PATENT NO. 4,323,741, 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
NOTE: See Index on page
230
VAC
MAXIMUM
WORKING PRESSURE
433
E
2
AIRLESS PAINT SPRAYER
lV@,
n
.
Hazard
Never use 1 ,1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluidscontaining
such solvents in this equipment. Such
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.
Refer to the Technical Data on page 43 for more information.
of
Using
Fluids
GRACO INC. P.O.
Containing Halogenated Hydrocarbons
use
could result in a serious chemical reaction, with the possibility of explo-
Excessive Pressure Fluctuations
Motor
Electrical Short
SpinTest
BridgeTest
Repair
List of Tools
General Repair Notes
Power Supply Cord Replacement
Filter Replacement
ON/OFF Switch Replacement
Microswitch Replacement
...............................
.................................
....................................
.................................
&
Care
.........................
.......................
....................
............................
Output
.............................
...........
Is
Hot and Runs Intermittently
........
.........................
.............................
............................
...........................
...................
........
-
.
......................
.............
................
6
8
10
11
13
16
17
17
18
18
19
20
21
21
22
22
23
23
INTRODUCTION
ULTRA@
Your new Ultra@ 433 Sprayer functions and operates dif
ferently than other airless paint sprayers. This section will
help you become familiar with the sprayer before operat
ing it.
Pressure Control
The pressure control includes an
sprayer, the pressure adjusting control knob and a pres
sure sensing device. Its function is to control the motor
speed
sure at the pump outlet.
Motor
The DC motor has sealed bearings and replaceable
tor brushes. Its function is to drive the displacement
pump at the rate needed to supply sufficient paint volume
at 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 cy
cling, the motor sounds like an automobile starter crank
ing. When the pump
intermittently until the fluid pressure stabilizes, then the
motor will shut itself
to the sprayer and it will stay pressurized and ready to
use
unless you manually shut it off and relieve pressure.
Pressure Control Replacement
Pressure Control Calibration
Bearing Housing
Conn. Rod
Drive Housing
Motor Brush Replacement
Capacitor Replacement
Motor Replacement
Parts Lists and Drawings
Complete Sprayer
Pressure Control Assembly
NOTE:
Accessories 42
Technical Data 43
Dimen.sions.. 43
Warranty Back Cover
Fluid Filter
The fluid filter strains the paint to help avoid clogs in the
hose and spray tip. The filter includes a reusable element
and a pressure drain valve for relieving fluid pressure.
Hoses
The grounded, nylon spray hoses have spring guards on
both ends.
3/16 in.
nylon hose material acts as a pulsation dampener to ab
sorb pressure fluctuations.
Spray Gun
Graco high pressure spray guns have a trigger safety
which prevents accidental triggering when it
See
a
SwitchTip uses high pressure fluid to remove clogs from
the spray tip without removing
verse
which helps reduce the risk of fluid injection injury.
See manual 307-793, supplied, for the displace
ment pump repair instructions and parts list.
.........................
The152 m hose has a 1/4 in.
ID
whip hose allows flexible gun movement. The
&
Fig Z-I.
filter for final paint straining. The ReverseA-Clean IV
-A-
Clean IV DripLess tip guard is a safety feature
Replacement 32
..............................
.............................
.............................
RAC
The gun provided with the sprayer also has
.....................
....................
&
Replacement, 30
...................... 35
.......................
IV
DripLess Tip Guard
..............
................
.............
...............
24
25
25
26
27
28
..............
...............
.................
...................
................
ID.
The
is
engaged.
it
from the gun. The Re
0.9
33
34
38
40
m,
-
-
-
Because the motor is DC, it
age or voltage fluctuations than an AC motor, and an ex
tension cord of up to 45 m can be used.
Drive Assembly
The sealed drive assembly transfers power from the DC
motor to the displacement pump.
Displacement Pump
The positive displacement, volume
vides equal fluid delivery on both the up and down pump
strokes. The pump has a wet
Graco Throat Seal Liquid,
throat packings and piston rod.
