Graco E Series, ULTRA 433, 226-998 Instructions-parts List Manual

INSTRUCTIONS-PART.S LIST

This

manual contains

WARNINGS

READ AND RETAIN

AND

IMPORTANT

INSTRUCTIONS

FOR

REFERENCE

ORACO

307-670

Rev

Supersedes

G

D

ELECTRIC,

ULTRA@

207

bar

Model.226-998, Series

Complete sprayer with hose, gun, RAC

DripLessTM Tip Guard and SwitchTipTM.

U.S.

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-

BOX

WARNING

1:Ml

MINNEAPOLIS, MN

55440-1444

TABLE

OF

CONTENTS

Introduction 2 Warnings 4

Setup

Operation Shutdown Flushing Guidelines Troubleshooting Guide

Motor Won't Operate Low Output

No

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

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.

433

BASIC COMPONENTS

ONlOFF switch for the

so

that the sprayer maintains constant fluid pres

is

not cycling, the motor may hum

off.

However, there will stili be power

-

mo-

-

Bridge.Rectifier Replacement

Choke Replacement Varistor Replacement Circuit Board Replacement

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

jection,splashingfluidorsolventintheeyesorontheskin,or

injury from moving Darts or electric shock, always follow this

procedure whenever

ingorservicinganypartofthespraysystem,wheninstalling,

cleaning

I

spraying.

1.

2.

4

307-670

or

Engage the gun safety latch.

Turn the ON/OFF switch

I

Procedure

YOU

shut

Off

the sprayer, when check-

changing spray tips, and whenever you stop

to

OFF,

9

3.

-

~

Disengage the gun safety latch. Hold a metal art of the

'

. gun firmly to the side of a grounded metal pair and trig-

ger the gun

4.

Enoage the aun safetv latch.

5.

OGnihepre&uredra-invalve,

to catch the drainage. Leave the valve

ready

If

you

suspect that the spray tip or hose

clogged,orthatpressurehasnotbeenful~relievedafterfol-

lowinqthestepsabove,VERYSLOWLYloosenthetiDauard

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

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

fireorexplosionandseriousbodilyinjuryandpropertydamage.

If

you experience any static sparking or even a slight shock

while using this equipment,

ATELY. Check the entire svstem for orooeroroundina.

use the system again until corrected.

If

every pari of the spray equipment is not properly

STOP

the problem has b>en idenzfied and

SPRAYING IMMEDI-

Do

un-

not

Grounding

To reduce the risk of static sparking, ground the sprayer and all other spray equipment used or located in the spray area.

CHECKyourlocalelectricalcodefordetailedgroundinginstruc-

tions for your area and type of equipment. BE SURE all of this spray equipment:

1.

Sprayecconnect a ground wire and clamp (supplied)

true earth ground.

to

ground

to

a

3.

4.

5.

6.

7.

Flushing

Reduce the risk of fluid injection injury, static sparking, or splashing by following the flushing procedure given on page 11

&

page

partofthegunfirmlytothesideofagroundedmetalpailanduse

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!

-

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

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

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

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

WPE

OF

PROBLEM

:ondition B (continued)

Both lamps

REFER

ING

off

TO

~

THE WIR-

-.

DIAGRA~J

PAGE 14 TO IDENTIFY TP POINTS.

WHAT TO

If

check

1. Checkelectrical supply. Connectvoltmeter

to

190-250

2.

O

N

Check power supply

sprayer turned

TP1 and TP2. Meter should read 190-250

Volts.

CHECK

is

OK.

00

to the next check.

electrical outlet. Meter should read

Volts

to

ON.

See page 26.

circuit board with

Measure voltage at

WHAT TO

If

check

1.

Reset circuit breaker or replace outlet

is

DO

not

OK.

refer to this column.

fuse.lf circuit breaker or fuse continues

open, see "Electrical Short", page 18.

2. Unplug sprayer. Check continuity

polesofON/OFFswitch(302)fromTPlto

TP2 and

TP2

to

TP3. Replace switch

faulty.

of

to

both

if

:ondition

Red lamps Clear lamp off

Unplug

C

on,

sprayer!

TP4 to TP6 and TP3

Check for any loose connections.

-.

3.

Check all terminals and wires for damage or loose

4.

Checkmotorthermalcutoutswitch..Unplug

sprayer. Allow motor motor thermal switch leads at

TP10. Use ohmmeter

fit.

to

cool. Disconnect

TP9 and

to

check continuity.

Switch should be closed when motor

3. Replace damaged terminals and recon nect securely.

4.

close when motor is cool. See page 35.

is

cool.

5.

Check microswitch

pressure

in

the pressure control, discon

(306).

With no fluio

5.

nect wires TPlSandTP19. Checkcontinu- ity across switch terminals with an ohmrne-

fer. Switch contact should be closed. De

press actuator button.

An

audible "clickin-

-

dicates the contacts have opened. Ohm-

6.

Check circuit board (118) by substituting

6. Replace circuit board. See page

with a aood board. See Daoe 26.

1.

Checkcircuit board

(1

18) by removing from

1. Replace circuit board. See page 26. box withoutdisconnecting wires; see page 26 for removal procedure.

I

WARNING;

Removing the circuit board while still wired over-rides the optical detector which could cause the sprayer to over microswitch does enough

to

check lamp condition, then shut off immediately.

WARNING:

~

only!

Do

not allow any metal objects

not

function properly. Turn the sprayer

To reduce the risk of electric shock, handle board by edges

to

come in contact with the board!

Check continuity of

RFI

filter (310) from

to TP5. Replace filter

if

faulty.

Check power supply cord (31 1) for

nuitv from TP5 to TP7 and TP6

Replace cord

Replace electric motor

if

faulty.

if

switch does

conti-

to

TP8.

not

Replace ihe microswitch. See page 23.

26.

-

pressurize,

on

if

the

ONLY long

-

on

Plug in and turn

should be

board over

ofi

and unplug the sprayer.

on

-

rides the optical detector.

2. Check bourdon tube flag and

sprayer. Clear lamp

now - removing the circuit

detectorposi-

tion. Reinstall circuit board (see page 26). Turn pressure setting to maximum; flag should extend less than half way into opti cal detector

slot

from the bottom.

Turn

2. Calibrate pressure control to see corrects problem. See page 28.

-

If

not, replace bare pressure control box

(301). See page

27.

307-670

if

that

15

TYPE

OF

PROBLEM

TO

WHAT

If check

1.

Check for worn spray tip.

2. Check tinue to stroke whbn gh trigger is re

leased. Plug in and turn on sprayer. Primewith ily, then release and engage safety latch. Relieve pressure, turn plug sprayer.

3. Check electrical supply with

Meter should read

4. Check extension cord size and length;

must be at least 12 gauge wire and no longer than

5. Check (308) to circuit board (1 18) for damage

or page 26.

6.

Check stall pressure. Refer

tion Procedure on page 28.

7. Check bridge (308) terminalstomotor. Inspect wiring insula tion and terminals for signs of overheat ing. See page 24.

8. Check for loose motor brush leads and terminals. See page 33.

9.

Check for worn motor brushes which should be 14 mm minimum. See page

33.

10.Checkfor broken and misaligned motor

brush springs. Rolled portion of spring must rest squarely

11.Check motor brushes for binding in

brush holders. See page 33.

12.Checkcircuit board (1 18) by substituting

with a good circuit board. See page

13.Check motor armature for shorts by

ing an armature tester (growler) or per form spin test. See page 19.

14,Checkbridge(308)bysubstitvtingwitha

good bridge or by performing the bridge

test. See page

CAUTION:

armature is determined armature will immediately burn out a good bridge.

CHECK

is

OK,

go to the next check.

to

see that Dum0 does

paint.Triggergun momentar

190-250

15,2 m .

G1

and G2 leads from bridge

loose

wires or connectors. Refer

+

on

top of brush.

