Graco 235-699 User manual

INSTRUCTIONS-PARTS LIST
This manual contains IMPORTANT '
READ AND RETAIN FOR REFERENCE.
INSTRUCTIONS
and WARNINGS.
ELECTRIC, 120 VAC
490st AIRLESS PAINT SPRAYER
NOTE This is an example of the DANGER label on your sprayer.
This label is available in other languages, free of charge.
See page 32 to order.
I # I EXPLOSIONHAZARD
FIRE AND
I I . HAZARD
SKIN INJECTION
I
Spra palntlng, fluahlng or cleanlng equlpmnt wlth flammable Ilq- Uquldscan be Injected Into the body by hlgh pnssurs alrless Spray
I uldsrn conflned areas an result In are or exoloslon. or leab - esneclak hose leak
I
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
..
I
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1992, GRACO INC.

General Safety
This equipment generatesvery
high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid through
yourskinandintoyourbodyandcauseextremelyseriousbodily
injury, including the need for amputation. Also, fluid injected or
spiashedintotheeyesorontheskincancauseseriousdamage.
NEVERpointthespraygunatanyoneoratanypartofthebody.
NEVER put hand or fingers over the spray tip. NEVER try to
"blow back" paint: this is NOT an air spray system.
ALWAYS have the tip guard in place on the spray gun when
spraying.
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.
Besureequipmentsafetydevicesareoperatingproperlybefore
each use.
Medical Alert- -Airless Sorav Wounds
If any fluid appears to penetrak ydur skin, get EMERGENCY
MEDICAL CARE AT ONCE.
DO NOT TREAT AS A SIMPLE
CUT. Tell the doctor exactly what fluid was injected.
Note to Physlclan: Injection
in the skin is a traumatic injury It
is important to freaf the
injq surgically as soon as possible.
Do not delay treatment to research toxIcl$ Toxicity is a
concern. with some exotic coatings injected rrectly Into the
blood stream. Consultation with a plastic surgeon
or re-
constructive hand surgeon may be advrsable.
Spray Gun Safety Devices
eachuse.Donotremoveormodifyanypartofthegun;thiscan
Be sure all gun safety devices are operating properly before
cause a malfunction and result
in serious bodily injury.
Safety Latch
Wheneveryoustopspraying,evenforamoment,alwayssetthe
gunsafetylatchintheclosedor'safe"position,makingthegun
triggering of the gun.
inoperative.Failure1osetthesafetylatchcanresultinaccidental
Diffuser
jection when the tip is not installed. Check diffuser operation
Thegundiffuserbreaksupsprayandreducestheriskoffluidin-
regularly. Follow the Pressure Rellet Procedure, below, then
remove the spray tip. Aim the gun into'a metal pail, holding the
gunfirm1ytothepail.Usingthelowestpossiblepressure.trigger
the gun. If the fluid emitted is not diffused into an irregular
stream, replace the diffuser immediately.
ALWAYS have the tip guard in place on the spray gun while
Tip Guard
spraying. The tip guard alerts you to the fluid injection hazard
and helps reduce,
but does not prevent, the risk of accidentally
placing your fingers or any part
of your body close to the spray
tip.
Trigger Guard
Alwayshavethetnggerguardinplaceonthegunwhenspraying
to reduce the risk of accidentally triggering the gun if it is
dropped or bumped.
Spray
Tip Safety
spray tip clogs while spraying, engage the gun safety latch im-
Useearemecautionwhencleaningorchangingspraytips.Ifthe
then remove the spray tip to clean it.
mediately. ALWAYSfollowthe Pressure RellelProcedure and
fully relieved and the gun safety latch is engaged.
NEVER wipe off build-up around the spray tip until pressure is
Toreducetheriskofseriousbodilyinjury,includingfluidinjec-
Pressure Relief Procedure
tion. splashing fluid orsolvent in the eyesoron theskin, or in-
jury from moving parts or electric shock, always follow this
procedurewheneveryoushutoffthesprayer,whenchecking
or servicing any part of the spray system, when installing.
cleaning or changing spray tips, and whenever you stop
spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF
3. Unplug the power supply cord.
4. Disengagethegunsafetylatch.Ho1dametalpariofthegun
firmly to the side of a grounded metal pail, and trigger the
gun to relieve pressure.
5. Engage the gun safety latch.
6. ODen the pressuredrainvalve. having acontainerreadvto
citch thedrainage. Leave the valvg open until you ire
ready to spray again.
lfyoususpectthafthespraytiporhoseiscompletelyclogged,
orthatpressure has not been fullyrelievedafterfoliowing the
sfepsabove,VERYSLOWLYloosenthetipguardretainingnut
or hose end coupling to relieve pressure gradually, then
loosen completely. Now clear the
tip or hose. '
J
308-248

MOVING PARTS HAZARD ~,~%,~~~-~
Moving parts can pinch or amputate yourfingers or other body
parts. KEEP CLEAR of moving parts when starting or operating
the sprayer. Follow the Pressure Rellet Procedure
on page 2
before checking or servicing any part of the sprayer, to prevent
it from starting accidentally.
EQUIPMENT MISUSE HAZARD EE%%
General Safety
Any misuse of the spray equipment or accessories, such as
calsandfluids,orusingwornordamagedparts,cancausethem
overpressurizing. modifying parts, using incompatible chemi-
toruptureandresultinfluidinjection,splashingintheeyesoron
theskin,orotherseriousbodilyinjury,orfire,explosionorprop-
erty damage.
NEVER alter or modify any part
of this equipment; doing so
could cause it to malfunction.
CHECKallsprayequipmentregularlyandrepairorreplaceworn
or damaged parts immediately.
Alwayswearprotectiveeyewear,gloves,clothingandrespirator
as recommended by the fluid and solvent manufacturer.
Thissprayercandevelop2750psi(195bar)MAXlMUMWORK-
System Pressure
/NGPRESSURE.Besurethatallsprayequipmentandaccesso-
themaximumworkingpressureofanycomponentoraccessory
lies used are rated to withstand this pressure. DO NOT exceed
used in the system.
Fluid and Solvent Compatibility
BE SURE that all fluids and solvents used are chemically com-
patiblewiththewettedpartsshownintheTECHNICALDATAon
ture before using them in this sprayer.
page32.Alwaysreadthefluidandsolventmanufacturer'sI~era-
Do not use l,l,l-trichloroethane, methylenechloride. otherha-
vents in this equipment, which contains aluminum andlor zinc
logenated hydrocarbon solvents or fluids containing such
sol-
parts. Such use could result in a serious chemical reaction, with
the possibility of explosion, which could cause death, serious
bodily injury andlor substantial property damage.
HOSE SAFETY :::~~.r ~~,~,~,,,,,~~~,~~.....;..-..."",r~,~
.~i~,~.~~",~.~l;i",~ . -"-e
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 injuty or other serious bodily injuty or
property damage.
ALLFLUIDHOSESMUSTHAVESPRINGGUARDSONBOTH
at or close to the coupling which can result in hose rupture.
ENDSlSpringguardshelpprotectthehosefromkinksorbends
TIGHTEN all fluid connections securely before each use. High
pressurefluidcan dislodgea loose coupling orallow high pres-
sure spray to be emitted from the coupling.
NNERuseadamagedhose.Beforeeachuse,checktheentire
hose for cuts, leaks, abrasion, bulging cover, or damage or
movementofthehosecouplings.Ifanyoftheseconditionsexist,
sure hose or mend it with tape or any other device. A repaired
replacethehoseimmediately.DON0Ttrytorecouplehighpres-
hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULLY
Do not puli on
and hot surfaces ofthe pump and
gas engine.
Do not use fluids
hoses to move equipment. Keep
hoses clear
of moving parts
or solvents which are not compatible with the inner tube and
coverofthe hose. DONOTexposeGraco hosetotemperatures
above 180° F
(82" C) or below -40" F (-40' C).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
fluidhosesatleastonceaweek.1fyourhosedoesnothaveatag
groundedspraysystem. Checktheelectrical resistanceof your
on itwhich specifiesthemaximum electrical resistance, contact
the hose supplier or manufacturer for the maximum resistance
limits. Use a resistance meter in the appropriate range for your
ommended limits. reolace it immediatelv. An unarounded or
hose to check the resistance.
If the resistance exceeds the rec-
,,*, :,,.*...
poorly grounded hose can make your syetem haz;?rdous. Also
read FIRE OR EXPLOSION HAZARD.
Staticelectricityiscreatedbytheflowoffiuidthroughthepump
and hose. If every part 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 un-
pluggingapowersupplycord.Sparkscanignitefumesfromso1-
vents and the fluid being sprayed, dust particles and otherflam-
mable substances, whether you are spraying indoors
or
outdoors, and can cause afire or explosion and serious bodily
injury and property damage. Plug the sprayer into
a grounded
outlet at least
20 n. (6 m) from the sprayer.
Ifyouexperienceanystaticsparkingorevenaslightshockwhile
the entire system for proper grounding. Do not use the system
usingthisequipment,STOPSPRAYlNGIMMEDIATELY.Check
again until the problem has been identified and corrected.
To reduce the risk of static sparking, ground the sprayer and all
Grounding
other spray equipment used or located in the spray area.
tionsfor your area and
type of equipment. BE SURE to ground
CHECKyourlocaleiectricalcodefordetailedgroundinginstruc-
ail of this spray equipment:
1. Sprayer:plugintoaproperlygroundedoutlet.Donotusean
for at least 15 amps.
adapter.Exiensioncordsmusthavethreewiresandberated
2 Fluid hoses: use only grounded hoses with a maximum of
150mcombinedhoselengthtoensuregroundingcontinu-
ily. See Hose Groundlng Contlnulty.
3. Spraygun: obtain grounding through connection to a prop-
erly grounded fluid hose and sprayer.
4. Object being sprayed: according to local code
5. Fluid supply container: according to local code.
6. Allsolventpailsusedwhenflushing, accordingtolocalcode.
Useonlymetalpails,whichareconduciive.Donotplacethe
pail on a non-conductive surface, such as paper or card-
board, which interrupts the grounding continuity.
7. To maintain grounding continuity when flushing orrelieving
pressure, always hold a metal part
of the gun firmly to the
side of
a grounded metal pail, then trigger the gun.
Flushing Safety
Reducetheriskoffluidinjectioninjuty,staticsparking,orsplash-
ing by following the flushing procedure given on page 13 ofthis
manual. Follow the Pressure Relief Procedure
on page 2, and
firmly to the side of a grounded metal pail and use the lowest
removethespraytipbeforefiushing.Ho1dametaipartofthegun
possible fluid pressure during flushing.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards -
particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 - should be consulted.
308-248 3

