn

off

and unplug sprayer. Sea page

29.

sw

page

28.

I.

Be sure both

G1

and

62

leads from bridge

1308)

to

circuit board

(231

ere firmly

connected. See page

25.

procedure

on

page

27.

!.

Check stall pressure. Refer to Calibration

I.

Check bourdon tube flag and detector posi-

tion. Turn pressure setting to maximum; flag

should not drag or

bind

in optical detector

slot of circuit board.

,-CIRCUIT

BOARD

VIEWOFOPTICAL DETECTOR AND

FLAG

1.

Check circuit board

(23)

by substituting

with

i.

Check

LOW

OUTPUT section on page

16.

a good board. See page

25.

I.

Check to see if sprayer has been operating at

low

motor RPM and results

in

excessive heat

high pressure

with

small tips, which causes

build

up.

2.

Check to

see

if ambient temperature where

sprayer is located is more than

90°F

(32"Cl

or

if

sprayer is located

in

direct sun.

3.

Check to

see

if

sprayer has been left in a

stalled condition (sprayer turned

on,

pressurized, but

not

operating1 for long

periods of time.

Man

replacing

the

bare

pmsnure

control

box

1301).

remove the circuit board,

bridge.

circun

board, and

electrical

hardware and reinstall

in

the

MIW

bare

box.

WHAT

TO

DO

When check

Is

not

OK

refer

to

thls column

,.

Remove intake valve and clean. Check balls and mats far nicks; replace if necessary. See manual

307-793.

8.

Replace packings. See manual

307-793.

Also

check piston valve seat for hardened paint or nicks and replace

if

necessary.

.

Replace pin

if

missing. Be sure retainer

spring is fully

in

groove all around connact-

ing rod. See

28.

.

Replace connecting rod assembly. See page

28.

.

Check drive housing assembly for damage

and

replace

if

necessary. See page

29.

.

Reconnect securely. See page

24

and

25.

.

Calibrate pressure control.

See

page

27.

.

Carefully band flag into alignment with detector slot

to

sea

if that corrects problem.

If

not,

replace bare pressure control

assembly

1301)'.

Calibrate pressure control

after reassembly.

.

Replace circuit board. See page

25.

.

Decrease pressure setting or increase tip

size.

:.

Move sprayer

to

shaded, cooler area if

possible.

I.

Turn

off

sprayer whenever you stop spraying

for

a

while and relieve fluid pressure.

Tmubleshooting continued on nexrpage

ELECTRICAL SHORT

Building circuit breaker opens

turned

on.

as

soon as sprayer switch is

Any

short in any part of tht

CAUTION

motor power circuit, which

i:

connected to the output sidt of the bridge, will cause tht bridge to burn out immediats ly. Correctly diagnose an( repair

all

shorts before check

ing and replacing bridge

as

soon

es sprayer

is

plugged

Building circuit breaker opens

turned

on.

into outlet and sprayer is NO

after sprayer operates for

on1

Sprayer circuit breaker opens

6

to

10

minutes.

-

WHAT TO CHECK

If check

i.

OK,

eo

to

next check1

I.

Check

a11

electrical wiring for damaged in-

sulation, and

all

terminals for loose

fit

or

damage. Be sure to check wires between

pressure control and motor which ere ences-

ed

in conduit

(22).

See pege

29.

1.

Check for missing inspection plate gasket (see page

22).

bent terminal forks or other metal to metal contact points which could cause

e

short.

3.

Check motor armature for shorts by using an

test.

See

page

19.

Inspect windings for

armature tester (growler) or perform spin burns.

1.

Check bridge

(308)

by substituting with

a

good bridge or by performing bridge test.

See

page

20.

CAUTION:

Do

not

perform this check

until

armature is determined to be good. A bad armature

will

immediately bum out a good

bridge.

1.

Check 'Basic Electrical Problems'

on

page

14

2.

Check ONlOFF switch

(303)

See page

23.

Be

sum

the sprayer

is

unplugged1 Disconnec

wires

from

switch and check switch with

ohm meter. The ohm meter should read inwith the switch ON.

finity

with

the ON/OFF switch OFF, and zerc

burn the bridge out immediately, which in turi

CAUTION:

A short in the motor circuit wil

usually ceuses the ON/OFF switch to fail

in

thl

closed mode.

1.

Check electrical supply with volt meter. Meter should read

105

to

125

VAC.

2.

Check tightness of pump packing nut. Overtightening nut tightens packings

on

rod,

restricts pump action, and damages

-

packings.

See

page

28.

3.

Check stall pressure. Remove the plug from the top of the fluid filter, and install

a

5ooo

psi

(350

bar) fluid-filled pressure gauge.

See

Age

27.

Plug

in and turn

on

sprayer. Slowly

increase pressure setting to maximum.

PumF

Turn

off

and unplug sprayer.

should

stall

at

2560-2750

psi

1178195

bar).

system, reat circuit breaker button.

4.

After determining that there

is

no

short in

WHAT TO

DO

When

ckk

le

not

OK

refer

to

this

columr

1.

Repair or replace any damaged wiring or terminals. Securely reconnect

all

wires.

2.

Correct faulty conditions.

3.

Replace motor.