20

or 24.

Do

not perform this check until

to

not

con

off

and

un

volt

meter.

Volts.

to

Calibra

and - leads and

26.

us

be good. A bad

-

WHAT

If

1.

2. Service pump. See manual 307

3. Reset building circuit breaker; replace

4. Replace with a correct, grounded exten

5. Clean circuit board male terminals. Re

6.

7.

8. Tighten terminal screws. Replace

9. Replace brushes. See page 33.

10.Replace spring

11.Clean brush holders, remove carbon

12.Replace circuit board.

13.Replace motor.

14.Replace bridge.

TO

check

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

building fuse. Repair electrical try

sion cord.

place loose or defective lead terminals. Securely reconnect lead terminals to board.

Calibrate pressure control. See page 28.

Be

tered and firmly connected minals. Replace any damaged wiring. Securely reconnect wires to bridge.

brushes

33.

with brush. See page 33.

dust with small cleaning brush. Align brush lead with slot in brush holder to as sure free vertical brush movement.

DO

is

not

OK,

refer to this column.

you1

-

793.

another outlet.

sure male terminal blades are cen

loose

if

leads are damaged. See page

if

broken. Realign spring

See

page 35.

See

page 24.

outlet

to

female ter

terminal or

page

26.

or

-

16

307-670

IO

OUTPUT

TYPE OF PROBLEM WHAT TO CHECK

If check

Is

OK,

go

to

the next check.

~~...~~

If

check

~

is

-

"

not

OK,

refer to this column.

Motor runs and pump strokes

Motor runs but pump does not

stroke

1. Check paint supply.

2. Check for clogged intake strainer.

loose

3. Check for

4.

Check

to

ton ball are seating properly. ual 307-793.

5.

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

1. Check displacement pump connecting

rodpin. See page 31.

2.

Checkconnectingrodassembiyfordam-

age.

I

3.

See

Be sure crank'in drive housing rotates; plug in sprayer and turn

to

check. Turn

See

page 30.

suction tube or fittings.

see

if

intake valve ball and pis

page 30.

on

off

and unplug sprayer.

See

man

307-793.

momentarily

1.

Refill and reprime pump.

2. Remove and clean, ihen reinstall.

3. Tighten; use thread sealant or sealing

-

4.

-

5.

1. Replace pin

2. Replace connecting rod assembly.

3. Check drive housing assembly for dam

on

tape

Remove intake valve and clean. Check balls and seats for nicks; replace sary. See manual 307-793.

Replace packings.

Also

paint or nicks and replace

spring is fully necting rod. See page

page 30.

age and replace

32.

threads

check piston valve seat for hardened

if

necessary.

See

manual 307-793.

if

necessary.

if

missing.

in

Be

groove all around con

sure retaining

31,

if

necessary. See page

if

neces

-

See

-

'YPE OF PROBLEM

spray pattern varlations.

WHAT TO CHECK

If

check Is

1.

Be sure both G1 and G2 leads from bridge (308) to circuit board (118) are

firmly connected. See page 26.

2. Check stall pressure. Refer to Calibra tion procedure on page 28.

3. Check bourdon tube flag and detector position. Turn pressure setting to

mum; flag

tical detector slot of circuit board.

4.

Check circuit board ing with a good board. See page 26.

5.

Check

16.

OK,

sho.uld

''\

LOW

go

to the next check.

not

drag or bind in

CIRCUIT

FLAG

(1

18)

OUTPUT

section on page

BOARD

by

substitut

maxi-

op-

WHAT TO

If check

1.

Reconnect securely.

-

2. Calibrate pressure control. See page

28.

3. Carefully bend flag into alignment with

detector

lem. trol assembly (301). Calibrate pressure control after reassembly.

-

4.

Replace circuit board.

DO

is

not

OK.

refer

to

See

slot

to see

if

If

not,

replace bare pressure con

that corrects prob

See

this column.

page 26.

-

307-670

17

~~ ~~

WHAT TO CHECK

If

check

is

OK,

go

to the next check.

1.

Check to see ing at high pressure with small tips, which causes low motor

sulk in excessive heat build up.

2. Check where sprayer is located

32°Corifsprayerislocatedindirectsun.

if

sprayer has been operat-

to

see

if

ambient temperature

RPM

is

more than

and re-

~

~~ ~

WHAT TO

If

check is not

1.

Decrease pressure setting or increase tip

DO

OK.

refer to this column.

size.

2 Move sprayer

to shaded, cooler area

possible.

if

'YPE

OF

PROBLEM

Building circuit breaker opens a6

soon

as sprayer switch is turnec

on.

CAUTION

Any short in any part of the mot01 power circuit, which is connectec

to

the output side will cause the bridge immediately. Correctly diagnose and repairallshorts ing and replacing bridge.

of

the bridge

to

burn

ou

beforecheck-

3. Checkto see stalled condition (sprayer turned pressurized, but

if

sprayer has been left in a

not

operating) for long

on,

periods of time.

*

WHAT TO CHECK

If

check

is

OK,

go

to the next check.

1.

Check

all

electrical wirino for damaaed

insulation, and

all terminals for

or damage. Be sure to check wires

Ioos;

fit

be

tween pressure control and motor which are encased in conduit (22). See page

35.

2. Check for missing inspection plate gas

ket (see Daoe

othermetaliomeialcontactpointswhich

could cause a short.

3.

Check motor armature for shorts by us-

ing an armature tester (growler) or form spin test. See page windings for burns.

4.

Checkbridge (308) by substituting with a good bridge or by performing bridge test. See page 20.

CAUTION:

armature is determined armature will immediately burn out a good bridge.

331.

bent terminal forks or

Do

not

perform this check until

to be good. A bad

19.

per-

Inspect

3. Turn off sprayer whenever you stop spraying for a while and relieve fluid pres sure.

WHAT TO

If

check

1.

Repair

DO

is

not

OK,

refer to this column.

or

replace any damaged wiring or

terminals. Securely reconnect all wires.

-

2.

Correct faulty conditions

3.

Replace motor.

4.

Replace bridge.

See

page 35.

page 24

-

Building circuit breaker opens

as

soon

as

sprayer is plugged into outlet and sprayer is turned

on.

L

18

307470

~~

NOT

1.

Check 'Basic Electrical Problems' on page 13.

2. Check

ON/OFF switch (302). See page

23. Be sure the sprayer is unplugged! Disconnect wires from switch and check switch with ohm meter. The ohm meter should read infinity with the

ON/OFF

switch OFF, and zero with the switch

ON.

CAUTION:

A

short in the motor circuit will

burn the bridge out immediately, which in turn usually causes the fail

in the closed mode.

ON/OFF switch to

2.

Replace ON/OFF switch. See page 23.

SPIN

TEST

WARNING

Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection,

the eyes or on the skin, moving park or electric shock,

always follow this procedure whenever you shut sprayer, when checking or servicing any

spray system, when installing, cleaning or changing ready to catch the drainage. spray tips, and whenever

1.

Engage the gun safety latch.

2.

Turn the ON/OFF switch to OFF.

3.

Unplug the power supply cord.

4.

Disengage the gun safety latch.

injury from splashing fluid or solvent in

off

part of the

youstop spraying.

the

..

5.

Hold a metal part of the gun firmly

grounded metal pail, and trigger the oressure.

6,

Engage

7.

Open the Pressure drain valve, having acontainer

8.

Leave the pressure drain valve open until you are ready to spray again.

If

you suspect that the spray tip or hose clogged, ter following the steps above, wrap a rag around the tip guard retaining nut or hose end coupling and VERY SLOWLY loosen the then loosen completely. Now clear the tip or hose struction.

the

gun

safety

latch,

or

thatpressure has not been fullyrelievedaf-

partto relieve pressure gradually,

to

the side of a

gu.n to relieve

is

completely

ob

-

For checking armature, motor winding

cal continuity.