Conslgnes generales de skcurlte
Cet appareil produit
un fluide tres haute pression. Le fluide
pulverise par le pistolet ou le fluide sous pression provenant de
fuites ou de ruptures peut penetrer sous
la peau ou d I'interieur
du corps et entrainer des blessures tr&s graves, voir meme une
amputation. MOme sans &re sous pression, lefluide Qclabous-
santouentrantdanslesyeuxpeutaussientrainerdesblessures
graves.
quelconque du corps. NE JAMAlS mettre
la main ou les doigts
NE JAMAIS pointer le pistoletvers quelqu'un ou vers une partie
surl'ajutagedu pulvbrisateur. NE JAMAlS essayer de"refou1er"
la peinture. Cet appareil Nest PAS un compresseur
pneumatique.
TOUJOURSgarderlaprotectiondeI'ajutageenplacesurlepis-
tolet pendant la pulvdrisation.
TOUJOURS observer la March
B Sulvre pour DBtendre la
Presslon donnee plus
loin, avant de nettoyer ou denlever
I'ajutage du pulvhrisateur, ou d'effectuer un travail quelconque
sur une partie de I'appareil.
ou le corps.
NEJAMAlSessayerd'arr~terouded~vierlesfuitesaveclamain
Avant chaque utilisation, bien s'assurer que les dispositifs de
securite fonctionnent correctemenl.
Solns medlcaux
En cas de penetration
de fluide sous la peau: DEMANDER IM-
MEDIATEMENT DES SOINS MEDICAUX D'URGENCE. Ne
pas soigner cette blessure comme une simple coupure.
Avisaumedecin: Lapbnetration desfluides sous iapeau est un
traumatisme.
II est Important detralter ChlnIrglCalWnRnt
cette blessure Imm6dlatement. Ne pas retarder le traite-
ment pour effectuer des recherches surla toxicite. Certains
revetements exotiques sont dangereusement toxiques
quand
ils sont inject& directement dans le sang. II est
souhaitabie de wnsulter un chirurgien esthetique ou un
chirurgien specialise dans la reconstruction des mains.
Avant chaque utilisation, bien s'assure que tous ies dispositifs
Dlsposltlfs de securite du plstolet
de s6curit6 du pistolet fonctionnent correctement. Ne pas en-
lever ni modifier une partie quelconque du pistolet: ceci
risquerait d'entraher un mauvais fonctionnement et des bles-
sures graves.
Verrou
de sdcurit.4
A chaque fois que l'on s'arrete de pulv6ris6r. meme s'ii s'agit
d'un court instant, toujours mettre
le verrou de securitb du pis-
tolet sur la position "fermbe"
ou 'securitP ("sate") pour
empecherlepistoletdetonctionner.Siieverroudesecuriten'est
pas mis, le pistolet peut se declencher accidentellement.
Diffuser
Lediffuseurdupistoletsertddiviserlejetetareduireiesrisques
d'injectionaccidenteliequandI'ajutagen'estpasenp1ace.VBrif-
verification, detendre la pression en observant la Marche B
ier le fonctionnement du diffuseur regulibrement. Pour cette
Sulvre
pour Detendre la Presslon donnee plus loin puis en-
lever I'ajutage du pulv6risateur. Pointer
le pistolet dans un seau
en mbtal, en le maintenant fermement contre le seau. Puis, en
Utilisant
la pression la plus faible possible, appuyer sur la
gachette du pistolet. Si le fluide projete n'est pas diffuse sous
forme de jet irregulier, remplacer immediatement le diffuseur.
Protection
de I'aiutage
TOUJOURS maintenir la orotection de I'aiutaoe en olace sur ie
pistolet du
pulverisateurpendantlapulv6;isacon. La protection
de I'ajutage attire I'attention sur les risques d'injection etcontri-
bue
d reduire, mais n'evite pas le risque, que ies doigts ou une
ximite Immediate de I'ajutage du pulvbrisateur.
partiequelconqueducorpsnepassentaccidentellementapro-
Conslgnes de securite concernant l'ajutage du
E. alre extremement attention d l'occasion du nettoyage ou du
ulverlsateur
rempiacement des ajutages du pulvbrisateur. Si i'ajitage se
bouche pendant
la pulvbrisation, menre immediatement ie ver-
roudesecurRBdupistolet.TOUJ0URSbienobserverlaMarche
B Sulvre pour DBtendre 18 Presslon puis enlever I'ajutage du
pulverisateur pour
le nettoyer.
NE JAMAIS essuyer ce qui s'est accumulb autour de I'ajutage
du pulvbrisateur avant que
la pression ne soit completement
tombee et que
le verrou de skurite du pistolet ne soit engage.
Marche
6 Sulvre pour Detendre la Presslon
blessures par projection de fiuide ou celles causees par
de
Pour reduire les risques de blessures graves, y compris les
Bclaboussures dans les yeux ou sur la peau, par des pieces
en mouvement, toujours bien ObseNe Cette marche suivre
vbrification, du Bgale ou du nettoyage du systbme ou lors du
chaque fois que I'on arrete le pulvbrisateur,
d I'occasion de la
changement des ajutages.
1. Engager le verrou de sbcurite du pistolet.
2. Mettre ie levier d'arret du moteur sur ARRET (OFF).
3. Debrancher le cord d'alimentation.
4. DBsengagerleverroudesBcuritedupistolet.Toutenmain-
tenantunepartiem6talliquedupistoletfermementappuyB
wntrelecbled'unseauenm6tal,actionnerlepistoletpour
liberer la pression.
5. Engager le verrou de sBcurit6 du pistolet.
6. Ouvrir la soupape de &curite et la laisser ouverte jusqu'a
cequeI'onsoitpretdseservirdenouveaudupuiv6risateur.
bouche ou que la pression n 'a pas et6 completement iiberde
Sil'on soupconne que le tuyau ou I'ajutage estcompldtement
TRESLENTEMENTunraccorddeboutdetuyauouI'~croude
aprbs avoir procede aux operations ci-dessus, desserrer
retenue de ia protection de I'ajutage et liberer progressive-
ment
la pression.
4 308-248