See

page

30.

4.

Replace bridge.

See

page

24.

2.

Replace ONlOFF switch.

See

page

23.

1.

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

2.

Loosen

packing nut. Check for leaking

around throat. Replace pump packings, if

nBcB8881y.

See manual

307-753.

3.

Calibrate pressure control.

See

page

27.

4.

If

circuit breaker continues to open (button

pops up), replace the circuit breaker.

See

page

24.

Troubleshooting continued on next page

18

307-758

the risk of a fluid injection injury, injury from moving Darts. or electric shock.

trical continuity.

For checking armature, motor'winding and brush elecsetup

Remove the drive housing from the sprayer as das-

cribed in "Drive Housing Replacement", Steps

14,

page

29.

Remove the pressure control cover and screws, the

covers

IJ).

See

Fig

10.

motor cover, the fan cover

IF),

and

the

inspection

Disconnect the

two

leads from the motor to the bridge

Armature

Short

Clrcult Test

shorts,

the motor will coast

two

or three revolutions

Quickly turn the motor

fan

by hand.

If

them

are

no

before coming to a complete stop.

If

the motor does

not

spin freely and resists rotation, the

armature is shorted and the motor must be replaced.

See page

30.

1308).

see Fig

11.

Armature, Brushes, and Motor Wlrlng Open

Clrcult Test (Continuity) Connect the

two

black motor leads together with a

test

lead. Turn the motor fan by hand at about

two

revolutions

per second.

following: a) broken brush springs; b) broken brush

If

there

is

uneven or no turning resistance, check the

leads;

c)

loose brush terminal screws;

d)

worn brushes;

e)

broken motor leads; f)

loose

motor lead term@als.

Repair parts as

needed.

See

page

22.

If

there is

still

uneven or no turning resistance, replace

the motor. See page

30.

~ ~~

BRIDGE

TEST

Remove the bridge from the pressure control box and perform this test to determine

if

the bridge is functional.

See

Bridge Rectlfler Replacement, page

24.

Use

a

continuity tester, such as multi-meter set on the

X1

ohmsscale

(

IY

).

Eight individual checks,

or

tests,

must be performed. If

the bridge fails even one test,

it

must be replaced.

Fig

12

shows the position

of

the wires on the bridge.

Us-

ing the chart at the right, connect the meter wires

sa

indicated by the black dots for each test, then check the continuity.

In

Tests

1,2

and

3,

there should

be

NO

continuity.

In

Tests

4,5

and

6,

connect the + and - meter wires as indicated, check continuity, then switch the meter wire connections and check c0ntinu.W again. You should get

NO

continuity one way, and YES continu'w the

other way.

In

Tests

7

and

0.

connect the meter wires as indicated

by the black dots. Touch the indicated

"G"

wire to one

meter wire, and then to the other. You should get

NO

continuity one way, and YES continuity the other way.

BRIDGE

WIRES

REPAIR SECTION INDEX

..

-.

General Repair Notes

21

Procedure Page

Motor Brush Replacement

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

22

ONIOFF Switch Replacement

23

Power Supply Cord Replacement

23

Bridge Rectifier Replacement

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

24

Circuit Breaker Replacement

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

24

Circuit Board Replacement

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

25

Pressure Control Replacement

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

26

Stall Pressure Calibration

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

27

Bearing Housing

b

Connecting Rod Replacement

.....a

Drive Housing Replacement

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

29

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

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

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

Motor Replacement

30

Parts Lists b Drawings

"

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

-

Sprayer

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

32,

33

Pressure Control

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

34

Circuit Board

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

35

How To Order Replacement

Parts

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

33

The following tools are needed when repairing this sprayer.

Phillips screwdriver Small flatblade screwdriver Needle nose pliers Plastic mallet

2"

adjustable, open-end wrench

Adjustable wrench Torque wrench 3/16" hex key wrench

114"

hex key wrench

518" socket wrench 318" open end wrench

112" open end wrench 314" open end wrench 718" open end wrench

High quality motor oil

Bearina clreese

NOTE:

See

separate manuel 307-793 for displace-

"-

merit

pump repair.

For calibration procedure only:

318" ignition wrench

0.015"

spray tip

High pressure, oil-filled

test

gauge, Part No. 102-814

5

gallon pail Clean water Mineral spirits NEW

3ooo

psi (207 bar) high pressure spray hose,

Part No. 214-915.

GENERAL REPAIR NOTES

ing general repair notes and the repair procedure.

Be

Before repairing any part

of

the sprayer, read the follow-

sure you have the necessary

tools

and parts available.

1. When disconnecting wires in the pressure control assembly, use

needle

nose

pliars

to

separate mating

connectors. When reconnecting the wires, be sure the flat blade

of the insulated male connector is centered in the wraparound blade of the female connector when the connection

is

made.

rCAUT'ON1

tion, be sure

to

properly mate connectors, and

To reduce the risk of

a

pressure control malfunc-

nevar

pull on a wire to disconnect

it.

