Grace ULTRA PLUS+ 1000 231-350 A Series Operation manual

308–560
Rev. D
Supersedes Rev. B
and unreleased Rev. C
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
220/240 VAC, 8 AMP
ULTRAr PLUS+ 1000
AIRLESS PAINT SPRAYER
210 bar (3000 psi) Maximum Working Pressure
Model 231–350 Series A
Complete sprayer on Upright cart with hose,
gun, RAC IVt DripLesst Tip Guard
and SwitchTipt
U.S. PATENT NO. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
04794

2308-560
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spin Test 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 18. . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 19. . . . . . . . . . . . . . . . . . . . .
Power Supply Cord Replacement 20. . . . . . . . . . . . . . .
On/Off Switch Replacement 21. . . . . . . . . . . . . . . . . . . .
Pressure Control Replacement 22. . . . . . . . . . . . . . . . .
Filter Board Replacement 23. . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement 24.
Drive Housing Replacement 25. . . . . . . . . . . . . . . . . . . .
Motor Replacement 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 29. . . . . . . . . . . . . . . . . . . . .
Parts Drawing – Sprayer 34. . . . . . . . . . . . . . . . . . . . . . .
Parts List – Sprayer 35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing and List – Displacement Pump 36. . . . .
Parts Drawing – Pressure Control 37. . . . . . . . . . . . . . .
Parts List – Pressure Control 37. . . . . . . . . . . . . . . . . . . .
Wiring Diagram 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 40. . . . . . . . . . . . . . . . . . . . . . . . .
The Graco Warranty And Disclaimers 40. . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
WARNING


EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call Graco Technical Assis-
tance at 1–800–543–0339.
Do not alter or modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page 39 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Wear hearing protection when operating this equipment.
WARNINGWARNING
INSTRUCTIONS
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.

4308-560
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex-
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNINGWARNING
Liquids can be injected into the body by high pressure airless spray or
leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental trigger-
ing of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable liquids in
confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as cigarettes,
arcs from connecting or disconnecting power cords or turning light
switches on and off.
Failure to follow this warning can result in death or serious injury.
NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages,
free of charge. See page 39 to order.


K
04794
Fig. 1
J
S
P
E
F
D
A
C
T
G
L
R
0137
M
N
B
H
U
Major Components
AMotor DC motor, 220/240 Vac, 50 Hz, 8A, 1 phase
BPressure Adjusting Knob Controls fluid outlet pressure
CON/OFF Switch Power switch that controls 220/240 Vac main power to sprayer
DDrive Assembly Transfers power from DC motor to the displacement pump
EFluid Filter Final filter of fluid between source and spray gun
FSecondary Fluid Outlet Second spray gun operation is connected here
GPail Hanger Container for fluid to be sprayed may be hung here
HDisplacement Pump Transfers fluid to be sprayed from source through spray gun
J50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
KRAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces risk of injection injury
LContractor Gun High pressure spray gun with gun safety latch
MRAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray
tip without removing tip from spray gun
N3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and
spray gun to allow more flexibility when spraying
PPrimary Fluid Outlet Single spray gun operation is connected here
RPressure Drain Valve Relieves fluid outlet pressure when open
SPressure Control Controls motor speed to maintain fluid outlet pressure at displace-
ment pump oulet. Works with pressure adjusting knob.
TSpray Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun
UPressure Gauge Fluid pressure reference