Setup

Remove the drive housing from the sprayer as described in DRIVE

HOUSING

REPLACEMENT, Steps

Grid brush electri-

1-6,

page

32.

Remove the pressure control cover and screws, the mo-

tor cover, the fan cover (F), and the inspection covers

See

Fig

19-1.

Disconnect the

(308).

See

Armature Short Circuit Test Quickly turn the motor fan by hand. the motor will coast ing

to

a complete stop.

If

the motor does not spin freely and resists rotation, the armature page

35.

Armature; Brushes, and Motor Wiring Open Circuit

Test (Continuity)

Connect the two black motor leads together with a test lead.

Turn the motor fan by hand second.

two

leads from the motor

fig

19-2.

If

two

or three revolutions before com-

is

shorted and the motor must be replaced. See

atabout

to

the bridge

there are no shorts,

two

revolutions per

(J).

Fig

19-1

If there

lowing and repair parts

a)

b) broken brush leads

c) loose brush terminal screws

d) worn brushes

e)

f) loose motor lead terminals

If

motor. See page

is

uneven or

broken brush springs

broken motor leads

there is still uneven or no turning resistance, replace the

no

turning resistance, check the

as

needed. See page

35.

33.

fol-

Fig

19-2

307-670

19

BRIDGE

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

BRIDGE

Useacontinuitytester,suchasmulti-metersetonthexi

ohms scale. All tests must be performed.

test, it must be replaced.

Fig 20

-

1 shows the position Using the chart at the right, connect the meter wires as indicated and then check

Fig

20-1

RECTIFIER REPLACEMENT,

if

the bridge is functional.

If

the bridge fails even one

of

the wires

the,continuity.

on

page 24.

the bridge.

TEST

Check For

1.

Line short Connect meter + to bridge ACl Connect meter - to

2. Diode 1 Connect meter Connect meter

""""""""""__

Connect meter + to bridge ACI Connect meter - to bridae

3.

Diode 2 Connect meter + to bridge

Connect meter - to bridge AC2

""""""""""""""""

Connect meter Connect meter

4. Gate 1

Connect meter + to bridge Connect meter

5.

Gate 2 Connect meter Connect meter

5.

Diode

3

Connect meter Connect meter

""""""""""""""""

Connect meter + to bridge Connect meter

+

to

-

to

+

to bridge AC2

-

to

-

to bridge AC1

+to

bridge

-

to

bridge AC2

+to

bridge

-

to bridge

-

to bridge

bridge AC2

bridge bridge ACl

-

I

-

bridge

-

+

-

Ohmmeter Reading

No

continuib

Continuity

-

- -

- - -

No

continuity

Continuity

No

continuity

No

continuity

No

continuity

Continuity

No

continuity

-

20

307-670

~

GENERAL REPAIR NOTES

WARNING

Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, always follow this procedure whenever you

.shut off the sprayer, when checking or servicing any

part of

thespray system, when installing, cleaning or

changing spray tips, and whenever you stop spray ing.

1. Engage the gun safety latch.

2. Turn the

3. Unplug the power supply cord.

4.

Disengage the gun safety latch.

5.

Holdametalpartofthegunfirmlytothesideofa grounded metal pail, and trigger the gun to re lieve pressure.

6.

Engage the gun safety latch.

7.

Open the pressure drain valve, having a con tainer ready

8.

Leave the pressure drain valve open until you are ready to spray again.

If

you

plete& clogged, or that pressure

relievedafter following the steps above, wrap a rag

around the tip guard retaining nut or hose end cou- pling and VERY SLOWLY loosen the part to relieve pressure gradually, then loosen completely. Now clear the

'001

List

Phillips screwdriver Small flat blade

screwdriver Needle nose pliers Plastic mallet' 1/2 open end wrench Adjustable wrench 2 adjustable,

open

Torque wrench

ON/OFF switch to OFF.

to

catch the drainage.

suspect that the spray

ti0

or hose obstruction.

114"

311 6 hex key wrench

518"

318" open end wrench

3/4" open end wrench

718"

-

end wrench

High quality motor oil

Bearing grease

.~

tip

or hose

has

hex key wrench

socket wrench

open end wrench

is

not been

com

fu//y

CAUTION

be sure on a wire to disconnect

2. Route wires in the pressure control assembly care

-

Improper wire routing can result in poor sprayer per formance or damage to the pressure control.

-

3. Keep all screws, nuts, washers, gaskets, and electri

-

4. Test your repair before regular operation of the

-

1-

To reduce the risk of serious bodily injury, including

electric shock, electrical parts with your fingers or a tool while specting the repair.

Shut complete the inspection.

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

Do

to avoid damaging the pump packings.

to

properly mate connectors, and never pull

it.

Pulling on a wire could

fully through the legs

This is which moves as the pressure setting changes, and to avoid pinching the wires between the pressure trol box and cover.

cal fittings removed during repair procedures. These parts are not normally provided with replacement as semblies.

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.

Troubleshooting Guide, pages 13

tify other possible problems and solutions.

to avoid interfering with the bourdon tube,

DO

off

the sprayer and unplug it as soon as you

of

the U-shaped bourdon tube.

con-

CAUTION

If

necessary, refer to the

-

20, to help iden

WARNING

NOT touch any moving parts or

in-

-

1

CAUTION

not run the sprayer dry for more than

30

seconds

-

For

calibration procedure

3/8" ignition wrench Clean water

0.015"

High pressure. oil

5 gallon pail

.

spray tip Mineral spirits

-

filled NEW

lest gauge,

Part No. 102

When disconnecting wires in the pressure control as sembly, use needle nose pliers to separate mating connectors.

When reconnecting the wires, be of the insulated male connector wraparound blade of the female

-

814

on&:

207

bar hioh

pressure spray hose,

Part No.

214-915.

sure the flat blade

is centered in the

connector.

I

-

5.

Reinstall the motor cover before regular operation of

the sprayer and replace it directs cooling air around the motor to help prevent

overheating. It can also help reduce the risk of burns, fire or explosion: see the

WARNING

During operation, the motor becomes very hot and could burn your skin

als spilled on the hot, bare motor could cause a fire

or explosion. Always have the motor cover in place during regular operation to reduce the risk of burns,

fire or explosion.

if

it is damaged. The cover

WARNING,

if

touched. Flammable materi-

below.

307470

21

POWER SUPPLY CORD REPLACEMENT

WARNING

Before doing this procedure, follow the

Relief Procedure Warning

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

Refer

to

Fig

22-f

and

22-2

1.

Use the 19 mm open end wrench to remove the nut

(337)

from the filter stud (31

2.

Use the 13 mm socket wrench

(44)

Screws frame.

3.

Remove the pressure control mounting bracket

using a Phillips screwdriver.

4.

Disconnect the power supply cord wires

control box terminal strip (336) using a screwdriver.

5.

Install the new power supply cord

verse order of disassembly.

6.

Have a licensed electrician install a new plug on the other end of the cord. Be sure regarding the type of plug

holding the pressure control

on page 21 to reduce

0).

to

follow all local codes

to

use.

Pressure

remove the three

from

(31

1) in the re-

to

the

(89)

the

Fig

22-1

FILTER REPLACEMENT

Relief Procedure Warning

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

Refer

to

Fig

22-2

1. Remove the pressure control cover and screws.

2.

Use a needle nose pliers to remove the four wires from

the

filter (310).

3.

Use the lockwashers (337, 338) on the outside of the pressure control box.

4.

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

M8

wrench

on

page 21

to

remove the lower nut and

to

reduce

Fig

22-2

w-\

i

311

22

307-670

ON/OFF SWITCH REPLACEMENT

WARNING

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

Refer

to

fig

23-1

and

23-2

1. Remove the pressure control cover and screws.

2. Remove the wires attached to the switch (302) at

TPI and TP2. using a screwdriver. See page 26, Fig 26-2.