Pulling on

a

wire could loosen the connector from the wire.

~~~~ ~~~

2.

Route

wires in the pressure control assembly

carefully through the

legs

of tha U-shaped bourdon

tube, where appropriate,

to

avoid interfering with

the bourdon tube which moves

as

the pressure set-

ting changes and

to

avoid pinching the wires bet-

ween the pressure control box end cover.

CAUTION

Improper wire routing can result

in

poor sprayer

performance or damage

to

the pressure control.

3. Keep

all

screws, nuts, washers, gaskets, and elec-

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 13-20,

to

help iden-

tify other possible problems and solutions.

WARNING

To reduce the risk of serious bodily injury, including electric shock, DO NOT touch any moving

while inspecting

the

repair.

parts or electrical parts with your fingers or

a

tool

Shut

off

the sprayer and unplug

it

es soon

as

you

Reinstall

ell

covers, gaskets, screws and washers

before oDeratina the sDraver.

I

,

complete the inspection.

Do not run the sprayer dry for more than

30

CAUTION

seconds to avoid damaging the pump peckings.

5.

Reinstall the motor cover before regular operation of the sprayer and replace

it

if

it

is

damaged. The

cover directs cooling air around the motor to help

prevent overheating.

It

can

also

help prevent burns,

fire or explosion;

see

the WARNING, below.

"--------WARN

During operation, the mo

307-758

21

MOTOR BRUSH REPLACEMENT

Tools

Needed: Phillips screwdriver flatblade screwdriver

NOTE:

Replace the brushes when they have worn

to no

less

than

1/2

in.

See

STEP

1,

Fig

14.

Note that the brushes wear differentlv on

each side of the motor. Brush Repsi; Kit

220-349

is available.

CAUTION

seconds while checking the brushes to avoid

Do

not run the sprayer dry for more than

30

damaging the displacement pump.

11.

Reinstall the brush inspection covers, gaskets, and screws. Reinstall the motor cover, screws end washers.

WARNING

Before doing this procedure, follow the Pressure

the risk of injection injury, injury from moving

Relief

Procedure Warning on page

13

to reduce

1.

Remove the motor cover

(14).

See

Fig

13.

2.

Remove the screws (HI, inspection covers

(Jl

and

gaskets (Kl on each side of the motor.

See

Fig

13.

3.

Push down and then in on the spring clip slightly, and then pull the clip in end out of the brush holder. Refer to STEP

3,

Fig

14.

Keep the spring clip.

4. Loosen

the brush lead terminal screw and remove

the lead.

5.

Remove and discard the brush.

6.

Inspect

the

commutator for excessive pining, burn-

ing or gouging.

NOTE:

A black color on the commutator is normal.

Have the commutator resurfaced by a

qualified motor repair shop

if

the brushes

seem to be wearing too

fast.

..

..:

.

,

..

,..

.

. .

7.

Place a new brush

in

the holder

so

the lead is st the

top of the holder. Place the brush lead terminal on

the

terminal screw

so

the terminal

is

parallel with

the brush holder. lighten the terminal screw.

See

STEP

1,

Fig

14.

8.

Wnh the spring roll touching the brush, push the forked end of the spring clip into the brush holder.

See

STEP

2,

Fig

14.

When the fork passes through

the end of the holder, push the clip up or down until

the

fork hooks the end

of

the holder.

See

STEP

3,

Fig

14.

9.

Position the brush lead

as

shown in STEP

3,

Fig

14.

Be sure the brush lead does not touch any part of the armature or motor housing.

8.

With

the ONlOFF switch OFF, turn the

wise

to

minimum pressure. Plug in the sprayer.

pressure control knob

all

the way counterclock-

b.

Turn the ON/OFF switch

ON

and slowly increase the pressure until the motor comes up to full speed.

10.

Test the brushes:

c. Inspect the brush and commutator contact area

for excessive arcing. Arcs should not

"trail"

or

circle around the commutator surface.

WARNING

Do

not touch the brushes, leads, springs or brush

the

risk of electric shock and serious bodily injury.

holders while the sprayer is plugged in to reduce

n

307-758

D

OF

MOTOR

To

mmova brush. push down and In. and than pull out sprlng cllp

Fork mum hook holdar when InMlllng

down and In. and ihsn pull out sprlng cllp

BRUSH

LEAD

Fig

i4

.

POWER SUPPLY CORD REPLACEMENT

r".^ININGl

Before doing this procedure, follow the Pressure

the risk of

a

fluid injection injury, injury from mov-

Relief

Procedure Warning on page

13

to reduce

ina

Darts.

or electric shock.

UnDlua

the soreverl

1.

Remove the pressure control cover and screws.

ONlOFF switch

~302).

the whimwire going to the

2.

Disconnect the power supply cord lead from the bridge

(308).

and the green wire to the grounding

screw

(3431

and lockwasher

(327).

See

Fig

15.

3.

Loosen the strain relief bushing