Setup
WARNING
To reduce the risk of serious injury from static
sparking, injection, or over pressurization and
rupture of the hose or gun, all hoses must be electri-
cally conductive, the gun must have a tip guard, and
each part must be rated for at least 210 bar (3000 psi)
Maximum Working Pressure.
To avoid damaging the pressure control, which may
result in poor equipment performance and compo-
nent damage, follow these precautions:
1. Always use grounded, flexible spray hose at
least 50 ft. (15 m) long.
2. Never use a wire braid hose as it is too rigid to act
as a pulsation dampener.
3. Never install any shutoff device between the filter
and the main hose. See Fig. 2.
4. Always use the main filter outlet for one gun op-
eration. Never plug this outlet.
CAUTION
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Read the warning sec-
tion FIRE OR EXPLOSION HAZARD on
page 2 for more detailed grounding
instructions.
WARNING
NOTE: See Fig. 2 while doing the setup.
1. Fill the packing nut/wet-cup 1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
2. Connect the gun, 0.9 m (3 ft) hose and 15.1 m
(50 ft) hose. Screw the assembly onto the outlet
nipple. Don’t use thread sealant and don’t install
the spray tip yet!
3. Two gun hookup . Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 15.1 m (50
ft) long (minimum) main hose. For more flexible
gun movement, install a 3/16 in. ID, 0.9 m (3 ft)
hose between the main hose and the gun.
4. Check the Electrical Service.
Two gun hookup. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 15.1 m (50 ft)
long (minimum) main hose. For more flexible gun
movement, install a 3/16 in. ID, 0.9 m (3 ft) hose be-
tween the main hose and the gun.
a. Electrical requirements: 220/240 V AC, 50 Hz,
8A (minimum).
b. Use a grounded electrical outlet located at least
6 m (20 ft) from the spray area.
b. Do not remove the grounding prong of the power
supply cord and do not use an adapter.
c. Extension cord specifications: 10A, 3-wire,
grounding type. (Long lengths reduce sprayer
performance.)
5. Plug in the sprayer. Turn the ON/OFF switch
OFF. Plug the cord into a grounded electrical
outlet.
6. Flush the pump to remove the oil left in to protect
pump parts after factory testing. See Flushing
on page 11.
7. Prepare the paint according to the manufacturer’s
recommendations. Remove any paint skin. Stir the
paint thoroughly. Strain the paint through a fine
nylon mesh bag (available at most paint dealers)
to remove particles that could clog the filter or
spray tip. This is an important step for trouble-free
paint spraying.

7308-560
Setup
04787
ON/OFF SWITCH
1/4 npsm(m) FLUID OUTLET NIPPLE
DO NOT INSTALL ANY SHUTOFF
DEVICE HERE
PRESSURE ADJUSTING KNOB
PRESSURE
DRAIN
VALVE
PACKING NUT/ WET–CUP
FILL 1/3 FULL WITH TSL
Fig. 2


Startup
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that you
start it safely.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
NOTE: Flush the sprayer if this is a first-time startup.
See page 11.
NOTE: See Fig. 4 except where noted.
1. Put the suction tube into the paint container .
2. Turn the pressure adjusting knob fully coun-
terclockwise to zero pressure.
3. Plug in the sprayer.
CAUTION
Do not run the pump without fluid in it for more than
30 seconds to avoid damage to the displacement
pump packings.
To reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
WARNING
FIRE AND EXPLOSION HAZARD
4. Prime the pump.
a. Open the pressure drain valve (handle in down-
ward position). If you did not install a secondary
hose, be sure the nipple is tightly plugged with
the cap provided. Turn the ON/OFF switch to
ON. Slowly turn the pressure adjusting knob
clockwise until the sprayer starts. When fluid
comes from the drain hose, close the valve (han-
dle in forward position).
b. Disengage the gun safety latch. See Fig. 3.
Following the warning, above, trigger the gun
until all air is forced out of the system and the
paint flows freely from the gun.
c. Release the trigger. Engage the gun safety latch.
5. Check all fluid connections for leaks . Relieve
the fluid pressure before tightening connections.
6. Install the spray tip and tip guard. Engage the
gun safety latch. See Fig. 3. Install the spray tip
according to the instructions supplied with it.
7. Adjust the spray pattern.
a. Increase the pressure just until spray from the
gun is completely atomized. Use the lowest
pressure needed to get the desired results. This
reduces overspray and fogging, decreases tip
wear and extends the life of the sprayer.
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. Test the spray pattern. T o adjust the pattern,
engage the gun safety latch, loosen the retaining
nut. Position the tip guard horizontally for a hori-
zontal pattern or vertically for a vertical pattern.
Then tighten the retaining nut.
0137
GUN SAFETY
LATCH SHOWN
ENGAGED
GUN SAFETY LATCH
SHOWN DISENGAGED
Fig. 3
04788
ON/OFF SWITCH
OUTLET NIPPLE
PRESSURE ADJUSTING KNOB
PRESSURE
DRAIN
VALVE
DRAIN HOSE
Fig. 4

