Graco 232140 Operation manual

Instructions – Parts List
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
120 VAC, 15A
ULTRARMAX 795
Airless Paint Sprayer
3000 psi (21 MPa, 210 bar) Maximum Working Pressure
Model 232140, Series A
Basic sprayer on upright cart without
hose or gun
Model 232141, Series A
Complete sprayer on upright cart with hose,
gun, RAC IVDripLessTip Guard
and SwitchTip
U.S. PATENT No. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
308800F
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Related Manuals
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
7706A

2308800
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spin Test 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 16. . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 18. . . . . . . . . . . . . . . . . . . . .
Power Supply Cord Replacement 19. . . . . . . . . . . . . . .
On/Off Switch Replacement 19. . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 21. . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement 24.
Drive Housing Replacement 25. . . . . . . . . . . . . . . . . . . .
Motor Replacement 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 29. . . . . . . . . . . . . . . . . . . . .
Accessories 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing – Sprayer 32. . . . . . . . . . . . . . . . . . . . . . .
Parts List – Sprayer 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 36. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
WARNING
INSTRUCTIONS
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 your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts.
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 31 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical 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 expose
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.

3308800
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
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 surgical treatment.
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 7 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.
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.

4308800
WARNING
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 spray-
ing 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.
Use only with a grounded outlet that matches the grounded plug of this equipment.
MOVING PARTS HAZARD
Moving parts 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 7 to prevent the
equipment from starting unexpectedly.
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
triggering 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 31 to order.

5308800
Component Identification and Function
7706A
03008
Fig. 1
N
K
E
H
B
A
L
T
C
P
R
MD
J
S
G
F
U
V
AMotor DC motor, permanent magnet, totally enclosed, fan cooled
BDrive Assembly Transfers power from DC motor to the displacement pump
CPail Hanger Container for fluid to be sprayed may be hung here
DDisplacement Pump Transfers fluid to be sprayed from source through spray gun
EPrimary Fluid Outlet Single spray gun operation is connected here
FSecondary Fluid Outlet Second spray gun operation is connected here
GPressure Drain Valve Relieves fluid outlet pressure when open
HFluid Filter Final filter of fluid between source and spray gun
JPressure Adjusting Knob Controls fluid outlet pressure
KPressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
LON/OFF Switch Power switch that controls 120 VAC main power to sprayer
M3 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
N50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
PContractor Gun High pressure spray gun with gun safety latch
RRAC IV Switch Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
SRAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
TSpray Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun
UPower Cord Rack Holds wrapped power cord for storage
VSpray Hose Rack Holds wrapped spray hose for storage

6308800
Setup
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Working Pres-
sure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over-
pressurization and rupture of the hose or gun.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and compo-
nent damage, follow these precautions:
Do not allow material to freeze in sprayer.
Use nylon spray hose at least 50 ft (15 m) long.
Do not use wire braid hose.
Do not install shutoff device between sprayer and
gun. See Fig. 1.
NOTE: See Fig. 1, except where noted.
1. Fill packing nut full with Graco Throat Seal Liquid
(TSL), supplied. Fig. 2.
Fig. 2
7677A
2. Single gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Connect gun and hose assembly to primary
fluid outlet (F). Do not use thread sealant.
c. Do not install spray tip.
3. Two gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Unscrew cap from 1/4 npsm(m) secondary
fluid outlet (E).
c. Connect gun and hose assembly to secondary
fluid outlet.
WARNING
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. Also read FIRE OR
EXPLOSION HAZARD on page 4 and
Grounding, page 7.
4. Turn ON/OFF (L) switch OFF. Plug sprayer power
cord into grounded electrical outlet at least 20 ft
(6 m) from spray area.
5. Flush pump to remove oil. See Flushing,
page 10.
6. Prepare paint according to manufacturer’s recom-
mendations. Remove any paint skin. Stir paint
thoroughly. Strain paint through fine nylon mesh
bag (available at most paint dealers) to remove
particles that could clog filter or spray tip. This is
an important step for trouble-free paint spraying.