3. Use a 16 mm socket wrench to loosen and remove the nut and rubber boot (303) from the top pressure control box. Remove the switch guard (304).

4. Remove the

5. Remove the wires attached to the switch TP4 and

TP3 using a screwdriver. See page 26, Fig

ONlOFF switch.

of

26-2.

the

Fig

23-,

303

6.

Attach the wires to

7. Install the new switch rotation ring

the threads of the switch, and the external tab en gages with the blind hole (D) of the pressure control

box. See Fig

8.

Install the switch guard (304), aligning the internal

tab with the groove in the threads.

9. Powder the inside of the rubber boot (303) with tal cum, then shake excess out of boot.

10.

Install the nut and rubber boot and tighten.

11. Reconnect the wires to

12. Reinstall the pressure control cover and screws.

TP4

and TP3 of the new switch.

so

the internal tab of the anti-

(W)

engages with the vertical groove in

23-1.

TPI and TP2.

-

Fig

23-2

MICROSWITCH REPLACEMENT

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

Before doing this procedure, follow the Pressure Relief Procedure the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts, or electric shock.

IWARI/*jl

Refer

to

fig

23-2

1.

Remove the pressure control cover and screws.

2. Disconnect both wires from the microswitch (306). 6. Reinstall the cover and screws.

Warning

on page

21

to reduce

~ ~~ ~~~

microswitch.

if

4. Check to see has, be sure the fluid pressure is 0 bar, then loosen the

two

6

just the distance from the top of the flag to top inside

of the pressure control box to 40.79 Tighten the screws and recheck the dimension.

5. Perform the

page 28 before regular operation

the flag

mm hex nuts behind the microswitch. Ad-

STALL

(X)

has been loosened.

PRESSURE

+/

-

0.254 mm.

CALIBRATION

of

the sprayer.

If

on

it

307-670

23

BRIDGE RECTIFIER REPLACEMENT

Before doing this procedure, follow the

Relief Procedure Warning

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

electric shock.

iWARNINGl

Refer

to

Fig

24-f .

1.

Remove the pressure control cover and screws.

2.

Disconnect all wires from the bridge (308) at the ap propriate terminals.

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

two

screws (331). Loosen, but don't remove the screw near the back mounting plate loosen and remove the front screw. Slide the bridge

out.

4.

Slide the new bridge (308) into the box being sure the lockwasher (333) on the rear screw (331) FRONT of the bridge.

on page

Pressure

21

to

(89):

reduce

Then

is

IN

5.

Install.the front screw (331), lockwasher (333) and

nut (332).

CAUTION

The lockwashers (333) must be in front of the bridge

to

avoid overheating which will result in bridge

failure. Refer

6.

Make sure the bridge

and tighten the screws securely.

7.

Connect all wires. Carefully route the wires.

-

Be sure the flat blade of the insulated male connector is centered in the wraparound blade of

the female connector when the connections are

made. Improper connections may cause the sprayer

to

malfunction. Route all wires carefully

interference with the movement of the bourdon tube,

circuit board, or control box cover which could cause

a malfunction.

8.

Reinstall the pressure control cover and screws.

to

the Detail in Fig

is

flush with the side of the box

CAUTION

24-1.

to

avoid

1

Fig

24

24-1

307-670

CHOKE REPLACEMENT

WARNING

Before doing this procedure, follow the Relief

Procedure

Warning on page the risk of a fluid injection injury, splashing in the eyes or

on

the skin, injury from moving parts, or

electric shock.

Refer

to

Fig

25

7.

1. Remove the pressure control cover and screws.

2.

Remove the grounding screw (312) and remove the lead. Loosen the appropriate screw on the terminal strip (336) and disconnect the

yellow/green choke

lead.

3.

Use

the M8 wrench

to

remove the upper nut and

lockwasher (337,338) on the outside of the pressure

control box.

4.

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

the reverse order

of

disassembly.

Pressure

21

to reduce

-

309

VARISTOR REPLACEMENT

WARNING

Refer

to

Fig

25-2

and

25-3.

1. Remove the control box screws and cover.

2.

Remove the

(318, 319) and the old varistor from the switch (302).

3. Trim the leads Turn each lead outward enough for

two

screws (AB), the wiring harnesses

on

the new varistor (339)

to

the

screws

(A,

form a

B)

to

pass through.

to

loop

that is large

ON/OFF

28.5 mm.

Fig

25-1

318 319

A

FRONT VIEW SIDE VIEW

Fig

25-2

4.

Place a wiring harness on each screw, then place a loop of the varistor leads on each screw and thread

the screws

into

the switch.

5. Wrap the varistor under the switch.

Fig

25-3

\

FORM

LOOP

ENOUGH FOR SCREWS

TO

PASS

THROUGH

307670 25

LARGE

~~

CIRCUIT

eyes or on the skin, injury electric shock.

I

Refer

to

Fig

212-1

and

26-2.

1.

Remove the pressure control cover and screws,

2. Turn the pressure control knob all the way clockwise tension three or four threads of the pressure control knob shaftareexposed below the pressure adjustment nut

(S).

Step 2 circuit board while removing or installing it.

3. Disconnect ALL wires from the board, including the

two

connections are made. See Fig

4.

To remove the board from the box, pull out the black plastic cuit 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

was removed.

to

the minimum setting

on

the board. Also check to be sure only

Back down the nut,

CAUTION

is

essential

heavy black wires. Pay close attention to where

-

tipped pin (330). Push the bottom of the cir

to

reduce the risk of damaging the

from

moving parts, or

to

if

necessary. See Fig 26-1.

26-2.

BOARD

counter-

release spring

*~

it

REPLACEMENT

CIRCUIT

I

Fig

261

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

the female connector when the connections are

made.

Route all wires carefully to avoid interference with

-

the circuit board, bourdon tube, or pressure control cover.

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

r

PRESSURE

CAUTION

CONTROL

-

around blade

KNOB

of

i

REF

321. REF 320

7.

Perform the

starling on page 28,

STALL

PRESSURE

if

you installed a new board.

CALIBRATION

TPIO

Fig

26

262

307470

.

LY"

PRESSURE CONTROL REPLACEMENT

WARNING

Before doing this procedure, follow the

Relief

Procedure Warning

on page 21 the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving electric shock.

Refer

to

Fig

28

-

1.

Pressure

to

reduce

parts, or

9. Perform the starling on page

STALL PRESSURE CALIBRATION

28,

before regular operation of the

sprayer.

CAUTION

Do not allow the adapter

the new pressure control assembly. Turning

(A)

to

turn while installing

it

damage the sensitive bourdon tube. Hold .the

adapter firmly with a 19

mm open end wrench while

screwing In the nipple (123).

can

1. Disconnect the main fluid hose (23) and the secon dary fluid hose,

2. Disconnect the fluid hose placement pumpoutlet nipple trol inlet elbow

3.

Hold the hex of the pressure contwl adapter

if

used, from the sprayer.

(47)

from between the dis

(46)

andpressurecon-

(78).

(A)

firmly with a 19 mm open end wrench. Use a wrench

to

unscrew the nipple (123) and filter.

4.

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

5.

Refer to

CIRCUIT BOARD REPLACEMENT

on

page 26, remove the circuit board and retain.

6.

Remove the conduit (22).

7.

Use a 13 mm open end wrench to loosen and remove the three pressure control mounting screws

(40)

lockwashers

and nuts (120) located below the

pressure control box. Remove the box.

8.

Install the new pressure control assembly in the re

(44)

-

and

verse order of disassembly.

-

Fig

28-1

307

-

670 27

STALL

PRESSURE

CALIBRATION

WARNING

USE EXTREME CAUTION WHEN

fluid injection injury or other serious bodily injury which can result from component rupture, electric shock, explosion, or moving parts.