EL ROCIADO a ALTA PRESIC~N PUEDE CAUSAR GRAVES LESIONES.
SOLO PARA US0 PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.
Lea y entienda todo el manual de instrucci6nes antes de manejar el equipo.
PEL~GRO DE ~NYECC~~N DE FLU~DO ~~~~~~~~~~~~~~~~
Seguridad general
Este equipo genera un Ruido a una presi6n muyalta. El roclado
delapislola,~sescapesdefluidooroturasdeloscomponentes
pueden inyectar fluido en la piel y el cuerpo y causar lesiones
extremadamente graves, incluyendo a veces la newsidad de
amputaci6n.Tambi~n,elfluidoinyectadoosalpicadoenlosojos
puede causar graves datios.
cuerpo.NUNCAcolocarlarnanoolosdedosencimadelabo-
NUNCA apuntar la pistola hacia alguien 0 alguna parte del
quilla. NUNCAtratar de "hacer retornar la pintura"; este NO es
un sisterna de rociado de aire.
SIEMPRE tener colocado el protector de la boquilla en la pis-
tolamientras se est6 pulverizando.
SIEMPRE seguir el procedimiento de descarga de presibn,
vicioa cualiquier equipo del sistema.
dadom~sabjo,antesdelimpiarosacarlaboquillaodedarser-
cuerpo.
NUNCA tratar de parar
o desviar 10s escapes con la mano o el
Asegurarquetodosiosaparatosdeseguridaddele~uipoestan
funci6nando bien antes de cada USO.
Tratamiento medico
Si pareciera que un, poco de fluido penetrb la piel. conseguir
TRATAMIENTO MEDICO DE URGENCIA DE INMEDIATO.
NOTRATARLAHERlDACOMOUNSlMPLEC0RTE.Deciral
medico exactamente cua fiuido fue.
Aviso a1 m&dico: Si se llega a inyectar este fluido en la iel se
causa una lesi6n traumAtica
Es Importante tratar quhrgb
camente la lesibn a ia brevedad oslble. No demorar el
tratamiento para investigar la toxicid)ad.
La toxicidad es aigo
desumaimportanciaenaigunaspinturasex6ticascuandose
wnsultaraunespecialistaencirugiapiasticaoreconstructiva
inyectandirectamentealtorrentesanguineo.Sira~nveniente
de las manos.
Aparatos de segurldad de la plstola pulverlzadora
Asegurarquetodoslosaparatosprolectoresdeiapistolaestan
funci6nando bien antes de cada uso. No sacar ni modificar
ningljna pieza de la pistola pues podriacausar el malfunci6na-
mientodelamismaconlasconsiguienteslesionespersonales.
Pestillo de seguridad
Cadavez que se deje de pulverizar, aunque sea por un breve
ci6n "cerrada"
lo que deja la pistola inoperante. El no hacerlo
momento, siempre colocar el pestillo de seguridad en la posi-
puede llevar al disparo imprevisto de la pislola.
Difusor
El dfusor de la pistola dispersa el chorro pulverizado y reduce
el riesgo de inyecci6n cuando
no esta instalada la boquilla.
Revisarconregularidadelfunci6namientodeldifusor.Seguirel
procedlmlento de descarga de presl6n. dado mas abajo, y
co,soslenibndolabienfirmecontrael.Utilizandolapresi6nm~s
despues sacar la boquilla. Apuntar la pistola a un balde metdli-
baio posibie. disparar la pistola. Si el Ruido emitido
no sale dis-
persoenunchorroirregular,reemplazardeinmediatoeldifusor.
Protector de la boguilla
SIEMPREtenerelprotectordeiaboquillacolocadoenlapistola
mientrasseesthpulverizando. Esteprotectorllamalaatenci6n
contra el peligro de inyecci6n y ayuda a reducir, per0 no evita,
lacolocaci6naccidentaldeiosdedosocualquierotrapartedel
cuerpo cerca de la boquilla.
Segurldad de la boquilla pulverizadora
Tenermuchocuidadoallimpiarocambiarlasboquiilas.SiIlega-
raaobstruirsemientrasesl~pulverizando,enganchareipestillo
de la pistola de inmediato. SIEMPRE seguir el procedlmlenlo
de descarga de presl6n y despues sacar la boquilla para lim-
piarla.
NUNCA limpiar la acumulacibn de pintura alrededor de la
bo-
y el pestillo este enganchado.
quillaantesdequesehayadescargadoporcompletolapresi6n
Procedimlento de descarga de preslon
Parareducirelriesgodesufrirgraveslesionescorporaies,in-
ciuyendo inyecci6n o lesiones causadas por pie& en
movimiento
o choque elbctrico, siempre seguir este
procedimiento al apagar la maquinapukrerizadora, al revisar
0 dar sewicio a cualquier parte del sistema de pulverizaci6n,
al instalar, limpiar
o cambiar las boquillas, y cadavezque se
deja de pukrerizar.
1. Enganchar el pestillo de la pistola.
2. Mover el interruptor elbctrico (ON/OFFj a laposicibn OFF
3. Desenchufar el cord6n electrico. 1
(apagado).
2 6
4. Desenganchar el pestillo de la pistola. Sujetar una parte
metalicadeiapistolabienfirmecontraunbaldedemetal,y
disparar la pistola para descargar la presi6n.
5. Enganchar el pestillo de la pistola.
6. Abrir la valvula de presibn. Dejar la valvula de alivio de
presibn abierta hasta que se este nuevamente list0 para
pulverizar.
Si se sospecha que la boquilla
o la manguera est6 com-
pietamente obstruida,
o que no se ha descargado por com-
pleto la presi6n despubs de haber seguido el procedimiento
anterior,aflojarmuylentamentelatuercaderetenci6ndelpro-
tector de la boquilla o acoplamiento de la punta de la man-
guera y descargar gradualmente la presion, despues.
aflojarlo porcompleto. Luego, despejar la boquiilao la man-
guera.
308-248