2
307-670
is
less sensitive to low volt
-
balanced pump pro-
-
cup which, when filled with
helps prevent damage to the
-
-
Fig
3-1
\
CONTRACTOR GUN
WlTH
RAC
517 SIZE
'
IV
DRIPLESS
SWITCHTIP
WHIP
END HOSE
TIP
GUARD
AND
307470 3
HIGH
FOR
Read and understand
PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS
all
instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General
This equipment generates very high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid through gun safety latch in the closed or"safe"position, making the gun
yourskin and into your body and causeextremelyserious bodily inoperative. Failure
injury, including the need for amputation. Also, fluid injected or tal triggering of the gun.
splashed into the eyes or on the skin can cause serious dam
age.
NEVER pointthespray gunat anyoneorat any partofthe body,
NEVER put hand or fingers Over the spray tip. NEVER
"
blow back" paint; this is NOT an air spray system.
ALWAYS have the tip guard in place
spraying. the gun.
ALWAYSfollow the Pressure Relief Procedure,
cleaning or removing the spray tip or servicing any system
NEVER
Be sure equipment safety devices are operating properly before
each use.
Medical
. . . - -. - -.
If
any fluid appears
MEDICAL
CUT.
Note to Physician: Injection in the skin is a traumatic inju
important to treat the injury surgically as
not
with some exotic coatinos iniected directlv into the blood
stream. Consultation with
hand surgeon may be advisable.
Spray
Be sure all gun safety devices are operating properly before
each use. Do
cause a malfunction and result in serious bodily injury.
Safety
on
the spray gun when gunfirmlytothepail.
below;
try
to'stop or deflect leaks with your hand or body.
Alert-Airless Sarav Wounds
. .
.
-. . . . . . .
CARE
Tell the doctor exactly what fluid was injected.
delay treatment to research toxicity. Toxicity
Gun
Safety Devices
not
.
- -
to
AT ONCE.
remove or modify any part of the gun; this can
-,-~-,
penetrate your skin. get
DO
-
a plistic surgeon br reconstructive
NOT
~ ~~~~~~
TREAT
soon
EMERGENCY
AS
as possibr. Do
is
try
before
A
SIMPLE
It is
a concern
to
Safety
Wheneveryoustopspraying,evenforamoment,
-
Latch
to
set the safety latch can result in acciden
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
injection when the tip is not installed. Check diffuser operation
regularly. Follow the Pressure Relief Procedure, below, then
remove the spray tip. Aim the gun into a metal pail, holding the
If
the fluid emitted is not diffused into an irregular
stream*
Tio
ALWAYS have the tip guard in place
spraying. The tip guard alerts you
and helps reduce, but does not prevent, the risk of accidentally
placing your fingers or any part of your body close
tip.
Trigger
Always have the trigger guard in place
ing
dropped or bumped.
Spray
Use extreme caution when cleaning or changing spray tips.
the spray tip clogs while spraying. engage the gun safety latch
immediately. ALWAYS foilow the Pressure Relief Procedure
and then remove the spray tip to clean
NEVER wipe
fully relieved and the gun safety latch is engaged.
replace
Guard
.~
~ ~
Guard
to
reduce the risk of accidentally triggering the gun
Tip Safety
Usingthelowestpossiblepressure,trigger
the
diffuser
off
buiid-up around the spray tip until pressure is
immediately'
to
the fluid injection hazard
on
the spray gun while
on
the gun when spray
it.
alwayssetthe
to
the spray
if
it
is
-
-
If
i
,
Pressure Relief
To reduce the risk of serious bodily injury, including fluid in
retai6n nut'or hose end coupling and relieve pi&sure
gradual
9
y,
to
relieve pressure.
having acontainerready
open
to
spray again.
then loosen completely. Now clear the tip or hose.
until you are
is
completely
I
I
I
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers or other body
pans. KEEP CLEAR of moving parts when starting or operating
the sprayer. Follow the Pressure Relief Procedure on page
beforechecking or servicing any part ofthe sprayer,
from starting accidentally.
to
prevent it
4
EQUIPMENT MISUSE HAZARD
General
Anv misuse of
ovirpressurizing, modi$ing'parts. using incompatible chemi
cals and fluids, or using worn or damaged parts, can cause
them
oron the skin, or other serious bodily injury, or fire, explosion or
property damage.
NEVER alter or modify any part of this equipment; doing
could cause it
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately.
Always wear protective
tor as recommended by the fluid and solvent manufacturer.
S
Tlis sDraver can develoo
PRESSURE. Be sure that
used are rated
maximum working pressure of anv component or accessory
used in the system.
Fluid
BE
patible with the wetted parts shown in
on page
literature before using them in this sprayer.