This procedure sets the sprayer WORKING PRESSURE. Perform this procedure PRESSURE. Normal operation whenever the pressure control assembly and reinstalled or replaced properly calibrated.

Improper calibration can cause the sprayer

pressurize and result in component rupture, fire or ex- rated hose

plosion. the maximum working pressure, resulting in poor sprayer performance.

NEVER attempt by performing these calibrations in any other way. duce the risk of electric shock.

Service Tools Needed:

NEW 15.2 m, hose, Part No.

0-5000 psi (0-350 bar) fluid-filled pressure gauge, Part No.

It

may alsopreventthesprayerfrom obtaining

to

increase the fluid outlet pressure sembly when the control box cover is removed,

231

bar, flexible, nylon airless spray

210-541

102-814

to

PERFORMING

to

207 bar MAXIMUM NEVER EXCEED

is

removed higher pressures could result in component rupture,

be sure the sprayer is fire or explosion.

to

THIS CALIBRATION PROCEDURE to

new1 5.2 m spray hose rated for at least 207 bar

over

Use a

-

could

tUre,

AVOID touching the wire in the pressure control as-

207

bar MAXIMUM WORKING

PRESSURE.

develop a high

reduce the risk of a

of

the sprayer at

A

used,

pressure

leak

fire,

under-

or

rup-

to re-

New spray tip, size 0.015”

5 gallon pail and water

Mineral spirits

Calibration Setup.

Refer

fig

28-f

and

29-1.

1.

Follow

page

0.01 test hose and connect the hose

2. Remove the pressure control screws and cover.

3.

Remove the plug from the top of the fluid filter, and install the test gauge (W).

4.

Place the pump suction tube in a5gallon pail ofclean

water.

5. Be sure the gun safety latch is engaged

the

Pressure

21.

Remove the spray hose and gun. Install a

5”

spray tip in the gun. Connect the gun

Procedure continued on next page

Relief

Procedure Warning

to

the sprayer outlet.

to

a new

on

Fig

20-1

28

307670

6.

Use a 9 rnm ignition wrench

justment nut

(S)

counterclockwise about

STALL

to

turn the pressure ad

PRESSURE

turns. See Fig 29-1.

7.

With the pressure control knob setting, turn the sprayer switch

THE DISPLACEMENT PUMP SHOULD

If

it does cyde, shut the sprayer switch OFF, disen-

(B)

at the minimum

ON.

See Fig 29-1. mineral spirits in the pump

NOT

gage the gun satety latch, trigger the gun into a

grounded waste container until pressure is relieved, and engage the latch again. Turn the nut

(S)

further clockwise. Turn the sprayer on again to be sure

THE

8.

Slowly

turn the pressure control knob

to the maximum

PUMP

DOES

NOT

CYCLE.

(B)

clockwise

setting and hold it there. Use a9 rnm

ignition wrench to slowly turn the pressure adjust

ment nut

ACTLY

(S)

clockwise until the test gauge reads

207 bar.

two

full

CYCLE

a little

EX-

CALIBRATION

-

To

prevent the pump, hose and gun with mineral spirits. to close the drain valve, first. ,Use the lowest pressure necessary to flush. Follow the

Relief Procedure Warning

ready to spray again.

10

Remove the test gauge assembly and reinstall the

plug. Flush out water with mineral spirits.

-

pump

corrosion, flush the water out

on page

to

protect it until you are

~~

-

Pressure

21.

Leave the

Be

of

sure

9. The calibration procedure is now completed.

WARNING

Follow the

page

Pressure Relief Procedure Warning

21.

on

Fig 29-

1

307470

29

BEARING HOUSING & CONNECTING

ROD

REPLACEMENT

Before doing this procedure, WARNING follow

Relief the risk of a fluid injection injury, splashing in the eyes or in the skin, injury from moving parts or tric shock. Be sure to unplug the sprayer!

Refer

NOTE: Stop the sprayer at the bottom of its stroke

1.

2.

3.

4.

5.

Procedure

to

Fig

30-1

the crank

must be lowered manually, carefully rotate the blades of the fan with a screwdriver.

Remove the front cover and screws (31, 32).

If

the crank

rotate the blades of the fan with a screwdriver.

Unscrew the suction tube (42) from the ing a wrench pump from loosening.

Disconnect the pump outlet hose (47) from the placement pump outlet nipple (46).

Use a screwdriver to push aside the retaining spring (35) at the top of the pump. Push the pin (20) out the rear.

Warning

for Steps

(E)

in its lowest Dosition. If the crank

(E)

must be lowered manually, carefully

on

the pump intake valve

-1

the

on

page 21 to reduce

7

to

74.

Pressure

elec- premature bearing wear.

~ ~ ~ ~~ ~~

pum6,'hold-

to

keep the

to

get

dis-

DO

NOT

use

the bearing cAuTIoN-1 housing screws (33) to

to

align or seat the bearing housing; the bearing and

drive housing will not align properly and will result in

14. Install the screws (33) and lockwashers bearing housing and tighten evenly

FILL

procedure continued

CAVITY

WITH

on

page

(49)

to

13-16 N.m.

3

7

try

on the

6.

Loosen the jam nut (38) with an adjustable wrench.

Unscrew and remove the displacement pump.

7.

Use a screws (33) and lockwashers (49) from the bearing housing (27).

8.

Lightly tap the lower rear of the bearing housing (27) with a plastic mallet to loosen it from the drive ing (2). Then pull the bearing housing and the con

necting rod assembly (3) straight

ing.

9.

Inspect the crank

parts as needed.

10

Evenly lubricate the inside of the bronze bearing in

the bearing housing with high quality motor oil. Liber

ally pack the roller bearing in the connecting rod as

sembly (3) with bearing grease.

11. Assemble the connecting rod and bearing housing

(27).

12. Clean the mating surfaces of

housings.

13. Align the connecting rod with the crank (E) and care-

fully align the locating pins in the drive housing with the holes in the bearing housing (27). Push the bear- ing housing with

5

mm hex key wrench to remove the four

off

the drive hous

(E)

for excessive wear and replace

the

bearing and drive

onto

the drive housing or tap

a

plastic mallet.

hous-

it

into place

-

42

W

Fig

3CL1

30

307470

-

BEARING HOUSING & CONNECTING

Refer

to

Fig

3

1 - 1

14. Screw the displacement pump about 314 of the way into the bearing housing the pin hole in the connecting rod assembly (3) and continue screwing in the pump until the pin slides easily into the hole. Back off the pump until the top

threads of the pumpcylinder are flush with the face of

the bearing housing and the outlet nipple ing back. Push the retaining spring (35) into the groove -all the way around the connecting rod. Tighten the locknut (38) very tight

N.m- with a 2-1/4 in. open end wrench and a light

hammer.

Be sure the retaining spring (35) is- firmly in the

groove all the way around,

from working loose due

If the pin works loose, it or otherparts could break

due

to

could be projected through the air and result

ous

bodily injury or property damage, including dam

age

to

SeeFig30-1and31-1.

the force of the pump action. These parts

the pump connecting rod or bearing housing.

(27).

WARNING

to

prevent the pin

to

vibration. See

Hold the pin (20) up

(46)

is fac-

-

about

Fig

90

to

(20)

31-1.

100

off

in

seri

to

-

ROD

REPLACEMENT

90-100

N.M

15.

Reinstall the front cover and screws (31,32). Recon

nect the suction tube (42) and pump outlet hose (47).

Fig

30

-

See

1.

-

Fig

31-1

307670

31

1

!

i

DRIVE HOUSING REPLACEMENT

the risk of a fluid injection injury, splashing in the eyes or in the skin, injury from moving parts or elec

tric

shock. Be sure

Refer

to

Fig

32-17.

NOTE:

1.

2.

3.

4.

Stop the sprayer at the bottom of its stroke to get

the crank

manually, carefully rotate the blades of the fan with a screwdriver.