PELlGRO POR MAL US0 DEL EQUIP0
Segurldad general Preslon del slstema
Cualquier mal us0 del equipo pulverizador o 10s accesorios, tal
estd pulverizadora puede desarrollar 195 barias (2750 psi) de
como sobre presurizaci6n, modificaci6n de piezas, us0 de presi6n DE TRABAJO MAXIMA. Asegurar que todo el equipo
mat~rialesyproductosquimicosincompatibles,oufilizaci6nde
pulverizadory sus accesorios tienen la capacidad para aguan-
piezas daiiadas
0 desgastadas, puede hacen que se rompan y
tar la presibn maxima de trabajo de est& pulverizadora. NO ex-
causenlainyecci6ndefluidouotraslesionescorporalesgraves,
ceder la presi6n maxima de trabajo de ningljn cornponente o
incendio, explosibn o daiion a la propiedad. accesorio de este sistema.
NUNCA alterar o modiicar ningljna pieza de este equipo; el Siempreleerlasinstrucci6nesdelfabricantedelfluidoysolvente
Compatlbllldad de fluldo
hacerlo podria causar una averia. antes de usarlos en estA pulverizadora, dadas en la pdgina
32.
REWSAR con regularidad el equipo pulverizador y reparar o respiradero, tal como recomiendan 10s fabricantes del fluido y
Siempre usar gafas, guantes, vestirnetas protectora y un
reemplazar de inmediato las piezds datiadas
0 desgastadas. del solvente.
SEGURIDAD EN EL US0 DE LAS MANGUERAS .E:E ~y:<@-i!
Elfluidoqueescapaaaltapresi6nporlasmangueraspuedeser MANEJARY PASAR CUIDADOSAMENTE IAS MANGUERAS.
rotura
o rajadura debido a cualquier tip0 de desgaste. datio o o solventes que Sean incompatibles con el tub0 interno y ia
muypeligroso.Sienlamanguerasedesarrollaunescape,una Notirardelasmanguerasparamovere1equipo.Nousarfluidos
maltrato. el chorro a aka presi6n emitldo por alii puede Causal
cubiertadelamanguera.NOexponerlasmanguerasatempera-
una lesion por inyeccibn u otras lesiones corporales graves o
turas sobre 82" C (180' n o baio -40° C 1-40' n.
.dahos a la propiedad.
ITODAS LAS MANGUERAS PARA FLUIDOS TIENEN QUE manguera
TENER GUARDAS DE RESoRTE EN EICTREMoS! Lacontinuidaddelcircuitodepuestaatierraapropiadoesesen-
Estas~rote~en~asman~uerascontradob~eceso retorceduras cialparamantenerconectadoatierraelsistemapu1verizador.Es
traducirse en roturas de la manguera.
en loS acoplamientos CerM de ellos. IDS que POdrian indispensable revisar la resistencia elbctrica maxima de las
mannuerasdeairevdefluidooorlomenosunaveznlasemana.
-
Continuldad del circulto de puesta a tierra de la
~ ~
Antes de usarlas, APRETAR bien fumes todas las conexiones. Si la manguera notiene una etiqueta en la cual se especifica la
~" ~~~ - "r.. ~
El fluido a alta presi6n puede desalojar un acoplamiento suelto
o dejar que por el escape un chorro a aka presi6n.
NUNCA usar una manguera que estd datiada. Siempre,
revisarla en busca de cortaduras. escapes, abrasion. cubierta
abuilada,
o acoplamientos sueltos o datiados. Si llegara a en-
cnntrarse cualquiera de est& condici6nes, reemplazar de
in-
mediato la manguera. NO intentar racoplar una manguera de
aka presi6n
o enmendarla con cinta adheslva u otro material
similar. Una manguera que ha sido remendada
no aguante el
fluido a alta presi6n.
PELIGRO DE INCENDIO 0 EXPLOSION *?!%ZS
guera crea electricidad estatica. Si todas las partes del equipo
El flujo a aka velocidad del fluido ai pasar por la bomba y man-
convirtiendo al sistema en algo peligroso. Tambih. pueden
pulverizador
no tienen buena tierra, pueden ocurrir chispas.
co.Est~schispaspuedeninflamarlosvaporesdelossolventes
producirsechispas a enchufaro desenchufarel cord6n electri-
yelchorrodefluidopulverizado,particulasdepolvoyotrassus-
tanciasinflamables, seaalaire libreo bajotecho, loquepodria
causar unaexplosi6n
o incendio y graves lesionescorporalesy
tomacorrientequeseencuentreaporlomenos6m(ZOpies)de
dahos al a propiedad. Enchufar siempre la pulverizadora a un
la maquina y del area que se va a rociar.
Si ocurre una chispa de electricidad estatica
o incluso un ligero
choque electrico mientras se usa el equipo. DEJAR DE PUL-
VERIZAR DE INMEDIATO. Revisartodo el sistema en buscade
una tierra apropiada. No usar de nuevn el sistema hasta haber
identificado y soluci6nado el problema.
Peusta a tierra
Para reducir el reisao de ChisDas estdticas. conectara tierra la
pulverisadora y togo el otro equipo de pulverisar que se use
o
se encuentre en el lugar que se va a rociar. CONSULTAR el
codigoelectricode lalocalidad
paralasinstrucci6nessobre las
conexiones a tierra exigidas para la zona y tip0 de equipo.
ASEGURARdeconectaratierratodoesteequipopuivensador:
1. Pulverizadora: enchufar el cord6n electrico. o cable exten-
sor, cada
uno un enchuf de tr&s patas en buen estado, a un
tornacorreinte con puesat a tierra aporpiado. No usar un
adaptador.Totosloscablesextensorestienenquetenertr&s
hilos y una capacidad de 15 amperios.
resistenc'k elbctrica. ponerse
en contact0 con el proveedor 0
fabricante de la manguera para la informaci6n sobre 10s lirnites
de resistencia. Usar un metro de resistencia en la gama
apropiade para comprobar la resistencia; si excede
10s limites
tener una manguera sin puestd a tierra
o con la puesta a tierra
recomendados,reemplazarladeinmediato.Esmuyarriesgado
en malas condicibnes. Leer tambih la information sobre
RIESGO DE INCENDIO 0 EXPLOSION, mds arriba.
2. Mangueras para fluidos: usar solamente mangueras con
puestd a tierra de una longitud combinada de
150 m (500
pies), para asequrar buena continuidad a tierra. Referirse
iambibn al pirrafo sobre contlnuldad
a tlerra de la
manugeura.
3. Pistola: hace la puesta a tierra conectandola a una man-
guera de fluido y pulverizadora bien conectadas a tierra.
4. Suministrar un recipiente: de acuerdo al codigo de la
localidad.
5.' 0bjetoqueseestirociando:deconformidadconelcodigo
local.
6. Todos 10s baldes de sohrente usados durante el lavado, de
conformidad con el c6digo local. Usarsolarnente baldes de
meta/,queseanconductivos.nocolocarelbaldeenunasu-
perficienoconductiva,comopapeiocart6n,queinterumpe
la continuidad a tierra.
7. Para mantenar la continuidad a tierra durante el lavado o
descargadepresion,siempreapoyarunapartemetdlicade
la pistola bien firme contra el costado del balde de metal,
despues apretar el gatilio.
Segurldad durante el lavado
piel,
o que ocurra una descarga de electricidad esatica.
Para reducir el riesgo de que se inyecte
o salpique fluido en la
siempreseguirlasINSTRUCC16NESPARAEClAVAD0,dadas
enlapagina13.Seguirelprocedlmlentodedescargadepres-
1611 en la pagna 6. y quita la boquilla rociadora antes de lava,:
Apoyarunapartemetalicadelapistolabienfirmecontraelcos-
tadodeunbaldedemetalyusarlepresi6nm~sbajaposibiede
fluido durante el lavado.
308-248 7