(328).

Remove the

power supply cord

(3111.

4.

Install

the

new cord in the reverse order

of

disassembly.

5.

Reinstall the cover and screws.

Fig

15

ONlOFF SWITCH REPLACEMENT

rwARN'NGl

Before doing this procedure, follow the

Pressure

the risk of a fluid injection injury, injury from mov-

Rellef

Procedure Warning on page

13

to reduce

ina

MRS.

or electric shock.

UnDlua

the soraverl

1.

2.

3.

4.

5.

6.

7.

8.

Remove the pressure control cover and screws.

Use

a

needle nose pliers to disconnect the upper

terminal wire from the microswitch

(302)

for ease in

removing the ONlOFF switch

(303).

Refer to Fig

15.

Use

the pliers to disconnect the

two

black wires

from the ON/OFF switch

(3031.

Refer to Fig

15.

Use

a

5/8

socket wrench to loosen and remove

6YD'

the nut and rubber boot

(304)

from the top of the

pressure control box. Remove the switch guard

(305).

See

Fig

16.

TO

Remove the ONlOFF switch.

rotation ring

(WI

engages with the vertical groove

Install the new.switch

so

the internal tab of the anti-

in the threads of the switch, and the external tab engages with the blind hole (Dl of the pressure control box.

See

Fig

16.

Install the switch guard

(3051,

aligning the internal

tab with the groove in the threads.

See

Fig

16.

Install the nut and rubber boot

(304)

and tighten.

See

Fig

16.

PRESS

CONTROL

303

Fig

16

9.

Reconnect the wires to the ON/OFF switch

13031

and reconnect the wire to the microswitch

(302).

Refer to Fig

15.

10.

Reinstall the pressure control cover and screws.

307-758

23

BRIDGE RECTIFIER REPLACEMENT (Refer to Fig 17)

Before doing this procedure, follow the Pressure

and tighten

the

screws

securely.

the risk of s fluid injection injury, injury from mov-

Relief

Procedure Warning on page 13 to reduce

ARNING

6.

Make sure the bridge is flush with the side of

the

box

7.

Connect

all

wires. Carefully route the wires.

1. Remove the oressure control cover and screws.

IcAuTloNl

Be

sure

the

flat

blade of the insulated male con-

nector is centered. in the wraD-around blade of the

~~

2.

Disconnect

ell

wires from the bridge

(308)

at the ap-

~ ~~~~ ~ ~~~~ ~~~~~

I

female connector when the connections ere

soraver to malfunction.

made. Improper connections may cause the

propriete terminals.

I

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

two

screws

(331).

Loosen,

but don’t remove the

screw near the beck of the control box. Then loosen

Route

all

wires carefully to avoid interference with

and remove the front screw. Slide tha bridge out.

the

movement of the bourdon tube, circuit board,

or control box cover which could causes malfunc-

4.

Slide the new bridge

(308)

into the box being sure

the lockwasher

(333)

on the rear screw (331) is

IN

FRONT

of the bridge. Refer to the Detail in Fig 17.

8.

Reinstall the pressure control cover and screws.

~~

~,~~

~~ ~ ~~~~~~~~~ ~~

5.

Install the front screw, lockwesher and nut

(332).

NOTE: The most common cause of bridge failure is

CAUTION

a

faulty motor. Check the motor before

The lockwashers

(333)

must be in front of the

replacing the bridge to prevent damaging

bridge to avoid overheating which will result in

the new bridge.

bridge failure. Refer to the Detail in Fig 17.

BRIOQE

INSTALLATION DETAIL

Before doing this procedure, follow the Pressure

it

out of the box.

Relief

Procedure warning on page 13 to reduce

the risk

of

a

fluid injection injury, injury from mov-

ing parts, or electric shock.

Unplug

rhe

sprayer/

6.

install the new circuit breaker in the reverse order of

7. Reinstall the pressure control cover and screws.

disassembly.

1. Remove the pressure control cover and screws.

2.

Use

a

small screwdriver to slide the terminal adapter

3.

Disconnect the single black wire from the circuit

4.

-Use

a

5/8”

socket wrench to loosen the nut and boot

off

the circuit breaker terminal.

breaker

(309)

to the

ON/OFF

switch

(303).

(310) on the circuit breaker button.

24

307-750

CIRCUIT

BOARD

REPLACEMENT

ARRllNG

CAUTION

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

13

to reduce

To

reduce the risk of malfunction,

be

sure the flat

blade of the insulated

male

connector ara

the risk of

a

fluid injection injury, injury from mov-

cantered exactly in the wraparound blade of the

female connector when connections are made.

Route all wires carefully to avoid interference with

1.

Remove the pressure control cover and screws.

the circuit board, bourdon tube end pressure control cover.

2.

Turn the pressure control knob

all

the way counter-

tension on the circuit board

(23).

Also check to be sure-only three or four threads of the pressure control knob shaft are exposed below the pressure ed-