Remove the front cover and screws (31, 32). Re move the six screws (1 19) and motor cover (14).

Disconnect the pump outlet hose (47) from the dis placement pump outlet nipple (46).

Use a 5 mm hex key wrench to remove the four

screws

housing.

Lightly tap the lower rear of the bearing housing (27)

with a plastic mallet to loosen

ing rod assembly straight

(33)

(2).

Then pull the bearing housing and connecting

to

unplug the sprayer!

(E)

in its lowest position. To lower it

and lockwashers (49) from the bearing

it

from the drive hous

off

the drive housing.

-

CAUTION

DO

NOT

allow the gear cluster (9)

moving the drive housing (2). It is easily damaged

-

dropped. The gear may stay engaged in either the front end bell or the drive housing.

DO

NOT

lose the thrust balls (10) located at each end of the gear cluster (9) or allow them to fall be tween gears. The balls, which are heavily covered with grease, usually stay in the shaft recesses, but could be dislodged. If caught between gears and not removed, the balls will seriously damage the drive housing. ings will wear prematurely.

7. Liberally apply bearing grease to the gear cluster (9). Check

8.

Place the bronze-colored washer

ver-colored washer (4) on the shaft protruding from the big gear in the drive housing (2). Align the gears and push the new drive housing straight onto the front end bell and locating pins.

9. Starting at Step

to

reassemble the sprayer.

If

the balls are not in place, the bear

to

be sure the thrust balls

5

and working backwards, continue

..

to

fall when re

(1

0)

are in place.

(5)

THEN

-

if

-

the sil-

5.

Use a 6 mm hex key wrench to remove the two

(65)

screws (51) and lockwashers the drive housing, the ckwashers (65) from the rear

bell (Ib) and the two screws (21) and lockwashers

(65)

from the upper rear

(Ib).

6.

Lightly tap the drive housing

to

loosen

off.

it

from the front end bell, then pull

.

two

of

from the recess of

screws

of

the motor front end bell

(2)

(30)

the motor front end

with a plastic mallet

it

and

lo-

straight

Fig 32-1

32

307-670

i

MOTOR

WARNING

REPLACEMENT

NOTE:

New motor brushes are included with each Packing Repair Kit. Replace them when

replac-

ing the packings, and/or when they have been

worntoaminimumof14mmonthelongestside.

1.

Remove the motor cover screws

(14).

See

Fig

33-1.

2. Remove the screws

(H),

inspection covers

gaskets (K) on each side of the motor. See

(1

19)

and cover

(J)

and

Fig33-I.

3. Loosen the brush lead terminal scrsw and remove the lead.

4.

Push down on the spring clip slightly then pull the clip away from and out

33-2.

Keep the spring clip.

5.

Remove and discard the brush.

6.

Inspect the commutator for excessive pitting, burn

ofthe brush holder.

Refer

to

Fig

ing or gouging.

NOTE:

A

black color on the commutator is normal.

Have the commutator resurfaced by a qualified motor repair shop

too

wearing

fast.

if

the brushes seem

to

be

Fig 33-

1

SPRING

107-398

CLIP

\

,

BRUSH

'

BRUSH

HOLDER

107-149

-

COMMUTATOR

7.

Placea new brush in the holder

are as shown in the first part of Fig 33

so

the bevelededges

-

2, and the

brush lead is routed as shown in the second part of

Fig

33-2.

8.

Slowly push the tabbed end of the spring clip into the brush holder until the clip tab engages. in the holder

and the rolled .portion of the tension spring rests

squarely on the brush.

9.

Route the brush lead

to

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

10.

Test the brushes:

a.

With the ON/OFF switch OFF, turn the pressure

control knob all the way counterclockwise

minimum pressure. Plug in the sprayer.

b. Turn the

ON/OFF switch ON and slowly increase

the pressure until the motor comes up to full

speed.

c. Inspect the brush and

for excessive arcing. Arcs should not

commutator contact area

"

trail" orcir-

cle around the commutator surface.

WARNING

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

to

CAPACITOR

BRUSH HOLDER

\

MOTOR

/

END

BELL

Fig 33-2

Do

not

run the sprayer dry for more than

ICAUTIONl

while checking the brushes

disDlacement DumD.

11.

Reinstall the brush inspection covers, gaskets, and

to

avoid damaging the

30

seconds

screws. Reinstall the motor cover and screws.

307-670

33

MOTOR CAPACITOR REPLACEMENT

WARNING

1,

Remove the control box cover. Disconnect the motor

leads.

2.

Remove the fan cover

of

rear

3.

Use a screwdriver to gently lift the fan tab out of the motor shaft groove and remove the fan

4.

Remove the inspection cover

gasket

34

5.

Push down slightly on the spring clip and pull tiieclip

out of the brush holder. See

6.

Gently push the brushes inspect. Replace

7.

Make a matchmark between the front end bell and the motor housing and the rear end bell (M) and the motor housing reassembly. Also make a mark on the front of the mo tor housing. Refer

8.

Use a the rear end beii (M).

the motor. See

(K)

from each side of the motor

-

1.

11

mm socket wrench

(1)

(F)

and screws

Fig

34-1.

(J),

Fig

out

of the brush holder and

if

necessary. See page

to use as alignment marks during

to

Fig

34-1.

to

remove the nuts from

(G)

(N).

screws

(1).

34-2.

33.

from the

(H),

and

See

Fig

-

Fig

34-1

9.

Gently tap alternate ears of the rear end bell with a plastic mallet to loosen it, then pull it straight not pull the motor armature out. Retain any washers

that fall out when the bell is removed.

10.

To

replace the capacitor, remove the brush lead ter

minal screws

sulation plate of the rear end bell (P). Install a new

capacitor.(X). making sure the ceramic case of the

capacitor is not cracked. Maintain a between the capacitor and any grounded metal

patis. Always replace both capacitors at the same

time.

11.

Position the rear end bell (M) over the tie bolts and push matchmarks carefully and install the lockwashers and nuts.

12.

Position the fan

into place, making sure the fan tabs engage in the motor shaft groove.

13.

InStall the fan cover

14.

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

seal

(8)

See

Fig

and

screws.

(Y)

and the screw

it

onto the motor housing. Align the

(N)

over the motor shaft and push it

(F)

and screws

into conduit elbow, around the motor lead.

35-1.

Reinstall the pressure control cover

(2)

going into the in

3

mm clearance

(G)

(77b) and push conduit

off.

Do

-

INSULATION

BRUSH LEAD

BRUSH HOLDER

Fig

34-2

'

ut

It

DETAIL

WITH MOTOR LEAD FACING BACK

OF

MOTOR BRUSH SHOWN

MOTOR

"

OF

i

34

307470

~~

~

~~

MOTOR

REPLACEMENT

WARNING

Before doing this procedure, follow the Pressure

Relief Procedure Warning on page 21

to

reduce

the risk of a fluid injection injury, splashing in the

eyes or in the skin, injury from moving parts or elec

-

tric shock. Be sure to unplug the sprayer!

1. Disconnect the pump outlet hose (47) from the dis-

placement pump outlet nipple (46).

2.

Remove the pressure control cover and screws and disconnect the four motor leads. Remove the con-

duit seal from the conduit elbow coming into the con trol

box.

3.

Use an adjustable wrench to loosen the conduit con

nector nut

(77a)

at the pressure control assembly

(43).

4.

Swing the conduit (22) away from the-pressure con

trol elbow (77b).

5.

Pull

the motor leads through the elbow, one at a

'

time.

Always pull the motor leads one at a time to avoid

loosening the terminals.

I

.

cAuT'oNl

6.

Loosen the connector nut (77b) atthe motor and pull the conduit (22) away from the motor, then pull the leads through the conduit, one at a time.

7.

Unscrew the elbow (77b) from the motor.

8.

Pull

the wires through the elbow, one at a time.

