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