justment nut

(SI.

Back down the nut, if necessary.

See

Fig

18.

clockwise to the minimum setting to release spring

6.

Perform

the

stall

pressure

Calibration

on

page

27.

CAUTION

the circuit board while removing or installing

it.

Step

2

is

essential to reduce the risk

of

damaging

3.

Disconnect

ALL

wires from the board, including the

two

heavy black wires. Refer to Fig

19.

Pay close

attention to where connections are made.

4.

To

remove the board from the box, pull out the

black plastic-tipped pin

(330).

Push the

bottom

of the circuit board toward the wall of the box and carefully slide the board out.

5.

Install the board in the box

at

the

same

angle

as

it

was removed. Reconnect the wires

as

indicated in

Fig

19.

Ease

the pin

(330)

into the retainer.

Fig

18

Fig

19

PRESSURE CONTROL REPLACEMENT

(Refer

to Ag 201

Tools

Needed: Phillips screwdriver 112" open end wrench

314'

open end wrench

Adjustable wrench

Small screwdriver

ARNING

Relief Procedure Warning on page

13

to reduce

the risk of

a

fluid injection injury, injury from mov-

ing parts, or electric shock.

Unplug

the

sprayer1

1. Disconnect the main fluid hose

(901

and the secon-

2.

Disconnect the fluid hose

(47)

from

between

the

I

dary fluid hose,

if

used,

from the sprayer.

displacement pump outlet nipple

(46)

and pressure

47

control inlet nipple

(344).

3.

Loosen the filter bracket nut

(28)

and washer (13)

using

a

314"

open end wrench.

4.

Hold the pressure control adapter

(341)

firmly with

a

314"

open end wrench.

Use

an adjustable wrench

to

loosen

the swivel union

(81,

then remove the fluid

filter

(48).

5. Remove the pressure control cover and screws

(38,

151, and disconnect the four motor leads

at

the ap-

propriate terminals.

8.

Refer to Circuit Board Replacement on page

22,

remove the circuit board end retain.

7.

Remove

the

conduit

(221.

8.

Use

a

112" open end wrench to loosen and remove

the pressure control mounting screws

(441

located

below the pressure control box. Remove the box.

9.

Install the new pressure control assembly in the

reverse order of disassembly.

Be

sure to re.install

the conduit connector

(541

to prevent motor con-

the conduit

seal

(¬ shown1 around the wires in

ne

20

-

tamination from entering the control box.

10. Perform the pressure control calibration procedure

on

page

27,

before regular operation of the sprayer.

m

307-7513

STALL

PRESSURE

CALIBRATION

WARNING

USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk

of

a

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

shock, fire, explosion, or moving parts. This procedure

sets

the sprayer to

2750

psi

(195

bar1

MAXIMUM WORKING PRESSURE. This procedure

NEVER attempt to.increase the fluid outlet pressure by performing this calibration

in

any other wey.

must be performed whenever

a

new or used circuit

board,

ar

pressure control assembly

is

removed and

NEVER EXCEED

2750

psi

(195

bar) MAXIMUM

reinstalled or replaced, to be sure the sprayer is pro-

WORKING PRESSURE. Normal operation of

the

perly calibrated.

sprayer

at

higher pressures could result in compo-

nent rupture, fire or explosion.

pressurize and result in component rupture, fire or

Improper calibration can cause the sprayer

to

over- AVOID touching the wires in the pressure control

explosion.

It

may

also

prevent the sprayer from ob-

assembly with your fingers or tools when the control

1

taining, the maximum working pressure which would

box cover is removed to reduce

the

risk of electric

result in poor sprayer performance.

shock.

Callbratlon Setup

(See

Fig

21

and

22)

1.

Follow the Pressure

Relief

Procedure Warning on

page

13.

Remove the spray hose end gun. Install

a

0.015”

spray tip in the gun. Connect the gun to the

new

test hose and connect the hose to the sprayer

outlet.

2.

Remove the pressure control screws and cover.

3.

Remove the plug from the top of the fluid filter, and

4.

Place the pump suction tube in

a

5

gallon

pail of

5.

Be

sure the gun safety latch is engaged.

6.

Use

a

3/8”

ignition wrench to turn the pressure ed-

justment nut

(SI

counterclockwise about

two

full

turns.

See

Fig

22.

7.

With

the pressure control knob

at

the

minimum

set-

ting, turn the sprayer switch ON.

install the test gauge (W).

clean watar.

THE SPRAYER SHOULD NOT STARTI

lf

it

does

start,

shut the sprayer switch OFF,

disengage the gun safety latch, trigger

the

gun into

a

grounded waste container until pressure

is

relieved.

justment nut

(SI.

a

little

further counterclockwise.

Engage the gun safety latch. Turn the pressure ad-

Turn the sprayer on to be sure

it

does

not

start.

8.

Slowb