9308-560
Startup
Cleaning a Clogged Tip
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
1. Clean the front of the tip frequently during the day’s
operation. First, relieve pressure.
2. If the spray tip does clog, release the gun trigger, en-
gage the gun safety latch, and rotate the RAC IV
handle 180. See Fig. 5.
3. Disengage the gun safety latch and trigger the gun
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,
shut off and unplug the sprayer, and open the pres-
sure drain valve to relieve pressure. Clean the spray
tip as shown on the RAC IV package.
0137
GUN SAFETY
LATCH SHOWN
ENGAGED
TIP GUARD HANDLE
SHOWN IN SPRAYING
POSITION
TURN HANDLE 180,
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
Fig. 5

10 308-560
Shutdown and Care
WARNING
FLUID INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
1. Check the packing nut/wet-cup daily. First relieve
pressure. Keep the wet-cup 1/3 full of TSL at all times
to help prevent fluid buildup on the piston rod and
premature wear of packings.
Tighten the packing nut just enough to stop leakage.
Over tightening causes binding and excessive pack-
ing wear. Use a round punch or brass rod and light
hammer to adjust the nut. Refer to Fig. 6.
2. Clean the fluid filter often and whenever the spray-
er is stored. Follow the Flushing Guidelines on page
11 or refer to manual 307–273, supplied, for the
cleaning procedure.
3. Lubricate the bearing housing after every 100
hours of operation. First relieve pressure. Remove
the front cover. Fill the bearing housing cavity with
SAE 10 non-detergent oil. See Fig. 7.
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
5. Flush the sprayer at the end of each work day and
fill it with mineral spirits to help prevent pump corro-
sion and freezing. See page 11.
To prevent pump corrosion, never leave water or any
type of paint in the sprayer when it is not in use. Pump
water or paint out with mineral spirits.
CAUTION
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.
PACKING NUT/
WET–CUP
TIGHTEN
Fig. 6
01218A
04797
FILL BEARING HOUSING
CAVITY WITH SAE 10
NON-DETERGENT OIL
AFTER EVERY 100
HOURS OF OPERATION
FRONT
COVER
Fig. 7