Safet
t
1
e spray eauipment or accessories, such as
to
rupture and result in fluid injection, splashing in the eyes
to
malfunction.
-.
eyewear, gloves, clothing and respira
stem
Pressure
to
withstand this pressure.
and
SURE
Solvent Compatibility
that all fluids and solvents used are chemically com-
43.
Always read the fluid and solvent manufacturer's
207
all
bar MAXIMUM WORKING
spray equipment and accessories
DO
NOT exceed the
theTECHNlCAL DATA
so
HOSE SAFETY
High pressure fluid
hose develops a leak, split or rupture due
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
ENDS! The spring guards help protect the hose from
kinks or bends at or close
hose rupture.
TIGHTEN all
pressure fluid can dislodge a
sure spray
NEVER use a damaged hose. Before each use, check the en
tire hose for cuts, leaks, abrasion. bulging cover, or damage or
movement
ist, replace the hose immediately.
pressure hose or mend it with tape or any other device.
paired hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULLY.
hoses
and hot surfaces of the pump and gas engine.
-
or solvents which are
coverofthe hose.
above
Hose
Proper hose grounding continuity is essential
groundedspriy system. Checkthe electrical resistanceof your
fluid hoses at least once a week.
tag on it which specifies the maximum electrical resistance,
conlact the hose supplier or manufacturer for the maximum re
sistance limits. Use a resistance meter in the appropriate range
for your hose
the recommended limits, replace it immediately. An un
grounded or poorly grounded hose can make your system haz
ardous.
lo
of
to
move equipment. Keep hoses clear of moving paris
62"
C or below -40' C.
Grounding
Also
in
the hoses can be very dangerous.
to
the coupling which can result in
fluid connections securely before each use. High
be emitted from the coupling.
the hose couplings.
loose coupling or allow high pres
If
DO
to
any kind of wear,
any of these conditions ex
NOT try
to
Do
not
DO NOTexposeGraco hosetotemperatures
compatible with the inner tube and
Do
Continuity
to
If
your hose does not have
to
check the resistance.
read FIRE
OR
EXPLOSION HAZARD.
If
the resistance exceeds
If
the
recouple high
no1 use fluids
maintaining a
A
re-
not pull on
a
-
-
-
-
-
-
FIRE OR EXPLOSION HAZARD
2.
Fluid
Static electricity is created by the flow of fluid through the pump
and hose.
grounded, sparking may occur, and the system may become
hazardous. Sparking may also occur when plugging in or
plugging a power supply cord or using a gasoline engine.
Sparks can ignite fumes from solvents and the fluid being
sprayed, dust particles and other flammable substances,
whether you are spraying indoors or outdoors, and can cause a
the lowest possible fluid pressure during flushing.
hoses:use only grounded hoses with a maximum of
150 m combined hose length
ity. See Hose Grounding Continuity.
Spraygun: obtain grounding through connection
erly grounded fluid hose and sprayer.
Object
being
sprayed: according
Fluid
supply container: according
All solvent pails used when flushing, according
code. Use only metal pails, which are conductive. Do not
place the pail on a non
or cardboard, which interrupts the grounding continuity.
To
maintain grounding continuity when flushing orrelieving
pressure, always hold a metal part of the gun firmly
side of a grounded
Safety
12 of this manual. Follow the Pressure Relief Procedure
4.
and remove the spray tip before flushing. Hold a metal
metal pail, then trigger the gun.
to
ensure grounding continu-
to
a prop
to
local code.
to
local code.
to
local
-
conductive surface, such as paper
to
the
on
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards-
particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 - should be consulted.
-
307-670
5
1.
Connect Hose and Gun.
Refer
to
Fig
SETUP
6-1
NOTE:
2.
When tightening fittings at the pressure control,
hold one wrench firmly on the hex of the pressure
control fitting to keep it from rotating. Use an
other wrench to tighten the mating fitting.
a. Remove the cap from the filter outlet nipple and
screw the
b. Connect the whip hose between the fluid hose
and the gun inlet connection.
c. Don't use thread sealant, and don't install the
spray tip yet!
If you are supplying your own hoses and spray
gun, be sure the hoses are electrically conduc
tive, that the gun has a tip guard and that each
part is rated for at least
sure. This is to reduce the risk of serious bodily
injury caused by static sparking, fluid injection or
over
-
pressurization and rupture of the hose or
gun.