7308800
Setup
Grounding
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire or
explosion that could cause serious injury or death.
1. This equipment requires a 120 VAC, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
Fig. 3 Grounding Prong
Grounded
Outlets
2. Do not alter ground prong or use adapter.
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
Startup
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1. Engage gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Disengage gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Engage gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loos-
en tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose obstruction.
Use this procedure each time you start sprayer to en-
sure sprayer is ready to operate safely.
Startup Procedure
NOTE: Flush sprayer if first-time startup.
See page 10.
NOTE: See Fig. 4 except where noted.
4. Put suction tube (39) into paint container.
5. Turn pressure adjusting knob (J) fully counter-
clockwise to zero pressure.
6. Plug in sprayer power cord.
CAUTION
Do not run pump without fluid in it for more than 30
seconds to avoid damaging pump packings.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce risk of static sparking and
splashing when priming or flushing
system, hold metal part of gun firmly to
side of grounded metal pail before triggering gun.
7. Prime pump.
a. Open (handle down) pressure drain valve (G).
If no secondary hose is installed, be sure sec-
ondary outlet cap is installed. Turn ON/OFF
(L) switch ON. Slowly turn pressure adjusting
knob clockwise until sprayer starts. When fluid
comes from drain hose, close pressure drain
valve (handle forward).
b. Fig. 5. Disengage gun safety latch. Following
warning, above, trigger gun until all air is
forced out of system and paint flows freely
from gun.
c. Release trigger. Engage gun safety latch.
8. Check all fluid connections for leaks.Relieve fluid
pressure before tightening connections.
9. Fig. 5. Engage gun safety latch. Install spray tip.
Install tip guard. See manual 308644, supplied.

8308800
Startup
10. Adjust spray pattern.
a. Increase pressure just until spray from gun is
completely atomized. Use lowest pressure
necessary to get desired results. This reduces
overspray and fogging, decreases tip wear and
extends the life of the sprayer.
b. For more coverage, use larger tip rather than
increasing pressure.
c. Test spray pattern. To adjust pattern, engage
gun safety latch, loosen retaining nut. Position
tip guard horizontally for horizontal pattern or
vertically for vertical pattern. Then tighten
retaining nut. Fig. 5.
Fig. 4
J
L
39
G
FE
7691A
03008
GUN SAFETY
LATCH ENGAGED
GUN SAFETY
LATCH DISENGAGED
Fig. 5
RAC IV
HANDLE
RETAINING
NUT
Cleaning a Clogged Tip
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
1. Relieve pressure.
2. Clean front of tip frequently during operation.
3. If spray tip clogs, release gun trigger, engage gun
safety latch, and rotate RAC IV handle 180.
See Fig. 5.
4. Disengage gun safety latch and trigger gun into
waste container. Engage gun safety latch again.
5. Rotate RAC IV handle 180to original position,
disengage gun safety latch, and resume spraying.
6. If tip is still clogged, engage gun safety latch, shut
off and unplug the sprayer, and open pressure
drain valve to relieve pressure. Clean spray tip as
shown in manual 308644.

9308800
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
1. Check packing nut (A) daily. First relieve pressure.
Keep packing nut full of TSL at all times to help
prevent fluid buildup on piston rod and premature
wear of packings.
If pump begins to leak, loosen packing nut and
remove throat nut spacer (228). Tighten packing
nut just snug. Over tightening causes binding and
excessive packing wear. Use a round punch or
brass rod and light hammer to adjust nut. Refer to
Fig. 6. When leakage occurs again, repack the
pump.
2. Clean fluid filter often and whenever sprayer is
stored. Follow Flushing Guidelines on page 10 for
cleaning procedure.
3. Lubricate bearing housing after every 100 hours of
operation. First relieve pressure. Remove front
cover (49). Fill bearing housing cavity (B) with SAE
10 non-detergent oil. See Fig. 7.
4. For very short shutoff periods, leave suction tube
in paint, relieve pressure, and clean spray tip.
5. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 10.
CAUTION
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.
6. Coil hose and hang it on hose rack when storing it,
even for overnight, to help protect hose from kink-
ing, abrasion, coupling damage, etc.
A
TIGHTEN
Fig. 6 7692A
228
49
Fig. 7
B
7693A

10 308800
Flushing
When to flush
Determine material to spray from column 1. Flush with
material in column 2. Then follow recommendations in
one of next three columns.
CAUTION
Do not leave water or water-based fluids in sprayer if
it could freeze. Push water out with mineral spirits.
Frozen fluid in sprayer prevents starting and may
cause serious damage.
If you are going to: Flush with: Prime with: Clean with: Store unit with:

Spray with new sprayer or
sprayer that has been
stored
Mineral spirits, then
compatible solvent
such as water or
mineral spirits
Compatible paint,
such as latex or
oil-base
Compatible solvent
such as water or
mineral spirits
Mineral spirits
Spray latex paint Warm, soapy water,
then clean water
Latex paint Warm soapy water,
then clean water
Mineral spirits
Spray oil paint Mineral spirits Oil-base paint Mineral spirits Mineral spirits
Change latex to oil paint Warm, soapy water,
then clean water
Mineral spirits Mineral spirits Mineral spirits
Change oil to latex paint Mineral spirits, then
soapy water, and fi-
nally, clean water
Latex Warm, soapy water,
then clean water
Mineral spirits
Change colors, same base Compatible solvent
such as water or
mineral spirits
How to flush
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing,
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 when
flushing.
1. Follow Pressure Relief Procedure on page 7.
Engage gun safety latch.
2. Turn pressure adjusting knob (J) fully counter-
clockwise to zero pressure.
3. Remove spray tip from gun. See Fig. 8. Remove
filter bowl, filter support and screen. Clean screen
separately and install bowl without screen or
support to flush it.
4. Put suction tube into a grounded metal pail with
1/2 gallon of compatible solvent. Close pressure
drain valve (G).
5. Start sprayer. See page 7. To save fluid still in
sprayer, trigger gun into another container until
next fluid appears, then trigger gun back into fluid
compatible solvent container. Circulate flushing
fluid a few minutes to thoroughly clean system.
6. Do not run pump dry for more than 30 seconds to
avoid damaging pump packings!
7. Follow Pressure Relief Procedure on page 7.
Engage gun safety latch.
8. Unscrew filter bowl and reinstall clean screen.
Install bowl and hand tighten.
9. Remove suction tube and screen and clean them
separately.
G
FILTER
BOWL
SCREEN
FILTER
SUPPORT
Fig. 8
J
7694A

11308800
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 7.
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 pressure control knob setting. The mo-
tor will not run if it is at the minimum setting
(fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. Check for a clogged spray tip or fluid filter. Re-
fer to separate gun, tip, or fluid filter instruction
manual.
2. Relieve pressure, refer to separate gun, tip,
or fluid filter instruction manual for cleaning.
Basic Mechanical Problems 1. Check for frozen or hardened paint in pump
(64). 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
(66). It must be completely pushed into con-
necting rod (63) and retaining spring (68) must
be firmly in groove of connecting rod. See Fig.
25.
2. Push pin into place and secure with spring
retainer.
3. Check for motor damage. Remove drive
housing assembly (67). See page 25. Try 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 pressure control safety
continues to trip, see ELECTRICAL
SHORT on page 15.
2. Check electrical supply with volt meter. Meter
must read 105–125 VAC.
2. Reset building circuit breaker; replace
building fuse. Try another outlet.
3. Check extension cord for damage. Check ex-
tension cord continuity with a volt meter.
3. Replace extension cord.
4. Check sprayer power supply cord (79) for
damage such as broken insulation or wires.
4. Replace power supply cord. See page 19.
NOTE 1: Thaw 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 sprayer until it has thawed completely. If paint hardened (dried) in sprayer, pump packings must be replaced.
See page 29 (Displacement Pump Repair).

12 308800
Troubleshooting
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
Basic Electrical Problems
(continued)
Follow Pressure Relief Pro-
cedure on page 7. Remove
gun from hose. Remove pres-
sure control cover.
1.Check leads from motor to be sure they are
securely fastened and properly mated.
1. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely re-
connect leads.
2. Check for loose motor brush lead connections
and terminals. See page 18.
2. Tighten terminal screws. Replace brushes
if leads are damaged. See page 18.
3. Check brush length which must be 1/2 in. mini-
mum. See page 18.
NOTE: The brushes do not wear at the same
rate on both sides of the motor. Check both
brushes.
3. Replace brushes. See page 18.
4. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush. See page 18.
4. Replace spring if broken. Realign spring
with brush. See page 18.
5. Check motor brushes for binding in brush
holders. See page 18.
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.
See page 18.
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 motor control board (104) by perform-
ing motor control board diagnostics on page
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
8. Replace with new pressure control board
(104). See page 21.
Refer to wiring diagram on
page 35 to identify test points
(TP).
1. Check power supply cord (79). Connect volt
meter between TP1 (neutral) and TP2. Plug in
sprayer. Meter must read 105 to 125 VAC. Un-
plug sprayer.
1. Replace power supply cord. See page 19.
2. Check ON/OFF switch (80). Connect volt me-
ter between TP1 and TP3 terminal on ON/
OFF switch. Plug in sprayer and turn ON. Me-
ter must read 105 to 125 VAC. Turn off and un-
plug sprayer. Reconnect TP3.
2. Replace ON/OFF switch. See page 19.
3. Check motor thermal cutoff switch. Turn
sprayer OFF. Check for continuity between
TP4 and TP5 with ohmmeter.
3. If thermal switch is open (no continuity), al-
low motor to cool. If switch remains open af-
ter motor cools, replace motor. If thermal
switch closes after motor cools, correct
cause of overheating.
4. Check all terminals for damage or loose fit. 4. Replace damaged terminals and recon-
nect securely.