11308-560
Flushing
NOTE: Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be
sprayed, or to store the sprayer. Use this chart to determine the required flushing order for the fluid you are
using, and then follow the procedure below for flushing.
*Use this category for flushing a brand new sprayer and flushing after storage.
System has
this fluid in it:
Next fluid to be
s
p
rayed
Flushing order: Before you spray or store
s
p
rayer:
t
hi
s
fl
u
id
i
n
i
t: spraye
d
.Flush 1 Flush 2 Flush 3 sprayer:
*Oil-based
solvent or paint
Oil-based paint –
new color
Mineral spirits none none Prime with oil-based paint
Oil-based
solvent or paint
Water-based paint Mineral spirits Warm soapy
water
Clean water Prime with water-based
paint
Oil-based
solvent or paint
Prepare for
storage
Mineral spirits none none Relieve pressure,
Leave drain valve open
Water or water-
based paint
Water-based paint
– new color
Warm soapy
water
Clean water none Prime with water
Water or water-
based paint
Oil-based paint Warm soapy
water
Clean water Mineral spirits Prime with oil
Water or water-
based paint
Prepare for
storage
Warm soapy
water
Clean water Mineral spirits Relieve pressure,
Leave drain valve open
To reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
WARNING
FIRE AND EXPLOSION HAZARD
1. Follow the illustrated Pressure Relief Procedure
on page 12. Engage the gun safety latch.
2. Turn the pressure adjusting knob fully counter-
clockwise to zero pressure.
3. Remove the spray tip from the gun. Remove the
filter bowl and screen; see manual 307–273. Clean
the screen separately and install the bowl without
the screen to flush it. See Fig. 8.
4. Put the suction tube into a grounded metal pail
with 1/2 gallon of compatible solvent.
5. Start the sprayer. See page 8. To save the fluid
still in the sprayer, trigger the gun into another
container until the next fluid appears, then trigger
the gun back into the fluid you are pumping. Circu-
late the flushing fluid a couple of minutes to thor-
oughly clean the system.
6. Do not run the pump dry for more than 30 seconds
to avoid damaging the pump packings!
7. Follow the illustrated Pressure Relief Procedure
on page 12. Engage the gun safety latch.
8. Unscrew the filter bowl and reinstall the clean
screen. Install the bowl and hand tighten.
9. Remove the suction tube and screen and clean
them separately.
PRESSURE
DRAIN VALVE
FILTER
BOWL
SCREEN
FILTER
SUPPORT
Fig. 8 04789

12 308-560
Troubleshooting
04793
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid in-
jection, 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 of f the sprayer, when
checking or servicing any part of the spray system, when in-
stalling, cleaning or changing spray tips, and whenever you
stop spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and trig-
ger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container
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 is completely
clogged, or that pressure has not been fully relieved after fol-
lowing the steps above,
VERY SLOWLY loosen the tip guard
retaining nut or hose coupling to relieve pressure gradually,
then loosen completely. Now clear the tip or hose.
1,5 2 4 6 3
Perform all Troubleshooting procedures before disassembling the sprayer.
MOTOR WON’T OPERATE
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Basic Fluid Pressure Problems 1. Check the pressure control knob setting. The
motor will not run if it is at the minimum setting
(fully counterclockwise).
1. Slowly increase the pressure setting to see
if the motor starts.
2. Check for a clogged spray tip or fluid filter. Re-
fer to the separate gun, tip, or fluid filter in-
struction manual.
2. Relieve pressure, refer to the separate gun,
tip, or fluid filter instruction manual for
cleaning.
Basic Mechanical Problems 1. Check for frozen or hardened paint in the
pump (76) and/or pressure control tube. Using
a screwdriver, carefully try to rotate fan at back
of motor by hand. See page 17.
1. Thaw. Plug in sprayer and turn on. Slowly
increase pressure setting to see if motor
starts. If it doesn’t, see NOTE 1, below.
2. Check displacement pump connecting rod pin
(43). It must be completely pushed into con-
necting rod (68) and retaining spring (42) must
be firmly in groove of connecting rod. See Fig.
32.
2. Push pin into place and secure with spring
retainer.
3. Check for motor damage. Remove drive
housing assembly (67). See page 25. T ry to
rotate fan by hand.
3. Replace motor (73) if fan won’t turn. See
page 27.
Basic Electrical Problems 1. Check pressure control safety circuit. 2. Turn pressure control ON/OFF switch to
OFF to RESET. If the pressure control safe-
ty continues to trip, see ELECTRICAL
SHORT on page 16.
2. Check electrical supply with volt meter. Meter
should read 200–250 VAC.
2. Reset building circuit breaker; replace
building fuse. Try another outlet.
3. Check extension cord fordamage. Check ex-
tension cord continuity with a volt meter.
3. Replace extension cord.
4. Check sprayer power supply cord (314) for
damage such as broken insulation or wires.
4. Replace power supply cord. See page 20.
5. Check motor brush leads, terminals and brush
length. Brush length should be 1/2” (12 mm)
minimum. See page 19.
5. Tighten terminal screws; replace brushes.
See page 19.
NOTE 1: Thaw the sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm
area. Do not try to start the sprayer until it has thawed completely. If paint hardened (dried) in the sprayer, the pump packings and/or
pressure control must be replaced. See page 29 (Displacement Pump) or 22 (Pressure Control).