Two Gun Hookup.
npsm(m) nipple - See
cessory hose and gun. See
To
avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
1.
Always use nylon spray hose at least
long.
15.2
m main
WARNING
CAUTION
fluid
hose onto the nipple.
207
bar
Working
Remove the cap from the
Fig
6-1
-
and attach an ac-
Fig
6-2.
Pres
15.2
-
-
m
-
1/4.
Fig
6-1
ON/OFF SWITCH
DO NOT INSTALL ANY
SHUTOFF DEVICE
HERE
\
2.
Never use a wire braid hose as it is
act
as
a pulsation dampener.
3.
Never install any shutoff device between thefil-
ter and the main hose. See
4.
Always use the main filter outlet for one gun op
eration. Never plug this outlet.
3. Fill Packing Nutwet-Cup.
Fill the packing nut/wet-cup
Throat Seal Liquid (TSL), supplied.
4.
Check the Electrical Service
a. Be sure the electrical service is properly rated for
your sprayer and that the outlet you use is prop
erly grounded.
b. Have a licensed electrician attach an appropri
ate plug
c. Use an extension cord which has
minimum12gaugesize,andamaximumof45m
long. Longer lengths may affect sprayer per
formance.
to
the power supply cord.
Fig
See
1/3
6-1.
Fig
full
too
6-1
with Graco
3
wires of a
rigid to
-
-
...
^.
.
-
\
SECONDARY HOSE
-
.
HOSE
'
PRESSURE
DRAIN VALVE
6
307-670
5.
Plug
in
the Sprayer.
OFF.
Then plug the cord into a grounded electrical
outlet at least
6
Be sure the
ONlOFF
m away from the spray area.
WARNING
Proper electrical grounding is essential
to
reduce
the risk of fire or explosion which can result in seri-
ous
bodily injury and property damage. Refertothe
warning section
FIRE
OR
EXPLOSION HAZARD
on page 5 for more detailed grounding instructions.
f
6.
Flush the pump
was left in
to
a. Before using water
to remove the lightweight oil which
protect pump parts after factory testing.
-
base paint, flush with min
eral spirits followed by soapy water, and then a
clean water flush.
b. Before using oil
spirits only.
c. See
FLUSHING GUIDELINES
-
base paint, flush with mineral
-.
on page
for the flushing procedure.
SETUP
switch is
11
&
12
7.
Prepare the
paint
according
to
the manufacturer's
recommendations.
a. Remove any skin that may have formed.
b. Stir the paint
to
mix pigments.
c.. Strain the paint through a fine nylon mesh bag
(available at most paint dealers)
to
remove parti
cles that could clog the filter or spray tip. This is
probably the most important step toward
trouble
-
free spray painting.
I
-
307470
7
'(
OPERATION
WARNING
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 checking or servicing
any part of the spray system, when installing,
cleaning or changing spray tips, and whenever you
stop spraying.
1.
Engage the gun safety latch.
2.
Turn the ONlOFF switch
3. Disengage the gun safety latch.
part of the gun firmly
metal pail, and trigger the gun
sure.
4. Engage the gun safety latch,
5.
Open the pressure drain valve, having a con
tainer ready
valve open until you are ready
lf you suspect
pletely clogged,
relievedaffer following
around the tip guard retaining nut or hose end cou-
pling and VERY SLOWLY loosen the part
lieve pressure gradually, then loosen completely.
Now clear the tip or hose.
to
catch the drainage. Leave the
that
the spray
or
that
to
OFF.
Hold a metal
to
the side of a grounded
to
relieve pres
to
spray again.
tip
or
hose
pressure
the
has
not been fully
steps above,
wrap a rag
is
*
com
to
re
-
-
-
-
the
3. Put the suction tube into
4.
Lower the pressure setting
adjusting knob all the way counterclockwise. See
9-1.
5.
Disengage the gun safety latch.
6.
To prime the pump,
firmly against and aimed into a metal waste con
tainer.
open, turn the
crease the pressure setting until the sprayer starts.
Keep the gun triggered until all air is forced
system and the paint flows freely from the gun. Re
lease the trigger and engage the gun safety latch.
NOTE:
7. Check all fluid connections for leaks.
found, follow the
ing, to
8.