WARNING
sure the hoses are electrically conductive, that
If you supply your own hoses and spray gun. be
the gun has a tip guard, and that. each part
Is
rated for at least 2750psi (195 bar) Workng
Pressure. This
is to reduce the risk of serious
bodily Injury caused by static sparking, fluld in-
jection or over-pressurizatlon and rupture
of the
hose or gun.
CAUTION
To avpld damaging the pressure control, which
component damage, follow these precautions:
may result in poor equipment performance and
1. Always use nylon spray hose at least 50 R.
2. Never use a wire braid hose as it is too rigid
3. Never install any shutoff device between the
(6 m) long.
to act
as a pulsation dampener.
pump and the hose. See Flg
I.
1. Connect the hose and gun and screw it onto the
outlet nipple. Don't use
thread sealant, and don't
install the spray tip yet!
2. Fill the wet-cup. Pry off the wet-cup seal. Fill
the cup 113
full with Graco Throat Seal Liquid
(TSL), supplied. Install the seal.
3. Check the electrical service. Be sure it is 120 V,
60 HAC, 15 Amp (minimum). Use a properly
grounded outlet.
Do not remove the third
(grounding) prong
of the power supply cord, and
do not
use an adapter.
Use a 3-wire, 12 ga (minimum), 15 amp extension
cord up to 150
ft. (45 m) long. Longer lengths af-
fect sprayer performance.
4. Plug In the sprayer. Be sure the ON/OFF switch
is
OFF. Plug the cord into a grounded outlet at
least
20 R. (6 m) 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. Also
read
FIRE OR, EXPLOSION HAZARD on page 3.
5. Flush the pump to remove the oil which was left
in to protect pump parts after factory testing. See
page 13.
6. Prepare the paint according to the manufactur-
er's recommendations. Remove any paint skin.
Stir the paint to mix pigments. Strain the paint
through a fine nylon mesh bag (available at most
paint dealers) to remove particles that could clog
the gun filter or spray tip. This is an important
step toward trouble-free paint spraying.

OPERATION
How to use the gun safety latch
from accidental triggering. See Fig
2.
When engaged, the gun safety latch prevents the gun
If the gun still sprays when the gun safety latch
is engaged, adjust the gun. See manual
307-614, supplied.
How
to use the pressure drain valve
from the pump and to help prime the pump. If the
Use the pressure drain valve to relieve fluid pressure
tomatically to relieve fluid pressure.
If this happens,
valve senses an over pressure condition,
it opens au-
stop spraying immediately, shut
off and unplug the
sprayer. Determine the cause of the problem and cor-
the Troubleshooting Guide, page
14. See Fig 3.
rect it before operating the sprayer again. Refer also to
How
to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully coun-
terclockwise to obtain the minimum setting. Turn the
knob clockwise to increase pressure. See Fig
4.
TO INCREASE PRESSURE
ROTATE CLOCKWISE
PRESSURE ADJUSTING KNOB
Fig 4
How to use the RAC IV tip guard
WARNING
To reduce the risk of serious bodily injury from
from fluid injection:
NEVER operate the spray gun with the tip guard
removed.
of the spray tip when cleaning or checking a
DO NOT hold your hand, body, or
a rag in front
clogged tip. Always point the gun toward the
tip
is clear.
ground or into a pail when checking to see
if the
DO NOT try to 'blow back" paint: this
is NOT an
air spray sprayer.
The tip guard alerts you to the risk and helps prevent
placing any part of the body close to the spray tip.
The tip guard also adjusts the vertical or horizontal
spray pattern. See page
11. The tip guard holds a
reversing spray tip. The tip
is in the spraying position
when the tip handle polnts forward.
See Fig 5.
Clean the front of the tip frequently during the day's
operation. First, follow the Pressure Relief Proce-
dure Warning on page 2.
SPRAYING POSITION.
HANDLE SHOWN IN
How to remove a tip clog
1. Release the gun trigger. Engage the safety latch.
Rotate the
RAC IVtip handle 180". See Fig 5.
2. Disengage the safety latch. Trigger the gun into a
pail or onto the ground to remove the clog.
3. Engage the safety latch. Rotate the tip handle to
the spraying position.
4. If the tip is still clogged, engage the safety latch,
shut
off and unplug the sprayer, and open the pres-
sure drain valve to relieve pressure. Clean the
spray tip as shown in manual
307-848, supplied.
308-248 9

‘g STARTUP
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, includ-
ing fluid injection, Splashing fluid or solvent in the
eyes or on the skin, or injury from moving parts or
you shut
off the sprayer, check or service any part
electric shock, always follow this procedure when
spraytips, and whenever you stop spraying.
of the spray system, install, clean or change
1 Engage the
gun safety latch.
2 Turn the ON/OFF switch to OFF.
3 Unplug the sprayer.
4 Disengage the gun safety latch. Hold a metal
part of the gun firmly to the side of a
grounded metal pail. Trigger the gun to re-
lieve pressure.
5 Engage the gun safety latch.
6 Open the pressure drain valve. Leave it open
lf you suspect that the spray tip or hose is com-
pletely clogged, or that pressure has not been
fully relieved after fo/lowing the steps above,
VERY SLOWLY loosen the tip guard retaining nut
or hose.coup1ing to reileve pressure gradually,
then loosen completely.
until you are ready to spray again.
Use this procedure each time you start the sprayer to
you start it safely.
help ensure the sprayer is ready to operate and that
NOTE 1: If this is a first-time startup, flush the
NOTE 2: ‘Refer to Fig 9 and the other figures refer-
enced in the text as you start the sprayer.
1. Open the pressure drain valve. See Fig 6.
2. Don’t install the spray tip until the pump is
sprayer. See page 13.
primed!
Fig
6 W 1022
3. Put the suction hose into the paint. If you are
down below the
top of the pail to avoid splashing
pumping from a
1 gallon pail, push the
drain hose
paint when the drain valve is opened.
4. Turn the pressure setting to minimum.
5. Disengage the gun safety latch. See Fig 2, page
9.
CAUTION
To reduce the risk of damage to the displace:
ment pump packings, never
run the pump with-
out fluid in it for more than 30 seconds.
6. To prime the pump, turn the sprayer on. Slowly
When fluid comes from the pressure drain valve,
increase the pressure until the sprayer starts.
close the valve.
Fig
7
7.
To prime the hose, lower the pressure to reduce
splashing. Hold a metal part of the gun firmly
against and aimed into the side of a grounded
metal pail. See Fig
7. Hold the trigger open and
slowly increase the pressure until the pump
starts. Keep the gun triggered until all air is forced
the gun. Release the trigger and engage the gun
out
of the system and the fluid flows freely from
safety latch.
8. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
9. Install the spray tip. Engage the gun safety latch
first! See manual 307-848 for how to install the tip.
10 308-248

STARTUP
10. Adjust the spray pattern
a. Increase the pressure just until spray from the
gun
is completely atomized. To avoid exces-
sive overspray and fogging, and to extend tip
and sprayer life, always use the lowest pres-
sure 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
latch and loosen the retaining nut. Position
the tip guard horizontally for a horizontal pat-
tern or vertically for a vertical pattern.
Hold the
tip guard in place while tightenlng the retaln-
ing nut. See Fig
8.
NOTE 3: Spray patterns will change as tips wear.
Change the spray tip if adjusting the pres-
sure will not improve the spray pattern.
Fig
9 1022
308-248 11