13308-560
MOTOR WON’T OPERATE (Continued)
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Follow Pressure Relief Proce-
dure on page 13. Remove gun
from hose. Remove pressure
control.
1 . Check leads from motor to be sure they are
securely fastened and properly mated.
1. Replace loose terminals; crimp to leads. Be
sure male terminal blades are straight and
firmly connected to mating part.
Clean circuit board male terminals. Re-
place loose or damaged terminals. Se-
curely reconnect leads.
2. Check for loose motor brush lead connections
and terminals. See page 19.
2. Tighten terminal screws. Replace brushes
if leads are damaged. See page 19.
3. Check brush length which should be 12 mm
(1/2 in.) minimum. See page 19.
NOTE: The brushes do not wear at the same
rate on both sides of the motor . Check both
brushes.
3. Replace brushes. See page 19.
4. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush. See page 19.
4. Replace spring if broken. Realign spring
with brush. See page 19.
5. Check motor brushes for binding in brush
holders. See page 19.
5. Clean brush holders. Remove carbon with
small cleaning brush. Align brush leads
with slot in brush holder to assure free verti-
cal brush movement.
6. Check motor armature commutator for burn
spots, gouges and extreme roughness. Re-
move motor cover and brush inspection
plates to check. See page 19.
6. Remove motor and have motor shop resur-
face commutator if possible. See page 27.
7. Check motor armature for shorts using arma-
ture tester (growler) or perform spin test. See
page 17.
7. Replace motor. See page 27.
8. Check pressure control board (301) by substi-
tuting with a good pressure control board. See
page 22.
8. Replace with new pressure control board
(301). See page 22.
Refer to the wiring diagram on
page 38 to identify test points
(TP).
1. Check filter board. Connect volt meter to TP7
and ON/Off switch TP3.Connect a jumper
from TP4 to TP8. Plug in sprayer . Meter
should read 200 to 250 VAC. Unplug sprayer.
Remove jumper.
1. Temporary bypass to check (Replace filter
board?)
2. Check power supply cord (314). Disconnect
TP1 female (neutral) and TP2 female and
connect volt meter to these leads. Plug in
sprayer. Meter should read 200 to 250 VAC.
Unplug sprayer. Reconnect TP2.
2. Replace power supply cord. See page 20.
3. Check ON/OFF switch (307). Disconnect TP3
and TP4 and connect volt meter to TP3 and
TP4 terminal on the ON/OFF switch. Plug in
sprayer and turn ON. Meter should read 200
to 250 VAC. Turn off and unplug sprayer. Re-
connect TP3.
3. Replace ON/OFF switch. See page 21.
4. Check motor terminal cutoff switch. Connect
volt meter to TP1 female and TP6 female.
Plug in sprayer and turn on. Meter should read
200 to 250 VAC. Turn off and unplug sprayer.
4. Allow motor to cool. Correct cause of over-
heating. If switch remains open after motor
cools, check continuity between TP4 fe-
male and TP5 female with ohmmeter . If
open, replace motor.
5. Check all terminals for damage or loose fit.
Reconnect TP1, TP2, TP3, TP4, TP5, and
TP6 connectors.
5. Replace damaged terminals and recon-
nect securely.