Install the Spray Tip and Tip Guard.
gun safety latch is engaged. See
spray tip.
ual307-848, supplied with the gun, for installation in-
structions.
9.
Adjust the Spray Pattern
See
Fig
9-2.
ON/OFF switch
If the pump is hard
under the pressure drain valve and open it.
When fluid comes from the valve, close it. Then
disengage the gun safety latch and proceed as in
Step
6,
above.
the left, before tightening connections.
If
using the
hold a metal part of the gun
Squeeze the trigger and hold it
to
Pressure Relief Procedure Warn
RAC
paint container.
by turning the pressure
See
Fig
to
ON, and slowly in
prime, place a container
If
Be sure the
Fig
9-3.
install the
IV tip guard, refer
9-3.
out
of the
any are
to
man-
Fig
-
-
i
i
i!
-
-
Startup
Use this procedure each time
help ensure the sprayer is ready
start it safely.
NOTE:
1.
2.
For the first time startup, be sure
sprayer first. See page
GUIDELINES.
Close the pressure drain valve.
stalled a secondary hose, be sure the nipple is firmly
plugged with the cap.
Don't install the spray tip yet!
.'
you
to
11
See Fig
start the sDraver
operate and that you
to
&
12
for
FLUSHING
If you have not in
9-1.
to
flush the
a. Increase the pressure adjusting knob setting just
until spray from the gun is completely atomized.
To avoid excessive overspray and fogging, and
to
decrease tip wear and extend the life of the
sprayer, always use the lowest possible pres
sure needed
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. Test the spray pattern. TO adjust the direction of
-
the spray pattern, engage the gun safety latch
and loosen the retaining nut. Position the tip
guard horizontally for a horizontal pattern or ver-
tically for a vertical pattern. Then tighten the re
taining nut.
to
get the desired results.
-
-
8
307-670
OPERATION
Cleaning a Clogged
Tip
WARNING
To reduce the risk of serious bodily injury from fluid
injection:
NEVER operate the spray gun with thetipguard re
moved.
DO
NOT hold your hand, body, or a rag in front of
the spray tip when cleaning or checking a clogged
tip. Always point
waste container when checking to see
thegun toward the ground or into a
if
the tip is
clear.
DO NOT
try
to "blow back" paint: this is NOT an air
mrav sDraver.
1.
Clean the front of the tip frequently during the day's
operation. First, follow the
dure Warning
soaked
brush^
on page 8. Then use a solvent-
to wipe-away fluid build-up, which
Pressure Relief Proce
helps prevent tip clogging.
-
-
Fig
9-1
NEVER OPERATE THE GUN
WITH THE TIP GUARD
REMOVED
2.
If the spray tip does clog, release the gun trigger, en
gage the gun safety latch, and rotate the RAC
dle
180".
See
Fig
9-3.
3.
Disengage the gun safety latch and trigger the gun
IV
han
into a waste container. Engage the gun safety latch
again.
4. Return the handle to the original position, disengage
the gun safety latch, and resume spraying,
5.
If the tip is still clogged, engage the gun safety latch,
shutoff and unplug the sprayer, and open the pres
sure drain valve to relieve pressure. Clean the spray
tip as.shown in manual 307-848, supplied with the
RAC IV.
RAC
IV
HANDLE SHOWN
IN SPRAYING POSITION,
HANDLElBO",
TURN
DISENGAGES
LATCH AND TR
GUN
TO
CLEAR
GUN
SAFETY
LATCH
SHOWN EN.
GAGED
-
-
-
MAINTAIN FIRM
METAL TO METAL
CONTACT WHEN
Fig
9-2
FLUSHING
1
Fig
9-3
307-670
9
~~~
SHUTDOWN AND CARE
WARNING
To reduce the risk of serious bodily injury, including
on
fluid injection or splashing in the eyes or
or injury from moving parts, always follow the
sure Relief Procedure Warning
on page
checking, adjusting, cleaning and shutting down the
sprayer.
1
.
Check the packing nuvwet-cup daily. First follow the
Pressure Relief Procedure Warning
Be sure the wet-cup is 1/3 full of TSL at all times
help prevent fluid buildup
mature wear
tight enough
of packings. The packing
to
stop leakage, but no tighter. Over
on
the piston rod and pre-
tightening may cause binding and excessive packing
wear. Use a round punch or brass rod and light ham
mer
to
adjust the nut. See
Fig
10-1.