~ ~~
-
SHUTDOWN AND CARE
WARNING
follow the Pressure Relief Procedure Warning
To reduce the risk of serious bodily injury, always
on page
2 when instructed in this procedure to
1. Check the packing nutbetcup daily. Relieve
pressure
first. Keep the wet-cup 1/3 full of TSL at
all times
to help prevent fluid buildup on the pis-
ton rod and premature wear of packlngs.
2. lighten the packing nuffwetcup just enough to
stop leakage. Over-tightening causes binding
and excessive packing wear. Use a round punch
or brass rod and a light hammer to adjust the nut.
See Fig
10.
3. Clean the gun’s fluid filter often and whenever
the gun is stored. Relieve pressure first. Refer to
manual
307-614.
4. Periodically clean paint residue from the pres
sure transducer vent hole area. See Fig
11. Re-
place the transducer when leakage is excessive.
See page
27.
5. Lubricate the bearing housing after every 100
the bearing housing cavity with SAE 10 non-
hours of operation. Remove the front cover.
Fill
detergent oil. See Fig 11 ..
6. Flush the sprayer at the end of each work day
and fill
it with mineral spirits to help prevent pump
corrosion and freezing. See page
13.
CAUTION
To prevent pump corrosion, and to reduce the
chance.of fluid freezing in the pump in cold
the sprayer when
it is not in use. Freezing can
weather, never leave water or any type
of paint in
seriously damage the sprayer or result in a loss
of pressure or stalling.
7. For very short shutoff periods, leave the suction
hose in the paint, relieve pressure, and clean
the
spray tip.
8. Coil the hose when storing it, even for overnight,
to help protect the hose from kinking, abrasion,
coupling damage, etc.
WARNING
See the waming section, HOSE SAFEn, on
damaged hoses.
page
3, for information on the hazard of using
WITH
PRESSURE
RELIEVED
TURN
PACKING NUT
CLOCKWISE
TO TIGHTEN
c
Fig 10 u
PRESSURE
FILL BEARING HOUSING
TRANSDUCER CAVITY WITH
SAE NON-
VENT HOLE DETERGENT
OIL AFTER
EVERY 100 HOURS OF
OPERATION \
Fig 11
W
Ice7
12 308-248

..
~~ ~~~~
FLUSHING GUIDELINES
When to flush
1.
2.
3.
4.
5.
Before using a new sprayer: flush out the oil
which was left in to protect pump parts.
Before using water-base paint: flush with min-
clean water flush.
era1 spirits followed by soapy water, and then a
spirits only.
Before using oil-base paint: flush with mineral
such
as mineral spirits or water.
Changing colors: flush with a compatible solvent
flush with warm, soapy water, and then mineral
Changing from water-base
to oil-base paint:
spirits.
Changing from oil-base to water-base paint:
flush with mineral spirits, then warm, soapy water,
and then a clean water flush.
water and then mineral spirits. Leave the system
Storage after using water-base paint: flush with
the drain valve open.
filled with mineral spirits. Relieve pressure. Leave
Storage after using oil-base paint: flush with
mineral spirits. Relieve pressure. Leave the drain
valve open.
NEVER leave water or water-based fluids in the
the water out with mineral spirits. Frozen fluid in
sprayer
If there is a chance it could freeze. Push
the sprayer prevents
it from being started and
may cause serious damage.
6. Startup after storage. Before using water-base
paint, flush out the mineral spirits with soapy wa-
- paint, flush out the mineral spirits with the paint.
ter and then clean water. When using oil-base
How to flush
1. Follow Pressure Relief Procedure. See page 2.
2. Remove the.spray tip and clean It separately.
bowl, hand tight, without the screen. Clean the
Remove the filter screen and then reinstall the
screen separately. See Fig
12.
r .,
,/
Fig 12
3. Pour one-half gallon (2 liters) of compatible sol-
vent into
a grounded metal flushing pail. Put the
suction hose in the pail.
4.' Open the pressure drain valve. See Fig IO.
5. To save the paint still In the pump and hose,
follow Step
6, except put the drain hose in the
valve.
Put the drain hose in the flushing pail. Trig-
paint pail. When solvent appears, close the drain
ger the gun into the paint pall. When solvent ap-
pears, release the trigger. Continue with Step
6.
WARNING
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
METALTO METAL
MAINTAIN
FIRM
CONTACT BETWEEN THE
GUNANOAGROUNDEO
METAL CONTAINER
Flg 13
Me3
6. Lower the pressure setting. Turn on the sprayer.
Maintaining metal-to-metal contact, trigger the
gun Into the flushing pail. Slowly increase the
the gun
triggered until the solvent flows freely
sprayer pressure
just until
the pump starts. Keep
from the gun. Circulate the solvent to thoroughly
clean the sprayer. Release the gun trigger. En-
gage the gun safety latch.
7. Open the drain valve and circulate the solvent
through the drain hose to thoroughly clean
it.
Close the drain valve.
8. Remcive the suction hose from the pail. Disen-
gage the gun safety latch. Trigger the gun and
run the pump afew seconds to push air Into the
seconds to avoid damaging the pump packingsl
hose. Do not run the pump dry for more than
30
Relieve pressure.
9. Reinstall the clean filter screen.
IO. Remove and clean the inlet strainer. Wipe paint off
11. Refer to When To Flush, Step 1 again. Relieve
the suction hose and drain hose.
pressure.
12. Leave the drain valve open until you use the
sprayer again.
308-248 13

TROUBLESHOOTING GUIDE
WARNING
Toreducetheriskofseriousbodilyinjury,includingfluidinjec-
Pressure Relief Procedure
tion,injuryfromsplashingRuidorsolventintheeyesoronthe
skin,movingpartsorelectricshock,aEwaysfollowthisproce-
dure whenever you shut off the sprayer, when checking or
servicinganypartofthespraysystem,wheninstailing,clean-
ingorchangingspraytips,andwheneveryoustopspraying.
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 a grounded metal pail. Trigger the
5. Engage the gun safety latch.
gun
to relieve pressure.
6. Open the pressure drain valve, having a container
valve open until you are ready
to spray again.
ready
to catch the drainage. Leave the pressure drain
If
you suspect that the spray tip or hose is complete&
clogged, orthatpressure has notbeen fu/&re/ievedafferfo/-
/owing the steps above,
VERY SLOWLY loosen the the tip
guard retaining
nut or hose coupling to reliwe pressure
gradually, then loosen completely.
Check
evelything in the guide before disassembling the sprayer.
@gg&g BASIC PROBLEM SOLVING
YPE OF PROBLEM
:hid Pressure
Aechanical
Iiectrical
WHAT TO CHECK
rf check is OK, go to next check
1. Check pressure control k.nob setting. The pumF
won't develop much pressure
if it is at minimum
setting (fully counterclockwise).
2. Check for a clogged spray tip or fluid filter. See
page
9.
1. Check for frozen or hardenedpaint in pump
(20). Using a screwdriver, carefully try to rotate
fan at back
of motor bv hand. See page 18.
2. Check pump connecting rod pin (17). It must be
completely pushed into connecting rod
(15),
and retaining spring (la) must be firmly in con-
necting rod groove. See Fig
20, page 21.
3. Check for motor damage. Remove drive hous-
ing assembly (1 1). See page 26. Try to rotate
motor fan by hand.
1. Check electrical supply with volt meter. Meter
should read 105-125VAC.
2. Check extension~Gd for visible damaEUse a
to check.
volt meter or test lamD at extension cord outlet
3. Check sprayer power supply cord (50) for vis-
4. Check motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
~~ ~~
ible damage such as broken insulation or wires.
d. Broken leads.
e. Worn brushes.
NOTE: The brushes do not wear at same rate
on both sides of motor. Check both brushes.
WHAT TO DO
when check is not OK, refer to this column
1. Slowly increase pressure setting to see i
motor starts.
2. If tip is still clogged, relieve pressure: re-
fer to separate gun or tip instruction man
ual for tip cleaning. Clean or replace fib
element. See manual
308-249.
1. Thaw. Plug in sprayer and turn on. Slow!)
increase pressure setting
to see if motor
starts.
If it doesn't, see NOTE 1, below.
~~ ~ ~
2. Push pin into piace and secure with
spring retainer.
3. Replace motor (4) li fan won't turn.. See
page 24.
I. Reset building circuit breaker; replace
~~
building fuse. Try another outlet.
2. Replace extension cord.
3. Replace power supply cord. See page
25.
%. Refer to page 20.
a. lighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brust
leads with
slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 1/2" long.
area.Donottrytostartsprayeruntilithasthawedcompietelyordamagetomotorand/orstartboardmayoccur.Ifpainthardened(dried)
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
in sprayer, the pump packings and/or pressure transducer must be replaced.
See page 21 (pump) or 27 (pressure transducer),
14 308-248