turn the pressure control knob clockwise to

the maximum setting and hold

it

there. Use

e

3/8”

ianition wrench to slowlv turn the oressure adiustGent nut

(SI

clockwise ‘until the test gauge

Gads

EXACTLY

2750

psi

(195

bar).

9.

The’ calibretion procedure is now completed.

on page

13.

Follow the Pressure Relief Procedure Warning

CAUTION

To

preventpump corrosion,

flush the water out of

the pump, hose and gun with mineral spirits.

Be

sure to close the drain valve, first. Use the lowest pressure necessary to flush. Follow the Pressure

Relief

Procedure Warning on page

13.

Leave

the

mineral spirits in the pump to protect

it

until

you ere aready to spray again.

Fig

22

u

”^

-

WARNING

follow the Pressure

Relief Procedure Warning on page

13

to reduce

the risk of an injection injury, injury from moving

parts

or electric shock.

~

1.

Stop the sprayer

at

the bottom of its stroke to get

the crank

(271

in

its lowest position.

If

the crank must be lowered manually, carefully rotate the blades of the

fen

with e screwdriver.

2.

Remove the front cover

(31).

pail hanger

(821,

and

screws

(321.

3.

Unscrew the suction tube

(421

from the pump,

holding

a

wrench on the pump intake valve

to

kwp

the pump from loosening.

4.

Disconnect the pump outlet hose

(471

from the

outlet nipple

(461.

5.

Use

a

screwdriver to push aside the retaining spring

(351

at

the top of the pump. Push the pin

(20)

out

the rear.

6.

Loosen the jam nut

(381

with en adjustable wrench.

Unscrew and remove the displacement pump.

7.

U& a 3/16

hex key wrench to remove the three

screws and lockwashers

(30,631

from the recesa

of

the drive housing

(181.

8.

Use

e

5/32"

hex

key

wrench to remove the

two

screws end lockwashers

(21,

63)

from the top rear

of

the front end bell

(E).

9.

Lightly

ta~

the lower rear of the drive housina with

a

plastic mallet to loosen

it

from the motor front end

bell. Then pull the housing

off.

CAUTION

DO NOT ellow the gear cluster

(9)

to fall when

removing the drive housing

(18).

It

is

eesiM

damaged

if

dropped.

end of the gear cluster

(9)

or ellow

them to

fall be-

DO NOT lose the thrust balls

(101

located

at

each

tween gears. The ball, which

is

heavily covered

with

grease, usually

stays

in the shaft recesses, but could be dislodged. If caught between gears and not removed, the balls will seriously damage

the drive housing.

If

the bells are not in place, the

bearings will wear prematurely.

23

10.

Inspect the drive housing for damage end replace

if

needed.

11.

Pull the crankshaft

(27)

out. Inspect for wear or

damage and replace,

if

needed. Be sure a washer

(ma,

27bl is placed on each side of the crankshaft

assembly.

12.

Remove the connecting rod

(291,

inspect for wear

or damage, and replace

if

needed.

13.

Evenly lubricate the inside of the bronze bearing in

the drive housing

(18)

with high quality motor oil.

bearing grease.

Liberally pack the roller bearings and gears with

14.

Install the connecting rod

(29).

15.

Install the crankshaft

(271,

meshing the gears.

16.

Clean the mating surfaces of the drive housing

(181

and front end bell

(E).

17.

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

it

into piece with a plastic

mallet.

18.

Install the screws and lockwashers

130,

63)

and

tighten evenly.

CAUTION

DO NOT use~the drive housing screws to try to align or seat the housing, which would cause improper alignment and premature bearing weer.

19.

Install the connecting rod

(29).

20.

Screw the displacement pump about

3/4

of the

way into the drive housing

(181.

Hold the pin

(201

up

to the

hole

in

the connecting rod assembly

(29)

and continue screwing in the pump until the pin

the top threads of the pump cylinder are flush with

slides eesly into the hole. Beck

off

the pump until the face of the drive housing end the outlet nipple to the groove

all

the way around the connecting

(461

is facing back. Push the retaining spring

(35)

in-

rod. Tighten the jam nut

(381

to

76-86

ft-lb

(102-115

Nm)-very tight to prevent

it

from loosening which

will damage the drive housing.

See

Fig

24.

Be sure the retaining spring

(351

is firmly

in

the

WARNING

to prevent the pin

(201

from working

loose

due to

groove of the connecting rod,

all

the

way

around,

vibration.

See

Fig

24.

off

due to the force

of

the pumping action. These

If

the pin works

loose,

it

or other parts could break parts could be projected through the air and result cluding damage to the pump, connecting rod or

in serious bodily injury or property damage, indrive housing.

21.

Reinstall the front cover and

acrews

(31,

32

hose

(47).

Reconnect the suction tube

(42)

and pump

out11