9.

Remove the front cover and screws (31, 32).

10. Remove the motor cover (14) and screws

(1

19).

11, Use a 6 mm hex key wrench to remove:

-

two

screws (51) and washers (65) from the recess of

the drive housing,

-

two

screws (30) and washers (65) from the lower

rear of the motor front end bell (Ib),

two

-

I

screws (21) and washers (65) from the upper

rear of the motor front end bell (1 b).

I

Fig

35-1

307-670 35

~~

MOTOR

REPLACEMENT

12. Use a plastic mallet

pump (39) from the rear from the front end bell. Then pull the drive housing away from the end bell.

DO

NOT allow the gear cluster (9) moving the drive housing dropped. The cluster may stay engaged in either the front end bell or the drive housing.

DO

NOT lose the thrust balls

end of the gear cluster (9) or allow them

tween

gears. The balls, which are heavily covered with grease, usually stay in the gear recesses, but could be dislodged: If caught between gears and not removed, the balls will seriously damage the drive housing. ings will wear prematurely.

13. Use a 6 mm hex key wrench to remove the four screws (1 the motor bracket (A). Be sure to support the motor to keep the sprayer from tipping.

If

21), lockwashers

to

gently tap the displacement

to

loosen the drive housing

CAUTION

to

fall when re

(2).

It is easily damaged

(1

0)

located at each

to

fall be

the balls are not in place, the bear

*.

(40)

and nuts (120) from

-

if

-

14. Lift the motor assembly

screws'(41) and lockwashers

motor bracket (A).

15.

Secure the motor bracket

the motor assembly with the frame mounting holes.

Install the screws (120).

16. Liberally grease the gear cluster (9) and pinion gear

(B)

and pack all bearings in the motor front end bell.

Check

17. Place the bronze

silver

from the big gear in the drive housing (2).

18. Align the gears and push the drive housing (2)

straight onto the front end bell and locating pins.

19.

Starting at Step

to reassemble the sprayer.

NOTE:

20. Reinstall the motor cover and pressure control cover.

to

be sure the thrust balls

-

colored washer

-

colored washer

12

Use a turning motion on the conduit (22) when feeding wires through it.

off

the frame. Remove the

(62)

and remove the

(A)

to

the new motor. Align

(121), lockwashers

(4)

on the shafi protruding

and working backwards, continue

(40)

(1

0)

are in place.

(5)

and THEN the

and nuts

i

36 307-670

NOTES

307670 37

~~~

PARTS - COMPLETE SPRAYER

38

307-670

PARTS

DRAWING

-

BASIC

SPRAYER

REF

NO.

PART

1

221-069

Ib 220

le

107-219

1

f

178-934"

~~

-

995

"

NO.

lg 107-267

Ih 107-264

2

218-032

2a

107-327

3 218-034 4 178-967

5

107-089

6 220-365

8

107-447

9 179-961

10M69

10 14 181-743

14a

179-948

14b 179-951 14c

178-934'*

15 214-701

-

16 220

20 176 21

955

-

818

101-682

22 065-099 23 210-541

218435

27 30 100-643

TOMOTOR

DESCRIPTION QTY

MOTOR, electric 1

Includes replaceable items Ib, and one of item

10

.HOUSING, motor .BUSHING, 3/4 npt(rn)

.

.LABEL, WARNING

le-lh,

(Irontendbell)

x1/2

.TERMINAL .TERMINAL DRIVE HOUSING ASSEMBLY

Includes replaceable Item 2a

.GREASE, gear,

10

02.

ROD, connecting

SPACER

WASHE

R, race

CART

Includes replaceable items

54,

57

:

58

SEAL, conduit

GEAR CLUSTER

BALL, STEEL;

114 dia.

MOTOR COVER ASSY.

Includes items 14a - 14c

.LABEL, identification .LABEL, identification .LABEL, WARNING HOSE, grounded, nylon;

ft

(0.9

m)

3/16 ID; 3

long;

spring guards both ends

GUN. airless

SEE

307-614

FOR

PARTS

PIN, strai ht. hdls

CAPSCREW, socket head;

x

5/8"

1/4

long CONDUIT, electrical 241 HOSE, grounded, nylon; 50

ft

(1 5 rn) long;

1/4"

sprin guard both ends

HOUhNG, bearing

CAPSCREW,

SOC

hd; 114

,

.

rrn

x

1"

npt(f) 1

1

2 2

1

2

1 1

1

2

MM

ID

;

1 1

2

REF

NO.

PART

31 218-328

179-950" .LABEL.

31a

32 107-209 SCREW. mach. filh:

I

NO.

DESCRIPTION

COVER, bearing housing;

"_.

8-32x

WARNING

. . .

.. ..

1"

~~ ~

no.

33 107-210 CAPSCREW, sch; 3/8-16

unc-3a x 1-1

35

176-817

36 21

36a 179

8-326

-

949 .LABEL, identification

SPRING, retaining

COVER, pressure control

INCLUDES'ITEMS

36b 177-762** .LABEL, WARNING

38

178-941

39

218-347

40 100-214 41 107

-

212

42 180-573 43 221

44 101

-

116

344

46 162-453

NUT, hex DISPLACEMENT PUMP

SEE

307-793

LOCKWASHER, 5/16 CAPSCREW,

x

0.5

SUCTION TUBE PRESSURE CONTROL ASSY

SEE SEPARATE PARTS

ON

PAGE

40

CAPSCREW, hex head:

-

18 x 7/8" long

5/16

NIPPLE, hex; 1/4 npsm 1/4 nDt. 1-3/16 lona

47

218-083

HOSE,'grounded, nylon;

114

ID; 29 (736 rn) long;

spring guard both ends

48 214-570

49 106-115

50

220-286

51 107-218

54 107-310

176-884

57 58 101 59

-

242

104-811

60 106062 62

104-008

65 105-510

~~~

66 178-034 77 108-460 78 100-840

FLUID FILTER

See 307-273 lorparts

LOCKWASHER, spring; 3/8 PRESSURE DRAIN VALVE CAPSCREW, sch; 1/4

x

2.75"

CiP3 iubing

WASHER

RING, retaining HUBCAP WHEEL LOCKWASHER, spring, 5/16 LOCKWASHER, spring;