14 308-560
LOW OUTPUT
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warn-
ing then replace tip. See your separate gun
or tip manual.
2. Check to see that pump does not continue to
stroke when gun trigger is released. Plug in
and turn on sprayer. Prime with paint. Trigger
gun momentarily, then release and engage
safety latch. Relieve pressure, turn off and un-
plug sprayer.
2. Service pump. See pages 29–33.
3. Check electrical supply with volt meter. Meter
should read 200–250 VAC.
3. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or try
another outlet.
4. Check extension cord size and length; must
be at least 1.5 mm 2 (12 AWG) wire and no
longer than 100m (300 ft).
4. Replace with a correct, grounded exten-
sion cord.
5. Check +, –, M+ and M– leads from motor to
pressure control circuit board (B1) for dam-
aged or loose wires or connectors. Inspect
wiring insulation and terminals for signs of
overheating. See page 27.
5. Be sure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or damaged
wiring. Securely reconnect terminals.
6. Check for loose motor brush leads and termi-
nals. See page 19.
6. Tighten terminal screws. Replace brushes
if leads are damaged. See page 19.
7. Check for worn motor brushes which should
be 12 mm (1/2 in.) minimum. See page 19.
7. Replace brushes. See page 19.
8. Check for broken and misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush.
8. Replace spring if broken. Realign spring
with brush. See page 19.
9. Check motor brushes for binding in brush
holders. See page 19.
9. Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holder to assure free verti-
cal brush movement.
10.Check stall pressure. Gauge should read 170
bar (2500 psi) minimum.
10.Replace with new pressure control board
(301). See page 22.
11. Check pressure control board (301) by substi-
tuting with a good pressure control board. See
page 22.
11. Replace with new pressure control board
(301). See page 22.
12.Check motor armature for shorts by using an
armature tester (growler) or perform spin test.
See page 17.
12.Replace motor. See page 27.

15308-560
NO OUTPUT
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor runs and pump strokes 1. Check paint supply. 1. Refill and reprime pump.
2. Check for clogged intake strainer. 2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. 3. Tighten; use thread sealant or sealing tape
on threads if necessary.
4. Check to see if intake valve ball and piston ball
are seating properly. See page 29.
4. Remove intake valve and clean. Check
balls and seats for nicks; replace if neces-
sary. See page 29. Strain paint before us-
ing to remove particles that could clog the
pump.
5. Check for leaking around throat packing nut
which may indicate worn or damaged pack-
ings. See page 29.
5. Replace packings. See pages 29–33. Also
check piston valve seat for hardened paint
or nicks and replace if necessary. Tighten
the packing nut/wet-cup.
Motor runs but pump does not
stroke
1. Check displacement pump connecting rod pin
(43). See page 32.
1. Replace pin if missing. Be sure retainer
spring (42) is fully in groove all around con-
necting rod. See page 32.
2. Check connecting rod assembly (68) for dam-
age. See page 24.
2. Replace connecting rod assembly . See
page 24.
3. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off
and unplug sprayer. See page 25.
3. Check drive housing assembly for damage
and replace if necessary. See page 25.
EXCESSIVE PRESSURE FLUCTUATIONS
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Spray pattern variations. 1. Be sure leads to pressure control circuit board
(B1) are firmly connected. Be sure all male ter-
minals blades are centered and firmly con-
nected to female terminals. See Fig. 33.
1. Reconnect securely. See Fig. 33.
2. Check maximum working pressure. 2. Replace with a new pressure control board
(301). See page 22.
3. Check pressure control board (301) by substi-
tuting with a good pressure control board. See
page 22.
3. Replace with a new pressure control board
(301). See page 22.
4. Check LOW OUTPUT section, page 14.