~~~~

~~~

MOTOR REPLACEMENT

(Refer

to Fig

28)

IWARNINGl

Before doing this procedure, follow the Pressure the risk of

a

fluid injection injury, injury from mov-

Rellef

Procedure Warnlng on page

13

to'reduce

ing parts, or electric shock.

Unplug

the

sprayer1

1.

Remove the motor shield

(14)

and screws

(64).

2.

Disconnect the pump outlet hose

(47)

from the

displacement pump outlet nipple

(48).

3.

Remove the screws

(151

and pressure control cover

(36)

end disconnect the four motor leads. See

Fig

19,

page

25.

4.

Use an adjustable wrench to loosen the conduit connector nut

(546)

et

the pressure control

assembly

(43).

5.

Swing the conduit

(22)

away from the conduit

elbow

(546).

8.

Remove the conduit

seal

(5)

from around the wires

in

the pressure control. Pull the motor leeds

through the elbow, one at

a

time.

CAUTION

Always pull the motor leads one

at

e

time to avoid

loosening the terminals which could result

in

e bad

connection and poor sprayer performance.

7.

Loosen the nut of the connector

(54a)

at

the motor

and pull the conduit

(22)

away

from the motor, then

pull the leads through the conduit, one

at

a

time.

8.

Unscrew the connector elbow from the motor.

9.

.Pull the wires through the elbow, one

et

a

time.

10.

Remove the front cover end screws

(31,321.

11.

Use

e

114"

hex key wrench to remove the three

screws

(30)

and washers

(63)

from the recess of the

drive housing, and the

two

screws

(21 1 and washers

(63)

from the top rear

of

the motor front end bell

(E).

12.

Use

a

plastic mallet to gently tap the displacement

pump

(391

from the rear to loosen the drive housing from the front end bell. Then pull the drive housing away from the end bell.

r-

CAUTION

DO

NOT allow the gear cluster

(91

to fall when

removing the drive housing

(18).

It

is

easiiy

damaged if dropped. The cluster may stay engag-

ed

in either the front end bell or the drive housing.

end of the gear cluster

(91

or ellow them to

fall

DO NOT

lose

the thrust balls

(10)

located

at

each

with grease, usually

stays

in the gear recesses, but

between gears. The bell, which is heavily covered could be dislodged.

If

caught between gears and

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

not removed, the balls will seriously damage the bearings will wear prematurely.

13.

While supporting the motor to keep the sprayer from tipping, remove the nuts

(40).

lockwashers

(41)

and camcrews

(37)

holdina the motor mount-

ing plate

(72)

to the frame.

Liftihe

motor assembly

off

the frame.

14.

Remove the mounting plate

(721.

four screws

(79)

and lockwashers

(63)

from the old motor; and in-

stell

them on the new motor.

IcAuT~oNl

Be sure to instell the correct length of screw. Longer screws will damage the motor.

15.

Place the new motor assembly on the frame and align with the frame mounting holes. Install the screws

(73).

lockwashers

(41)

end nuts

(40)

tightly.

18.

Liberally grease the gear cluster

(91

and pinion gear

(0)

and pack

all

bearings in the motor front end

bell. Check to be sure the thrust balls

(10)

are in

place.

17.

Be sure the bronzecolored washer

(27a)

is in place

on the cranksheh

(27).

18.

Align the gears and push the drive housing

(18)

straight onto the front end bell end locating pins.

19.

Starting

et

Step

11

end working backwards, con-

tinue to reassemble the sprayer.

NOTE:

Use

e

turning motion on the conduit when

feeding wires through

it.

20.

Reinstall the conduit seal (hot shown) around the

wires in the conduit elbow

(Mb)

at

the pressure control to keep contaminants from entering the pressure control.

21.

Reinstall the motor cover and pressure control

cover.

~ ~~

30

307-758

PARTS DRAWING

Ultra"

wo

Sprayem

Model

231-032.

Series A

Includes items

1-83

Model

231-041

Includes item

1-94

Model

po-409.

CSA

Certlfled

Includes items

1-94

PARTS LIST

UltraTM

500

Sprayers

Includes items

1-83

Model

231-032.

Series

A

Model

po-404

Basic Sprayer

Same

as

Model

231

-041

except

is

CSA Certified Complete

Sprayer

REF PART DESCRIPTION NO. NO.

Includes

items

1-94

Model

231-041

Includes items 1-94

aTy

REF

PART

DESCRIPTION

an

NO.

50

220-286

VALVE, pressure relief

54 108-160 CONNECTOR, conduit,

45O

1 220-353 MOTOR, electric: 112 HP

Includes replaceable items la to

IC,

1

and one each of items 10 and 11 1

57

*178034 TAG, warning

1

la

107-267 .TERMINAL, female

2

58

101-242 RING, retaining

1

lb

107-504 .TERMINAL, female 1

59

206-994

THROAT SEAL LIQUID,

8

02.

2

IC

103-885 .TERMINAL, snap on 1

60

106-062 WHEEL

1

2

181-609 LABEL, identification 1

63

105-510 LOCKWASHER, spring, 114"

2

3 181-610 LABEL, identification

10

4 181-607 LABEL, identification 5 107-447 SEAL, conduit (see page

34)

6

220-365