TAG. WARNING

~~~

CONNECTOR, conduit ELBOW, street, 1/4

114 npt(f)

84

206-994

87

106075

89

183-573

115

181-072

118 218-355

1

19 108-865

THROAT SEAL LIQUID 8

02.

(0.27 liter)

SCREW, mach,

-

24 x 112, type "C

no 6 MOUNTING BRACKET STRAINER CIRCUIT BOARD

SEE PAGE

40

SCREW, rnach; panhead; no. 8-32 x 3/8 long

120 100 121 100

122 123 124

-

1 88

-

057

183-664 165-198

220-285

NUT, hex, 5/16 CAPSCREW, hex

-

18 X 3/4

5/16 PLATE, mounting NIPPLE, rdcg; 3/8 CAP

...

.

-

..

/2

36a. 36b

FOR

PARTS

SOC

hd; 5/16

LIST

x

-

20

1/4

,

ovhd,

-

18

npt(m)

hd;

x

thd frmg;

"

1/4 npt

QTY

1

4

4 1

1

1 1

1

7

2 1

1

3

1

4

1

2 2 2 2 2

2

2 6

1

2

1

8

1

6 7

4

1 1

1

"Eztm warning labels available free.

307-670 39

PARTS

-

PRESSURE

PRESSURE CONTROL ASSEMBLY 221-116

REF

NO. PART NO. DESCRIPTION QTY

CONTROL

REF

NO. PART NO. DESCRIPTION QTY

I

!

,

i

300 218-351

302 107-437 303 105-659 304 107-255 306 107-435 308 218-400

309 218-366

wn 1n71477

-

.

- . -

.

31 1 065-140 312 100-035

318 218-365

~ ~ ~ ~ ~

319 218-368

320 218-369 321 218-370 322 218-371 323 218-372

324 107-438

PRESSURE CONTROL

INCLUDES

.ON/OFF SWITCH

.BOOT. switch

.GUARD, locking

.MICROSWITCH

RECTIFIER, bridge

CHOKE

FIITFR

,

-

. .

CORD SET, power supply, no plug SCREW, mach; slotted pan hd; HARNESS. wire HARNESS, wire HARNESS, wire HARNESS, wire HARNESS, wire HARNESS, wire SCREW, mach, no. 5-40

. - . -.

.

no.

~...~

x

1

302

TO

306

1

I

1

8

x

5/16'

~

fil

head;

1

1 1 1

5/8" 2

325 100-975 326 101-972

327

157-021

328 108-295

329 107-258

330 180-041 331 101-273 332

100-1

333 100-718

334 178

-

335 178-035..

336 107-436 337 105-329

1

338 100

-

339 108-096

'Extra warning labels available free.

NUT, hex mach,

LOCKWASHER, ext;shakeproof; no. LOCKWASHER. no. 8 internal BUSHING. strain relief

TIP, pin, black plastic

PIN SCREW,

79

NUT, hex, mscr, no. LOCKWASHER, internal,

shakeproof, no.

797

"

LABEL. warnina

LABEL

TERMINAL, strip

NUT, hex, M8

109

LOCKWASHER, external

shakeproof; VARISTOR

mach;

; warnins

x

5/16

n0.5

flat hd; no.

10-24

10

1.25

2

5 2

1

10-24 x 5/8" 2

thd

2

1

2

1

40

307670

'

337

338

!

THESE WIRES ARE CONNECTED

TO

TWO

TERMINALS ON THE OTHER

SIDE

OF

THE ON/OFF SWITCH

WIRING

\

DIAGRAM

,302

307-670

41

ACCESSORIES

DISPLACEMENT PUMP REPAIR KIT 220-845 SUCTION TUBE KIT208-259

Repair instructions included with kit. Includes:

MOTOR BRUSH KIT

220-367

Repair instructions included with kit.

SUCTION TUBE KIT

208-920

5

Includes:

REF

NO.

1

2

3 4 5

6

PART

NO.

101-818 CLAMP,HOSE

16&327 UNION, 90 DEG SWIVEL;

17&705 ADAPTER. INTAKE 17&706 17&957 181472

DESCRIPTION

NPT(M X F)

3/4

HOSE, 1” iD X 48”; NYLON

TUBE. SUCTION

STRAINER

gallon

(1

9

liter)

size

QN

REF NO. PART NO. DESCRIPTION

1

156589 UNION, 90 DEG ADAPTER;

2

214-961

3 156591

4 156 5

6

1

7 156-592 TUBE, RISER

8

I

9 161-377

10 159-101

-

100-220 176-684

15(t100 RETAINER, SCREEEN

314 NPT(F) X 3/4 NPT(F) SW

HOSE,

314 ID; NYLON;

SPRING GUARD ONE END

ELBPW.

X

593

1-1/2 - 24 NS

PACKING, O THUMBSCREW. 5/1+18 X 1” ADAPTER, BUNG

SCREEN, FILTER NUT, SCREEN RETAINER

CPLD

314 NPT(MBE);

90

DEG; 3/4 NPT

-

RING, NITRILE

55

gallon

(200

liter) size

c

QN

1

6

FT

(1.8

M);

!

1.

42

307670

TECHNICAL DATA

Power Requirements

Working Pressure Range

Cycles/liter

Maximum Delivery Power Cord Inlet Paint Strainer

Outlet Paint Filter

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

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

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

Stainless Steel Screen, reusable

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

Stainless Steel Screen. reusable

DIMENSIONS

Weight Height

Length

Width

(dry

w/o packaging)

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

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

,230 VAC, 50Hz,

1

phase, 7 amp minimum

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

No.

14 AWG, 3 wire, 2.6

........

0

3.2 literlmin

1190

250 micron

43 Kg (approx.)

-

207 bar

micron

71

1

mm

660mm

572mm

53

m

Pump Inlet Size Fluid Outlet Size

Wetted Parts:

Displacement Pump

UHMW polyethylene,

Filter

....

Aluminum, Carbon steel, Stainless Steel,

NOTE:

DelrinB

.....

3/4 npt(m) with

..........

. .

Carbon steel, Polyurethane,

20"

ID chamfer

1/4 npsm from fluid filter

DelrinB, Leather

307-670

43

WARRANTY

I

THE GRACO WARRANTY AND DISCLAIMERS

Graco warrants all equipment manufactured by workmanship on the date of sale by an authorized Graco distributor to the purchaser's sole remedy for breach of this warranty, Graco will, fora period of

it

and bearing its name to be free from defects in material and

orlginal purchaser for

use.

twelve months from the date of

As

sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive or replaced for twenty Gas Mechanical (GM) and Electric and maintained in accordance

train/gear box on EM and GM sprayers or power train on EH & GH spfayers, which will be repaired

-

four months from the date of sale for Gas-Hydraulic (GH) and

s

rayers and for thirty-six months from the date of sale for Electric-Mechanlcal (EM)

-

Hydraulic EH) Sprayers. This warranty applies on1 when the eqwpment is installed, operated

wlth Graco's wrltten recommenJations.

..

This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper

malntenance, negllgence,

accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable fo! malfunc- tion, damage or wear caused by the incompatibility with Graco equipment of structures, accessorles, equip

-

ment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or

or

maintenance of structures, accessories, equipment

This warranty is conditioned upon the repaid return of the equipment claimed to

ized Graco

dlstributor for verification o8he claim. If the claimed defect isverified, Graco will repair or replace

materials not supplied by Graco.

be

defective

to

an author-

free of charge any defective parts. The equipment will be returned to the original purchaser transportation

If

prepaid.

inspection of the equipment does not disclose any defect in material or workmanship. repairs will

be made at a reasonable charge, which charges may include the costs of parts, labor and transportation.

DISCLAIMERS AND LIMITATIONS

THE TERMS OFTHIS WARRANTY CONSTITUTE PURCHASERS SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY

OR

OTHER WARRANTIES (EXPRESS

NESS FOR A PARTICULAR PURPOSE, AND OF ANY

BASED ON NEGLIGENCE

DAMAGES

AMOUNT

YEARS OF THE DATE OF SALE.

OF

OR

LOSS

THE

OR

STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CONSEQUENTIAL

IS

EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACOS LIABILITY EXCEED THE

PURCHASE

IMPLIED), INCLUDING WARRANTY

PRICE

.

ANY

ACTION

NONXONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES,

FOR

BREACH

OF

O

F

WARRAN+

MERCHANTABILITY

MUST

BE

BROUGHT

OR

WARRANTY OF FIT-

WITHIN

TWO

(2)

!

...

,

(.

i

EQUIPMENT NOT COVERED BY GRACO WARRANTY

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES PARTICULAR PURPOSE, WITH RESPECTTO ACCESSORIES, EQUIPMENT, MATERIALS, MANUFACTURED BY GRACO.

switches, hose, etc.) are subject to the with reasonable

assistance in making any claim for breach of

Factory Branches:

Subsidiary and Affiliate Companies:

GRACO INC. P.O.

44

307-670

These items sold, but not manufactured by Graco (such as electric motor,

if

warranty,

any, of their

Atlanta, Dallas, Detroit,

manufacturer. Graco will provide purchaser

these warranties.

Los

Angeles, West Caldwell (N.J.)

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

BOX

1441 MINNEAPOLIS, MN 55440-1444

PRINTED

IN

USA.

307-670 12-

83

Revised

OF

MERCHANTABILITY AND FITNESS FOR

OR

COMPONENTS SOLD BUT NOT

4-88

A

!