16 308-560
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor is hot and runs intermit-
tently.
1. Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer
is located is no more than 32
C(90F) and
sprayer is not located in direct sun.
2. Move sprayer to shaded, cooler area if pos-
sible.
3. Determine if sprayer was turned on, pressur-
ized, but not operating for long periods of time.
3 Turn off sprayer whenever you stop spray-
ing for a while and relieve fluid pressure.
ELECTRICAL SHORT
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Building circuit breaker opens
as soon as sprayer switch is
turned on.
1. Check all electrical wiring for damaged insula-
tion, and all terminals for loose fit or damage.
Also check wires between pressure control
and motor which are encased in conduit (1).
See page 27.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Check for missing inspection plate gasket
(see page 27), bent terminal forks or other
metal to metal contact points which could
cause a short.
2. Correct faulty conditions.
3. Check motor armature for shorts. Use an ar-
mature tester (growler) or perform spin test.
See page 17. Inspect windings for burns.
3. Replace motor. See page 27.
4. Check pressure control board (301) by substi-
tuting with a good control board. See page 22.
4. Replace with a new pressure control board
(301). See page 22.
1. Check Basic Electrical Problems on page 12. 1. Perform necessary procedures.
2. Check ON/OFF switch (307) See page 21. Be
sure the sprayer is unplugged!
Disconnect
wires from switch. Check switch with ohmme-
ter. The reading should be infinity with the ON/
OFF switch OFF, and zero with the switch ON.
2. Replace ON/OFF switch. See page 21.
3. Check for damaged or pinched wires in the
pressure control. See page 22.
3. Replace damaged parts. See page 22.
Sprayer quits after sprayer op-
erates for 5 to 10 minutes.
1. Check Basic Electrical Problems on page 12. 1. Perform necessary procedures.
2. Check electrical supply with volt meter. Meter
should read 200 to 250 VAC.
2. If voltage is too high, do not operate
sprayer until corrected.
3. Check tightness of pump packing nut. Over-
tightening tightens packings on rod, restricts
pump action, and damages packings.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings, if
necessary. See page 29.


Spin Test
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
For checking armature, motor winding and brush electri-
cal continuity.
Setup
Relieve pressure. Remove the drive housing. See page
25.
Remove the motor shield (59), the fan cover (F) and the
inspection covers (J). See Fig. 9.
Remove the pressure control/cover(301). Disconnect
the – and + leads from the motor to the pressure control/
cover terminals M–, and M+. See Fig. 10.
Armature Short Circuit Test
Relieve pressure. Quickly turn the motor fan by hand. If
there are no shorts, the motor will coast two or three revo-
lutions before coming to a complete stop. If the motor
does not spin freely, the armature is shorted and the mo-
tor must be replaced. See page 27.
Fig. 9 J
F
59
01224A
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Relieve pressure. Connect the two black motor leads to-
gether with a test lead. Turn the motor fan by hand at
about two revolutions per second.
If there is uneven or no turning resistance, check the fol-
lowing: broken brush springs, brush leads, motor leads;
loose brush terminal screws, motor lead terminals; worn
brushes. Repair parts as needed. See page 19.
If there is still uneven or no turning resistance, replace the
motor. See page 27.
04790
M–
M+
+
–
Fig. 10
301

18 308-560
General Repair Information
To reduce the risk of a pressure control malfunction:
Always use needle nose pliers to disconnect a
wire. Never pull on the wire, pull on the connec-
tor.
Mate wire connectors properly. Be sure the flat
blade of the insulated male connector is centered
in the wrap-around blade of the female connec-
tor.
Route wires carefully to avoid interference with
the other connections of the pressure control. Be
sure the wires are not pinched between the cover
and the control box.
CAUTION
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet
Adjustable wrench
Adjustable, open-end
wrench
Torque wrench
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
Tool List
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
2. Test your repair before regular operation of the
sprayer to be sure the problem is corrected.
WARNING
To reduce the risk of serious injury, in-
cluding electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the repair.
Shut off the sprayer and unplug it as soon as you
complete the inspection. Reinstall all covers, gas-
kets, screws and washers before operating the
sprayer.
ELECTRIC SHOCK HAZARD
3. If the sprayer does not operate properly, review
the repair procedure again to verify that everything
was done correctly. If necessary, see the
Troubleshooting Guide, pages 12 – 16, to help
identify other possible problems and solutions.
CAUTION
Do not run the sprayer dry for more than 30 sec-
onds to avoid damaging the pump packings.
4. Reinstall the motor shield before regular op-
eration of the sprayer and replace it if it is dam-
aged. The cover 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, below.
WARNING
FIRE AND EXPLOSION HAZARD
During operation, the motor and drive
housing become very hot and could
burn your skin if touched. Flammable
materials spilled on the hot, bare motor could
cause a fire or explosion. Always have the motor
shield in place during regular operation to reduce
the risk of burns, fire or explosion.