13308800
Troubleshooting
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 page 29.
3. Check electrical supply with volt meter. Meter
must read 105–125 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 12 gauge wire and no longer than
300 ft.
4. Replace with a correct, grounded exten-
sion cord.
5. Check leads from motor to pressure control
circuit board (104) for damaged or loose wires
or connectors. Inspect wiring insulation and
terminals for signs of overheating.
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 18.
6. Tighten terminal screws. Replace brushes
if leads are damaged. See page 18.
7. Check for worn motor brushes which must be
1/2 in. minimum. See page 18.
7. Replace brushes. See page 18.
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 18.
9. Check motor brushes for binding in brush
holders. See page 18.
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. 10.Replace with new pressure control board
(104). See page 21.
11.Check motor armature for shorts by using an
armature tester (growler) or perform spin test.
See page 17.
12.Replace motor. See page 27.
12.Check motor control board (104) by perform-
ing motor control board diagnostics on page
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
11. Replace with new pressure control board
(104). See page 21.

14 308800
Troubleshooting
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
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 29–30. Also
check piston valve seat for hardened paint
or nicks and replace if necessary. Tighten
packing nut/wet-cup.
Motor runs but pump does not
stroke
1. Check displacement pump connecting rod pin
(66). See page 30.
1. Replace pin if missing. Be sure retainer
spring (68) is fully in groove all around con-
necting rod. See page 30.
2. Check connecting rod assembly (63) 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 motor control board are firmly
connected. Be sure all male terminals blades
are centered and firmly connected to female
terminals. See Fig. 29.
1. Reconnect securely. See Fig. 29.
2. Check maximum working pressure. 2. Replace pressure control board (104).
See page 21.
3. Check motor control board (104) by perform-
ing motor control board diagnostics on page
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
3. Replace with a new pressure control board
(104). See page 21.
4. Check LOW OUTPUT section, page 13.

15308800
Troubleshooting
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 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. 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 motor control board (104) by perform-
ing motor control board diagnostics on page
21. If diagnostics indicate, substitute with a
good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
4. Replace with a new pressure control board
(104). See page 21.
1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
2. Check ON/OFF switch (80) See page 19. Be
sure sprayer is unplugged! Disconnect wires
from switch. Check switch with ohmmeter.
The reading must be infinity with the ON/OFF
switch OFF, and zero with the switch ON.
2. Replace ON/OFF switch. See page 19.
3. Check for damaged or pinched wires in the
pressure control. See page 21.
3. Replace damaged parts. See page 21.
Sprayer quits after sprayer op-
erates for 5 to 10 minutes.
1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
2. Check electrical supply with volt meter. Meter
must read 105 to 125 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.
.
CAUTION
Any short in any part of the
motor power circuit will cause
the control circuit to inhibit
sprayer operation. Correctly
diagnose and repair all shorts
before checking and replac-
ing control board.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.

16 308800
General Repair Information
CAUTION
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 connector.
Mate wire connectors properly. Be sure flat blade
of insulated male connector is centered in wrap-
around blade of female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Be sure
wires are not pinched between cover and control
box.
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. 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 repair before regular operation of sprayer
to be sure problem is corrected.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of serious injury,
including 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,
gaskets, screws and washers before operating the
sprayer.
3. If sprayer does not operate properly, review
repair procedure again to verify that everything
was done correctly. If necessary, see Trouble-
shooting Guide, pages 11 – 15, to help identify
other possible problems and solutions.
WARNING
EXPLOSION HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materi-
als 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.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
4. Reinstall motor shield before regular operation
of sprayer and replace if damaged. 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 preceding WARNING.