2. Clean the fluid filter often and whenever the sprayer
is stored. First follow the
dure Warning
307
-
273, supplied, for the cleaning procedure.
on
Pressure Relief Proce
page 11. Refer
the skin,
Pres
-
11
before
on page
11.
to
nut should be
-~
to
manual
__
5.
For very short shutoff periods, leave the suction tube
in the paint, follow the
Warning
6.
Coil the hose and hang it
on page 11, and clean the spray tip.
ing it, even for overnight,
Pressure Relief Procedure
on
the hose rack when stor
to
help protect the hose
-
from kinking, abrasion, coupling damage, etc.
WARNING
Refer
to
the warning section
page 5 for information on the hazard
HOSE SAFETY
of
using dam
on
-
aged hoses.
-
-
3. Lubricate the bearing housing after every 100 hours
of operation. Fill the connecting rod cavity with
No.
10 non-detergent oil.
4.
Flush the sprayer at the end of each work day and
it with mineral spirits
and freezing. See
page
11.
'To
prevent pump corrosion, and
chance of fluid freezing in the pump
to
help prevent pump corrosion
FLUSHING GUIDELINES
CAUTION
to
reduce the
or
pressure con
SAE
fill
on
trol in cold weather, never leave water or any type of
paint in the sprayer when it is
can seriously damage the sprayer or result in a
not
in use. Freezing
loss
of pressure or stalling.
I
I
PACKING
Fig
10-1
NUT/
10
307-670
FLUSHING GUIDELINES
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 checking or servicing any
part of the spray system, when installing, cleaning or
changing spray tips, and whenever you stop spraying.
1.
Engage the gun safety latch.
2.
Turn the ON/OFF switch to
3.
Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun to relieve pressure.
OFF,
4.
Engage the gun safety latch.
5.
Open the pressure drain valve, having acontainer
ready to catch the drainage. Leave the valve open
until you are ready to spray again.
If
you
suspect that the spray tip or hose
clogged, or that pressure
has
not
been
is
completely
fully
relieved
after following the steps above, wrap a rag around the
tip guard retaining nut or hose end coupling and
VERY SLOWLY loosen the part to relieve pressure
gradually, then loosen completely. Now clear the tip or
hose obstruction.
1
1.
New Sprayer. Your new sprayer was factory tested
2
in lightweight oil which was left in to protect pump
parts.
Before using water
-
base paint, flush with mineral
spirits followed by soapy water, and then a clean
water flush.
Before
using
oil-basepaint, flush with mineral spirits
only.
2.
Changing Colors. Flush with a compatible solvent
such
as
3.
Changing
mineral spirits
from
or
water.
water-base
to
oil-base paint.
Flush with warm, soapy water, then mineral spirits.
4.
Changing
from
oil-base to water-base paint.
Flush with mineral spirits, followed by warm, soapy
water, then a clean water flush.
5.
Storage.
3
4
CAUTION
NEVER leave water in the sprayer
if
there
is
slightest chance it could freeze. Push the water out
with mineral spirits. Water left to freeze in the pressure control tube prevents the sprayer from being
started and causes serious damage to the pressure
control.
6.
Startup after storage.
-
Before using water
base paint, flush out mineral
spirits with soapy water and then a clean water flush.
When using oil
-
base paint, flush outthe mineral spir-
its with the paint to be sprayed and the sprayer
ready to use.
the
is
Water
-
base paint: flush with water, then mineral
spirits and leave the pump, hose and gun filled with
mineral spirits. Shut off the sprayer, open the pres
sure drain valve to relieve pressure and leave it open.
Oil-basepainttfiush with mineral spirits. Shut
off
the
sprayer, open the pressure drain valve to relieve
pressure and leave
it
open.
-
Continued on page
12.
307-670
11
~
How
to
Flush
~~
~~
FLUSHING GUIDELINES
1.
Follow the
page
2.
If
the sprayer has been used before, remove the filter
bowl and screen: see manual 307
Pressure Relief Procedure Warning
1
1.
-
273, supplied.
Clean the screen separately and install the bowl
without the screen to flush
FILTER
BOWL
it.
See
Fig
PRESSUR*
DRAIN VALVE
12-1.
on
7. Hold a metal part of the gun firmly against and aimed
into a metal wastecontainer.
the trigger and hold
to
ON,
and slowly increase the pressure setting until
it
open, turn the
SeeFig
12-2.