BASIC PROBLEM SOLVING
YPE OF PROBLEM
lectrical (continued)
NHAT TO CHECK
f checkis OK, go to next check
i. Check motor armature commutator for bum
spots. aouaes and extreme rouahness. Removc
motor cover and brush inspectron plates
to
check. See page 20.
3. Checkmotorarmatureforshortsusing armaturf
tester (growler) or perform motor test.
See pagc
18.
~~ ~~~
7. Check leads from pressure control and motor tc
motor start board
(47) to be sure they are se-
curely fastened and properly mated.
I. Check motor start board (47) by substituting
with a good board.
See page 25.
tor armature is determined to be good. A bad
CAUTION: Do
not perform this check until mo.
motor armature can burn out a good board.
3. Check power supply cord (50). Disconnect
black and white oower cord terminals: connecl
volt meter to these leads. Plug in sprayer. Mete
should read 105-125 VAC. Unplug sprayer.
IO. Check ON/OFF switch (52). Disconnect the "L"
wire between motor stalt board (47) and switct
and connect volt meter between exposed term1
nal
on switch and power cord's white wire. Plug
in sprayer and turn ON. Meter should read
105-125 VAC. Turn
off and unplug sprayer.
11. Check motor thermal cutout switch. Connect
ohmmeter between motork red leads. Meter
should read 1 ohm maximum.
12. Remove pressure control
(64) and check micro
switch operation with ohmmeter:
(1) With pressure knob at lowest setting and
stem pushed into control, readings should
be: white
& black = 1 ohm max.
white
& red = open.
(2) With pressure knob at highest setting,read-
ings should be: white
& black = open:
white
& red = 1 ohm max.
13. Check pressure transducer (29) for hardened
paint or damaged or worn components.
See
page 27.
NHAT TO DO
When check is
not OK, refer to this column
i. Remove motor and have motor shop
resurface commutator
if Dossible. See
page 24.
1. Replace motor. See page 24.
I. Replace loose terminals: crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
1. Replace board. See page 25.
3. Replace power supply cord. See page
25.
IO. Replace ON/OFF switch. See page 25.
11. Allow motor to cool. Correct cause of
overheating.
If switch remains open after
motor cools, replace motor.
12. Replace pressure control. See page 27.
13. Replace transducer. See page 27. Thor-
ough system flushing will help extendiife
of transducer.
INTERMEDIATE PROBLEM SOLVING
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
When check is not OK refer to this column
WHAT TO
DO
I
Low output I 1. Check for worn spray tip. I 1. Follow Pressure Rellef Procedure
2. Be sure pump does not continue to stroke when
gun trigger
is released. Plug in and turn on
tarily, then release and engage safety latch. Re-
sprayer. Prime with paint. Trigger gun momen-
lieve pressure. turn
off and undua sDraver.
Warning then replace tip.
See your sepa-
rate gun or tip manual.
2. Service pump.
See pages 21.
306-248 I5

INTERMEDIATE PROBLEM SOLVING
YPE OF PROBLEM WHAT TO CHECK
If check
is OK, go to newt check
WHAT TO
DO
When check is not OK, refer to this column
ow Output (continued)
3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with
ings and/or piston valve may be worn.
Service the pump.
See page 21.
pump rod (107). rod
(107) fully extended. the piston pack
)rain Valve Leaks
ransducer Leaks
lo Output: Motor Runs
md Pump Strokes
lo Output: Motor Runs
iUt Pump Does Not Stroke
4. Check electrical supply with volt meter. Meter
should read 105-125VAC.
5. Check extension cord size and length; must be
at least 12 gauge wire and less than 150
R.
6. Check motor brushes. See Electrical - What To
Check, item
4, on page 14.
with a good board.
CAUTION
Do not perform this check until mo-
tor armature is determined to be good.
A bad
motor armature
can burn out a good board.
7. Check motor start board (47) by substituting
4. Reset building circuit breaker: replace
buildina
fuse. ReDair electrical outlet or
try anoiher outlei.
5. Replace with a correct, grounded exten-
sion cord.
6.
See page 20.
7. Replace board. See page 25.
8. Replace motor. See page 24.
8. Check motor armature for shorts by using an
~~
armature tester (arowler) or Derform motor test.
._
See page 18.
worn parts. Check for debris trapped
on seat. valve and replace with new gasket (42a)
1. Slight leakage from transducer is normal. 1. Periodically remove residue from its cylin.
1. Check paint supply.
2. Remove and clean, then reinstall.
2. Check for clogged intake strainer.
1. Refill and reprime pump.
3. Check for loose suction tube or fittings. See
3. Tighten: use thread sealant on npt
1. Check drain valve for correct torque and/or
9. Tighten to 185 in-lb (21 N.m). Clean
and sealant (42d). See page 28.
der port. See page 27.
page 28. threads of inlet tube
(38). Check for dam.
aged O-ring (27).
4. Check to see
if intake valve ball and piston ball
4. Remove intake valve and clean. Check
are seating properly. See page 21.
ed.
See page 21. Strain paint before us-
ball and seat for nicks: replace as need-
ing
to remove particles that could clog
pump.
5. Check for leaking around throat packing nut
See page 21. check piston valve seat for hardened
which may indicate worn ordamaged packings.
5. Replace packings. See page 21, Also
Tighten packing nuvwet-cup.
paint or nicks and replace
if necessary.
. -
6. Release gun trigger. Observe resting position of
6. If pump consistently comes to rest with
ings and/or piston valve may
be worn.
Service the pump.
See page 21.
pump rod (107). rod (107) fully extended, the piston pack.
I
1. Check displacement pump connecting rod pin
1. Replace pin if missing. Be sure retainer
(17). See Fig 20, page 21. SPrina (18)
is fullv in aroove all around
I &nnectin$ rod.
.-
7. Check connecting rod assembly (15) for dam- 7. Replace connecting rod assembly. See
age.
See page 26. page 26.
8. Be sure crank in drive housing rotates: plug in
26.
and unplug sprayer. See page 26. age and replace
if necessary. See page
sprayer and turn
on briefly to check. Turn off
8. Check drive housing assembly for dam-
16 308-248

INTERMEDIATE PROBLEM SOLVING
YPE OF PROBLEM
;pray Pattern Variations
dotor
Is Hot and Runs
itermittently
luilding Circuit Breakel
)pens
As Soon As Sprayel
;witch
Is Turned On.
:ircuit breaker opens anel
prayeroperatesfor5tolC
rinutes.
3uilding circuit breaker
j plugged into outlet and
rpens
as soon as sprayer
;prayeris NOTturnedon.
WHAT TO CHECK
M check is OK, go to newt check
1. Spray tip worn beyond sprayer pressure capa-
bility.
2. Check transducer (29) for wear or damage.
3. Check pressure control (64) for smooth opera-
tion.
4. Check Low Output section, page 16.
1. Determine if sprayer was operated~achigh pres-
sure with small tips, which causes excessive
heat build
UD.
~~ ~~
2. Be sure ambient temperature where sprayer is
located is
no more than90'F and sprayer is no1
located in direct sun.
3. Check motor.
1. Check all electrical wiring for damaged insula-
tion, and all terminals for
loose fit or damage.
Also check wires between Dressure control and
motor.
See page 24.
2. Check for missing motor brush inspection plate
gasket
(see page 20), bent terminal forks or
cause a short.
other metal
to metal contact points which could
3. Check motor armature for shorts. Use an arma.
ture tester (growler) or perform motor test.
See
page 18. Inspect windings for burns.
4. Check motor start board (47) by substituting
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.
1. Check 'Basic Problems - Electrical' on page
14.
1. Check electrical supply with volt meter. Meter
should read 105-125 VAC.
2. Check tightness of pump packing nut. Over-
tightening tightens packings
on rod, restricts
pump
action, damages packings.
3. Check for damaged motor.
4. Check ONlOFF switch (52). Be sure sprayer is
unplugged1 Disconnect wires from switch.
Check switch with ohmmeter. The reading
zero with switch ON.
should be infinity with ON/OFF switch OFF, and
CAUTION A short in motor circuit can damage
switch and or motor start board (47).
WHAT TO DO
When check is not OK, refer to this column
1. Replace spray tip.
longer life.
NOTE A smaller size tip will provide
2. Replace transducer. See page 27.
3. Replace pressure control. See page 27.
1. Decrease pressure setting or increase til:
size.
2. Move sprayer to shaded, cooler area if
possible.
3. Replace motor. See page 24.
1. Repair or replace any damaged wiring 01
terminals. Securely reconnect all wires.
2. Correct faulty conditions.
3. Replace motor. See page 24.
1. Replace board. See page 25.
I. If voltage is too high, do not operate
sprayer
until corrected.
?. Loosen packing nut. Check for leaking
around throat. Replace pump packings,
A
necessary. See page 21.
3. Replace motor. See page 24.
1. Replace ON/OFF switch. See page 25.