17308800
Spin Test
WARNING
ELECTRIC SHOCK HAZARD
Do not touch brushes, leads, springs or
brush holders while the sprayer is
plugged in to reduce risk of electric
shock and serious bodily injury.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
For checking armature, motor winding and brush elec-
trical continuity.
Setup
1. Relieve pressure. Remove drive housing. See
page 25.
2. Remove motor shield (54), fan cover (A) and
inspection covers (82). See Fig. 9.
3. Remove pressure control cover (B). Disconnect
motor leads (F) and (G). See Fig. 10.
Armature Short Circuit Test
Relieve pressure. Quickly turn motor fan by hand. If
there are no shorts, the motor will coast two or three
revolutions before coming to a complete stop. If the
motor does not spin freely, the armature is shorted and
the motor must be replaced. See page 27.
Fig. 9 B
A
54
7703B
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Relieve pressure. Connect red and black motor
leads together with a test lead. Turn motor fan by
hand at about two revolutions per second.
2. If there is uneven or no turning resistance, check
following: broken brush springs, brush leads,
motor leads; loose brush terminal screws, motor
lead terminals; worn brushes. Repair parts as
needed. See page 18.
3. If there is still uneven or no turning resistance,
replace motor. See page 27.
Fig. 10
G82
F
7695A

18 308800
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in. Note
that brushes wear differently on each side of mo-
tor, so check both. Brush Repair Kit 220853 is
available. A new spring clip, 110816, may be
purchased separately.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure.
1. Relieve pressure.
2. Remove motor shield (54). Remove inspection
covers (B) and gaskets on each side of motor.
See Fig. 11.
B
54
Fig. 11 7703B
3. Push in spring clip to release hooks from brush
holder. Pull out spring clip. See Fig. 12.
Fig. 12
SPRING CLIP
110–816
HOOK
SPRING
01227
BRUSH
4. Loosen brush lead terminal screw. Pull brush lead
away, leaving motor lead terminal in place. Re-
move brush and spring. See Fig. 14.
5. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes seem to wear too fast.
CAUTION
When installing the brushes, follow all steps carefully
to avoid damaging the parts.
6. Install new brush so lead is in long slot of 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 terminal under terminal screw washer and
tighten screw. Be sure motor lead is still connected
at screw. See Fig. 14.
Fig. 14
SPRING
BRUSH LEAD
TERMINAL SCREW
MOTOR LEAD
TERMINAL
BRUSH
SPRING CLIP
01227
8. Place spring on brush as shown in Fig. 13.
9. Install spring clip and push it down to hook short
slots in housing. See Fig. 13.
10. Repeat for other side.

19308800
Motor Brush Replacement
11. Test brushes.
a. Remove pump connecting rod pin.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
d. Inspect brush and commutator contact area for
excessive arcing. Arcs must not trail or circle
around commutator surface.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch brushes, leads, springs or
brush holders when sprayer is plugged
in to reduce risk of electric shock and
serious bodily injury.
CAUTION
Do not run the sprayer dry for more than 30 seconds
while checking the brushes to avoid damaging the
displacement pump packings.
12. Install brush inspection covers and gaskets.
13. Break in brushes.
a. Operate sprayer for one hour with no load.
b. Install connecting rod pin.
Power Supply Cord
Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 15.
1. Relieve pressure.
2. Remove pressure control cover (82).
3. Disconnect power supply cord black (J) lead from
ON/OFF switch (80),the white wire (D) going to
circuit board, and green wire (E) to grounding
screw (107).
4. Loosen strain relief bushing (G) and remove power
supply cord (79).
5. Install power supply cord (79) and tighten strain
relief bushing (G).
6. Connect power supply cord black (J) lead to
ON/OFF switch (80), white wire to circuit board
(D), and green wire (E) to grounding screw (107).
7. Install pressure control cover (82).
On/Off Switch
Replacement
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 15.
1. Relieve pressure.
2. Remove pressure control cover (82).
3. Disconnect two wires (B) and (J) from ON/OFF
switch (80).
4. Press in on two retaining tabs on each side of
ON/OFF switch (80) and remove.
5. Install new ON/OFF switch (80) so tabs of switch
snap into place on inside of pressure control
housing.
6. Connect two wires (B) and (J) to ON/OFF switch.
7. Install pressure control cover (82).

20 308800
Power Supply Cord and On/Off Switch
Replacement
7696B
Fig. 15
D
107 E
B
82
80
79 G
J