Motor Brush Replacement
NOTE: Replace the brushes when they have worn to
less than 12 mm (1/2 in). Note that the brushes
wear differently on each side of the motor , so
check them both. Brush Repair Kit 222–157 is
available. A new spring clip, P/N 1 10–816 may
be purchased separately.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
on page 18 before doing this procedure.
1. Relieve pressure.
2. Remove the motor shield (59). Remove the in-
spection covers (J) and gaskets (K) on each side
of the motor. See Fig. 11.
J
F
59
Fig. 11 01224A
3. Push in the spring clip to release its hooks from
the brush holder. Pull out the spring clip. See Fig.
12.
Fig. 12
BRUSH
SPRING CLIP
P/N 110–816
HOOK
SPRING
01227
4. Loosen the brush lead terminal screw. Pull the
brush lead away, leaving the motor lead terminal in
place. Remove brush and spring. See Fig. 14.
5. Inspect the commutator for excessive pitting,
burning or gouging. A black color on the commuta-
tor is normal. Have the commutator resurfaced by
a qualified motor repair shop if the brushes seem
to wear too fast.
CAUTION
When installing the brushes, follow all steps care-
fully to avoid damaging the parts.
6. Install a new brush so the lead is in the long slot of
the holder. See Fig. 13.
Fig. 13
BRUSH
SHORT SLOT
LONG SLOT
BRUSH HOLDER
NOTE: SPRING MUST COIL
IN THIS DIRECTION
SPRING
CLIP
01227
7. Slide the terminal under the terminal screw washer
and tighten the screw. Be sure the motor lead is
still connected at the screw. See Fig. 14.
Fig. 14
SPRING
BRUSH LEAD
TERMINAL SCREW
MOTOR LEAD
TERMINAL
BRUSH
SPRING CLIP
01227
8. Place the spring on the brush as shown in Fig. 13.
9. Install the spring clip and push it down to hook the
short slots in the housing. See Fig. 13.
10. Repeat for the other side.

04791
Fig. 15
301
315
317
307
314
20 308-560
11. Test the brushes.
a. Remove the pump connecting rod pin.
b. With the sprayer OFF, turn the pressure con-
trol knob fully counterclockwise to minimum
pressure. Plug in the sprayer.
c. Turn the sprayer ON. Slowly increase the
pressure until the motor is at full speed.
d. Inspect the brush and commutator contact
area for excessive arcing. Arcs should not
“trail” or circle around the commutator surface.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
Do not run the sprayer dry for more than 30
seconds while checking the brushes to avoid
damaging the displacement pump packings.
CAUTION
12. Install the brush inspection covers and gaskets.
13. Break in the brushes. Operate the sprayer for at
least one hour with no load. Install the connecting
rod pin.
Power Supply Cord Replacement (Fig. 15)
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the illustrated Pressure Relief
Procedure warning on page 12 when-
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REPAIR INFORMATION
on page 18 before doing this procedure.
1. Relieve pressure.
2. Remove the pressure control board/cover (301).
3. Disconnect the power supply cord (314),
both leads from the ON/OFF switch (307), and
the green wire to the grounding screw (317).
4. Loosen the strain relief bushing (315) and remove
the power supply cord (314).
5. Install the new power supply cord in the reverse
order.
6. Install the proper plug on the other end of the
power supply cord. Follow all local codes to select
the proper plug.