MOTOR TEST
WARNING
Pressure Relief Procedure Warning on page 14
before doing this procedure. Unplug the sprayer1
For checking armature, motor winding and brush
electrical continuity.
Setup
Remove the drive housing. See page 26. This Is to
ensure that any resistance you notice in the armature
test is due to the motor and not to worn gears in the
drive housing.
Remove the motor brush inspection covers
(A). See
Remove the junction box screws
(56). Lower the junc-
tion box. Disconnect the
two leads (C) from the motor
to the board
(47). See Fig 15.
Armature Short Circuit Test
Remove the handle (24) and the fan cover (8). See
Fig
14.
Spin the motor fan by hand. If there are no shorts, the
ing to a complete stop.
If the motor does not spin
motor will mast
two or three revolutions before com-
freely, the armature
is shorted and the motor must be
replaced. See page
24.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Connect the two black motor leads together with a
test lead. Turn the motor fan by hand at about
two
revolutions per second.
When turning the fan on a DC motor, normally you
sense an even, pulsing resistance.
If there is irregular
turning resistance, or no turning resistance, check
and repair the following
as needed: broken brush
springs, brush leads, motor leads: loose brush termi-
nal screws, motor lead terminals; worn brushes. See
page
20.
the motor. See page
24.
If there is still uneven
or no turning resistance, replace
14.
M
Fig 14
V
1022
18 308-248

GENERAL REPAIR INFORMATION
To reduce the risk of serious bodily injury, including
Pressure Relief Procedure
4. Disengage the gun safety latch. Hold a metal
part of the gun firmly to the side of a grounded
fluid injection, splashing fluid or solvent
in the eyes metal pail, and trigger the gun to relieve pres-
or on the skin, or injury from moving parts or elec- sure.
tric shock, always follow this procedure whenever
5. Engage the gun safety latch.
you shut
off the sprayer, check or service any part
of the spray system, install, clean or change spray
tips, and whenever you stop spraying.
6. Open the pressure drain valve, having a con-
tainer ready to catch the drainage. Leave the
valve open
until you are ready to spray again.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
If you suspect that the spray tip or hose is com-
plete/y clogged, or that pressure has not been ful/y
relieved after following 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.
Tool List
These are the tools required to service all parts of the
sprayer.
3/16" Allen@ wrench: gear housing, legs, handle
3/8" Allen@ wrench: pump manifold
#1 Phillips@ screwdriver: junction box, pressure
3/8" socket wrench: motor mount
control, front cover
5/8" socket wrench: drain valve, outlet fittings,
13/16" socket wrench: drain valve
1-1/4" socket wrench: pump inlet valve
1/2" open end wrench: pump rod
11/16" open end wrench: piston jam nut
15/16" open end wrench: flats of inlet tube
144" open end wrench pump jam nut
5/64" drive pin: drain valve
pin
3" needle nose pliers: wiring, onloff switch
Hammer
& punch: packing nut
Torque wrenches: various fasteners
onloff switch boot, piston
1. When disconnecting wires in the junction box
assembly, use needle nose pliers to separate
mating connectors.
2. When reconnecting the wires, be sure the flat
blade of the insulated male connector is centered
in the wrap-around blade of the female
connector.
CAUTION
To reduce the risk of a pressure control malfunc-
tion, be sure to properly mate connectors, and
never pull on a wire to disconnect it. Pulling on a
wire could loosen the connector from the wire.
J
3. Route wires carefully through the drive housing
and motor. Avoid pinching the wires between the
junction box and the motor.
. CAUTION
performance or damage to the pressure control.
Improper wire routing can result in poor sprayer
-
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
sure the problem is corrected.
5. Test your repair before regular operation to be
6. If the sprayer does not operate properly, verify
that everything was done correctly. Also refer to
theTroubleshooting Guide, pages 14-17, to help
identify other possible problems and solutions.
WARNING
To reduce the risk of serious bodily injury, includ-
ing electric shock, DO NOT touch any moving
while inspecting the repair.
parts or electrical parts with your fingers
or a tool
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.
1- WARNING
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
1 explosion.

- ~~
MOTOR BRUSH REPLACEMENT
NOTE 1: Replacethe brushes when they have worn to
lessthan1/2in(13mm).RefertoFig17.
Note thatthe brushes weardifferentlyon
each side ofthe motor,
so check them both.
Brush Repair
Kit 235-727 is available.
r"wARN'NG 1
To reduce the risk of serious lnjuty, follow the
Pressure Relief Procedure Warning on page 19
before doing this procedure. Unplug the sprayeri
1. Remove both inspection covers (A) grid their gas-
kets. See Fig
16.
2.
3.
4.
the brush holder. Pull out the spring clip. See Fig
Push in the spring clip and release its hooks from
17.
Loosen the brush lead terminal screw. Pull the
brush lead away, but leave the motor lead termi-
nal in place. Remove and discard the brush. See
Fig 17.
Inspect the cornmutator for excessive pitting,
tator
is normal. Have the cornmutator resurfaced
burning or gouging.
A black color on the'commu-
by a qualified motor repair shop
if the brushes
seem to wear too fast or arc excessively.
5. Repeat for the other side.
CAUTION
When installing the brushes, follow all steps
carefully. Improper installation damages parts
beyond use.
6.
7.
8.
9.
to the fan-end ofthe motor. Slide the terminal under
Place a new brush in the holder
so the lead is closer
the terminal screw washer. Ensure the motor lead is
still connected at the screw. See Fig 17.
Holding the spring/cllp at'a slight angle, slide the
the end
of the holder. See Fig 18. Pull on the
spring/clip Into the brush holder
and hook it over
spring/clip to be
sure it stays in place. Be sure the
brush lead is tucked under the spring/cllp tab.
Repeat for the other side.
Test the brushes.
a. Wlth the sprayer
OFF, turn the pressure control
sure. Plug in the sprayer.
knob
fully counterclockwise to minimum pres-
b. Turn the sprayer ON. Slowly increase the pres-
sure until the motor is at
full speed.
c. Inspectthe brush and commutator contact area
for excessive arcing.
Arcs should not "trail" or
circle around the commutator surface.
WARNING
IcAw'oNl
Do not run the sprayer dry for more than 30 sec-
onds while checking the brushes to avoid dam-
aging the displacement pump packings.
IO. Install the brush inspection covers and gaskets.
HOOK, TERMINAL SCREW
BRUSH LEAD' /
Fig 17 Fig 18
20 308-248