FRAME

72

181-828 PLATE, mounting

1

7 181-073 STRAINER 1 74 178-160 ADAPTER, 318 nptlm) x 112 npt(f) 1

1

8

155-665 UNION. adaoter. 318 nosm(f1 76 176-884 WASHER. olain. 5/8"

2

1

64

108681 SCREW, mach; oval head; No. 6 1 x 3/8" 1 71 V7-762 LABEL, warning

Includes replaceable items

58

Et

76 1

73

W1-608 LABEL. warning

10

9

11 12 13

14 15 16

21

22

..

swivel x

3/8

nptim)

~

218364

GEAR

REDUCER

*178-934 LABEL, warning

100-069 BALL, 114". SST 100-509 PLUG, square head; 114 nptlm)

100-322 LOCKWASHER, external, 181-612 SHIELD, motor; includes

shakeproof; 7/16"

106-075 SCREW, mach. oval head; thread

one of item 11 forming; No. 10-24, Type C;

l/r'

179-936 BRACKET, mounting

220-368

HOUSING, drive

101-682 CAPSCREW,

sch;

1/4-20x5/8"

176-818 PIN

065-099

CONDUIT, electrical: specw length

1

79

101-550 CAPSCREW, soc

hd;

1/4-20 unc-&

2

1

81

108663

2

82

183-038 1

83

101-811

90

210-541

1

91

214-701

8

-

1 1

92

217-593

93

216-001

1

94

-

SPACER

x112"

HANGER, pail HUBCAP

cpld 114 npsmlf);

50

ft

(15

m)

spring

HOSE, grounded, nylon; 318" ID; guard both ends

HOSE, grounded, nylon; 3/16" ID; cpld 114 npsm(f);

3

ft

10.9

m);

spring

guard both ends SPRAY GUN; See 307-614 for parts SPRAY TIP KIT, Reverse-A-Clean

111

SPRAY.TlP OF CHOICE

2

'Extra Warning labels and tags available

at

no charge.

4 2 1

2

1

when ordering 0.79

ft

23

218405 CIRCUIT BOARD

(see

page

34)

n

218242

CRANKSHAFT

ASSEMBLY

1

HOW TO ORDER REPLACEMENT PARTS

na 107-434

.SPACER

27b

180-131

.WASHER, race

28

150-513

NUT, jam: 7/16"

29

218359

ROD, connecting

30

107-445

CAPSCREW, sch; 1/4-20 unrc-3a

Includes items

na

and nb 1

1.

To

be sure

you

receive the correct replacement

parts.

1

kit

or

accessories,

always

give

all

of

the

information

1 requested

in

the

chart

below.

2.

Check

the

parts

list

to

identify

the

correct

part

number;

1

do

not

use

the

ref.

na

when orderlng.

31 181-611

32

107-209

34

179-945

35

176-817

36

179-959

37

101-344

38

176-762

39 218-215

40

100-214

41 100-188

42

180-036

43

22045

44

100-057

47 218-083

46

162-453

48

214-570

x 1.5

SCREW, mach; filh; No.

E32x

1"

COVER, housing

ADAPTER, elbow, special; 1/4-18

npth

x

f) SPRING, retaining COVER, pressure control CAPSCREW, hex head; 5/16-unc-Za

x 718" NUT, hex PUMP, displacement; See 307-793

for parts

LOCKWASHER, 5/16"

TUBE, intake

NUT, heavy hex; 5/16-18 unc-2a PRESSURE CONTROL ASSEMBLY. CAPSCREW, hex head; 5116-unc-Za

See

page

34

x 314"

NIPPLE, 114 nptlm)

x

114 npsm

cpld 114 npsm(f);

29"

1715

mm)

long;

HOSE, grounded, nylon; 114" ID;

spring guard both ends

FLUID FILTER;

See

307-273 for parts

3 1

6

1

2

1 1

3.

Order all

parts

from

your

nearest Graco

distributor.

I

1

SERVICE INFORMATION

Listed

below

by the assembly changed are ADDED and

DELETED

parts.

ASSEMBLY PART REF PART

All Sprayers DELETED

23

218-397 Board

ADDED

23

218-405 Board

ADDED

83

104-811 Hubcao

307-758

33

PRESSURE

CONTROL

ASSEMBLY

Model

No.

Po466

Includes

items

301

to

346

NOTE:

A circuit board

is

not included with the pmure

COntlOl assembly.

See

item

23,

page

33

to order.

The

terminals

llsted

in this parts

list

are shown in

the wiring diagram on page

35.

342

(rear1

344

REF PART NO.

NO.

301

303

302 304

306

308

309

310 31 1

312 314 316 318 317 318

319

320

321

322

323

324

326

327

34

218128

105819

180043

105-658

107-266

218188

21a170

maws

107-268 107-254

107-288

107-293

107-287

107"

107-294

107-262

107-260 107-266 103-886

1M888

107-265

107-283 102-799 167421

307-758

DESCRIPTION

BAREPRESSURECONTROLBOX Includes item

302

to

3C6

.MICROSWITCH .ON/OFF SWITCH .BOOT. ON/OFF switch

JUMPER WIRE

.GUARD,

locking

BRIDGE, rectifier,

SCR

CIRCUIT BREAKER BOOT, circuit breaker CORD, power supply

TERMINAL, male

ADAPTER, terminal TERMINAL, female

TERMINAL, male TERMINAL, male TERMINAL, female TERMINAL, female TERMINAL,

female

TERMINAL, male TERMINAL,

female

TERMINAL,

female

TERMINAL.

female

TERMINAL;

ring

LOCKWASHER, No.

8,

internal

an

1

1 1

1 1 1 1

3

2

1 1 1 1 1 1

3

1

REF

PART DESCRIPTION

NO. NO.

QTY

328

108295

BUSHING. strain relief

329 107-258

TIP,

pin,

black

plastk

330

180041

331

101-273

SCREW, machine,

flat

head;

332

1OC-179

NUT, hex, mr, No.

10-24

thd

333

1OC-718

LOCKWASHER, internal, shakeproof;

234

**17&797

LABEL, WARNING

336

'*17&036

LABEL, WARNING

336

107-261

TERMINAL, male

338

107-504

TERMINAL,

male

337

107"3

TERMINAL,

female

341

151-360

ADAPTER,

3/8

nptlrnl

x

1/2

nptlm)

342

1OO-840

ELBOW,

street;

114

npth xf)

343

1ooMs

SCREW, mach,

slotted

pan hd; No.

344

182-463

NIPPLE,

1/4

nptlm)

x

1/4

npsm

8x

5/18"

long

346

10&460

CONNECTOR, conduit

**€air8

Warning labels and