Squeeze
ON/OFF
switch
the sprayer starts. Keep the gun triggered until all air
is forced out
of
the system and the solvent flows
freely from the gun. Release the trigger and engage
thegunsafetylatch.Thisprocedurehelpsreducethe
risk of static sparking and splashing.
NOTE:
If the pump is hard to prime, place a container
under the pressure drain valve and open it.
When fluid comes from the valve, close it. Then
disengage the gun safety latch and proceed as in
Step 7, above.
8.
Remove the suction tube from the pail. Disengage
the gun safety latch and trigger the gun
vent from the hose.
Do
not let the pump run dry for
to
force
sol
more than 30 seconds to avoid damaging the pump
packings! Then follow the
dure Warning
9.
Leave the pressure drain valve open until you are
on page
ready to use the sprayer again.
Pressure Relief Proce-
11.
If
the screen was re
moved, unscrew the filter bowl and reinstall the clean
screen. Reinstall the bowl, hand tight only.
IO.
If
you flushed with mineral spirits and are going to
use a water
lowed by a clean water flush. Then follow the
sure Relief Procedure Warning
-
base paint, flush with soapy water fol
Pres
on page
11.
-
-
(
-
-
i
Fig 12-1
3. Close the pressure drain valve.
4.
Pour
2.
liters of compatible solvent into a grounded
metal pail. Put the suction tube in the pail.
5.
Remove the spray tip from the gun,
6.
Lower the pressure setting by turning the pressure
if
it
is installed.
adjusting knob all the way counterclockwise.
Fig
12-2
12
307-670
TROUBLESHOOTING
Pressure
To
reduce
fluid
the
alwaysfollowthisprocedurewhenever
sprayer,
sDrav
sprajl
1.
2.
3.
4.
Relief
the risk
iniection.
eyes
svstem.
tips,
Engage
Turn the
Unplug
Disengage the
or
on
when
and
the
the
th'e ikin,
ON/OFF
iniuw
checking
when
whenever
gun
power supply
Procedure
of
serious bodily injury,
from
solashina
moving
installing,
or
sewicing
park
cleanina
yoistop
safety latch.
switch to
cord.
gun
safety
latch. obstruction.
fluid
or
spraying.
OFF.
or
electric
you
any
or
WARNING
'5.
Hold
including
solvent
in
shock,
shut
off
part
the
of
the
changing ready
"
grounded
oressure.
6,
ingage
7.
Open
8.
Leave
ready to spray
lf
you
clogged,
ter
following
auard retainina nut
SLOWLY
ally,
then
GUIDE
a
metal
part
metal
the
gun
the
Pressure
to
catch the drainage.
the
pressure
suspect
that
orthatpressure
the steps
loo&&
loosen
the
completely.
of
pail,
safety
drain
drain
again.
the
spray
above,
or
hose
part
the
gun
firmly
to
and
trigger
the
latch.
valve, having
valve
open
tip
or
has
to
hose
notbeen
wrap a rag around the
end
relieve pressure
Now
fullyrelievedaf
coudina
clear the tip
the
side
gun
to
a
Container
until
you
is
complete/y
and
or
of
a
relieve
are
tip
VERY
gradu
hose
-
-
:heck everything
TYPE
OF
Basic Fluid Pressure
Problems
Basic Mechanical Problems
in
the
PROBLEM
guide
-
E
%ask Electrical Problems
before
disassembling
~ ~~
TO
WHAT
If
check
1.
Check the pressure control knob setting.
The motor
mum setting (fully counterclockwise).
2.Checkforacloggedspraytip.Refertoyour
separate gun or tip instruction manual.
1. Check for frozen or hardened paint in the
pump (39)
don tube. Using a screwdriver, carefully
try to rotate fan at back of motor by hand.
See page 19.
2.
Check displacement pump connecting
rod pin
into connecting rod
spring (35) should be firmly in groove
connecting rod. See page
3. Check for.motor damaae. Remove drive
housing
to rotate fan by hand.
1.
Check electrical supply with volt meter.
Meter should read 190
2.
Check extension cord for visible damage.
Use a volt meter or test lamp at extension
cord outlet to check.
3. Check sprayer power supply cord
for visible damage such as broken insula
tion or wires.
4.
Check motor brush leads. terminals and
brush length. Brush length should be
mm minimum. See page 33.
CHECK
is
OK,
will
andlor pressure control bour-
(20).
It must be completelypushed
assembly~(2). 3ee page
the
go
to
the next check.
not run
sprayer.
if
it
is at the mini
(3)
and retaining
31.
-
250 Volts.
32.
(3ql)
Try
14
WHAT
If
1.
-
2.
1.
2.
01
3. Replace motor
1. Reset building circuit breaker: replace
2.
3.
-
4.
TO
check
Slowly increase the pressure setting to
if
the motor starts.
Relieve pressure, refer to your separate
gun or tip instruction
ing.
Thaw. Plug in sprayer and turn
crease pressure setting to see
starts.
ment pump packings (see manual
307
control box (301). See page 27.
Push pin into place and secure with the re
taining spring.
building fuse. Try another electrical outlet.
Replace extension cord.
Replace power supply cord. See page
Tighten terminal screws; replace brushes.
See page 33.
DO
is
not
OK,
refer
to
this column.
manual.for tip clean
on.
If
it
doesn't, replace the displace
-
793) andlor replace the bare pressure
(1)
if
fan won't turn.
see
Slowly in
if
motor
22.
-
-
-
-
if
Thaw the sprayer
not try
to
start the sprayer until it has thawed completely.
If
operate.
manual
When replacing the bare pressure control box (item 301), remove the
and reinstall these parts in the bare box.
paint hardened (dried) in the sprayer, the pump packings andlor bare pressure control must bereplaced. See page
307-793.
water or water-based paint has frozen
in
it,
due to exposure to low temperatures, by placing it in a warm area.
If
the bourdon tube was not damaged by
OWOFF
the
freezing,the pump should
switch, bridge, circuit board and electrical hardware
27
Do
or
307-670 13
‘YPE
OF
PROBLEM
WHAT TO CHECK
If
check
is
OK,
go
to the next check.
WHAT
If
TO
check is not
DO
OK,
refer to this column.
Diagnosing circuit board
indicator lamps. The nor
mal condition
clear lamp on when
telhg pump
Follow Pressure Relief
Procedure Warning.
move gun from hose. Re
move pressure control cover
and check for faulty
tion of circuit board lamps.
Condition
Both lamps on; pump
won’t operate and motor
is
not
is
to
A
running
red lamp on,
boardis
run.
Re-
condi-
1.
Check leads from bridge
be sure they are securely fastened ana
properly mated.
2.
Check
GI
and
circuit board (118) and bridge (308) for
damage or loose terminals.
-
3.
Check for loose motor brush lead connec
tions and terminals. See page 33.
4.
Checkbrush length which should be
minimum. See page 33.
NOTE:
same rate on both sides
Check both brushes.
5.
Check for brocen or misaligned motor
brushsprings.Rolledportionofspringmust
reslsquarrelyontopofbrush.Seepage33.
6.
Check motor brushes for binding in brush
holders. See page 33.
7.
Check motor armature commutator for
burn spots, gouges and extreme
ness. Remove motor cover and brush
spection plates
3.
Check motor armature for shorts using ar
mature tester (growler) or perform spin
test. See page 19.
3.
Check bridge (308) by substituting with a
good bridge or performing bridge test. See
page
CAUTION:
mature is determined to be good. A bad ar
mature
bridge.
The brushes do not wear at the
20.
Do
will
G2
to
not perform this check until ar
immediately burn out a good
(308)
connections between
of
check. See page 28.
to
motor tc
14
mm
the motor.
rough-
in-
1. Replace any loose terminals and crimp to
leads. Be sure male terminal blades are
straight and firmly connected to mating
part.
2.
Clean circuit board male terminals. Re
place loose or damaged terminals.
curely reconnect leads.
3. Tighten terminal screws. Replace
brushes
33.
4.
Replace brushes. See page 33.
5. Replace spring
with brush. See page 33.
6.
Clean brush holders. Remove carbon
with small cleaning brush.
leads with
free vertical brush movement.
7.
Remove motor and have motor ShOD
resurface commutator
page 35.
8. Replace motor. See page 35
-
9. Replace bridge. See page
-
-
if
leads are damaged. See page
if
broken. Realign spring
slot
in brush holder to assure
Align
if
possible. see
24
Se-
brush
-
!
WIRING DIAGRAM
14
307-670
I
302
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