Graco EM 5000 Operation manual

307–913
Rev. C
Supersedes Rev. B
and PCN C
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ELECTRIC–POWERED,
220/240 VAC, 50 Hz, 10 Amp
EM 5000
AIRLESS P AINT SPRA YER
21.0 MPa, 210 bar MAXIMUM WORKING PRESSURE
Model 222–246
Complete sprayer , with hose or gun, RAC IV 
DriplessT
ip Guard, and 621 size SwitchT ip
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
COPYRIGHT
1988, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001




Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Methods 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 14. . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Pressure
Control Replacement 16. . . . . . . . . . . . . .
Pressure Control Adjustment 17. . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod 19. . . . . . . . . .
Drive Housing 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion, Clutch, Clamp, Field & Motor 22. . . . . . . . .
Pinion Housing 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness 27. . . . . . . . . . . . . . . . . . . . .
Circuit Board 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Capacitor and Inductor Coil 28. . . . . . . . . . .
Reassembly 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing the Pump 32. . . . . . . . . . .
Displacement Pump 32. . . . . . . . . . . . . . . . . . . . . . .
Parts Lists & Drawings
Displacement Pump 35. . . . . . . . . . . . . . . . . . . . . . .
Sprayer 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 39. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic 40. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Change Summary
This manual was revised to include the changes from PCN C.
Part Identification
0479A
ABC
D
E
F
G
H
J
K
L
M
Key
APressure Adjusting Knob
BPressure Control ON/OFF Switch
CCapacitors
DMotor
EElectrical Junction Box
FPressure Drain Valve
GContractor Gun with RAC IV Dripless
T
ip Guard, and 621 Size SwitchT ip
H
0.9 m Hose
J 15.2 m Main Hose
K Displacement Pump
L Fluid Filter
MDrive Assembly
Fig. 1

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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
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
T echnical Data on page 40 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 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.
W ear hearing protection when operating this equipment.
 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.

307-913
4
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 may look like just a cut, but it is a serious injury . Get immediate medi -
cal attention.

Do not point the gun at anyone or at any part of the body .
 Do not put your hand or fingers over the spray tip.
 Do not stop or deflect leaks with your hand, body , glove or rag.
 Do not “blow back” fluid; this is not an air spray system.
 Always have the tip guard and the trigger guard on the gun when spraying.
 Check the gun dif fuser 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 6 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten 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 .

307-913 5
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.
 Disconnect all electrical 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 of f any light switch in the spray area while operating or if fumes are present.
 Do not operate a gasoline engine in the spray area.
 Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
 Use only electrically conductive hoses.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the sprayer .

Before servicing the equipment, follow the Pressure Relief Procedure on page 6 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.A void 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 T reatment”.
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.
A void 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 .

307-913
6
Setup
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below . Also read
the section FIRE OR EXPLOSION HAZ -
ARD
on page 5.
Grounding
1. Sprayer : plug the power supply cord, or extension
cord into a properly grounded outlet. Do not use an
adapter . All extension cords must have three wires
and be rated for 15 amps.
2. Fluid hoses: use only grounded hoses with a
maximum of 150 m combined hose length to
ensure grounding continuity .
3.
Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer .
4.
Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to
local code. Use only metal pails, which are con -
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter -
rupts the grounding continuity .
7.
T o maintain grounding continuity when flushing or
relieving pressure , always hold a metal part of the
gun firmly to the side of a grounded metal pail,
then trigger the gun.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in -
jected through the skin and cause seri -
ous injury . T o reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol -
low 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 tips.
1. Engage the gun safety latch.
2. T urn the ON/OFF switch to OFF .
3. Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the valve
open until you are ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above , wrap a rag around the
tip guard retaining nut or hose end coupling and very
slowly loosen the part to relieve pressure gradually .
Now clear the tip or hose.

 
Setup
1. Connect Hose and Gun (Refer to Fig. 2)
a. Remove the plastic cap plug from the filter outlet
nipple (E). Screw the 15.2 m main fluid hose (H)
onto the nipple.
b. Connect the 0.9 m hose (J) between the fluid
hose
and the gun inlet.
c. DO NOT use thread sealant on the hose and gun
connections. DO NOT install the spray tip yet!
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 21.0 MPa, 210 bar) Maximum Working
Pressure. These precautions reduce the risk of
serious injury caused by static sparking, fluid
injection, or over-pressurization and rupture of the
hose and gun.
2. Two Gun Hookup (Refer to Fig. 2) Remove the cap
from the secondary hose outlet (C). Attach an acces -
sory
hose and gun to the 1/4 npsm(m) nipple.
CAUTION
T o avoid damaging the pressure control, which may
result in poor equipment performance and compo -
nent damage, follow these precautions.
1. Always use nylon spray hose at least 15.2 m
long.
2.
Never use wire braid hose; it is too rigid to act as
a pulsation dampener .
3.
Never install any shutof f device between the filter
and the main hose. See Fig. 2.
4. Always use the main filter outlet for one gun
operation. Never plug this outlet.
3. Fill Packing Nut/Wet–Cup (See Fig. 2) Fill the
packing nut/wet–cup (D) 1/3 full with Graco Throat
Seal
Liquid (TSL), supplied.
4. Check the Electrical Service
a. Be sure the electrical service is 220/240 Volts,
50 HzAC, 10 Amp (minimum) slow blow. The
outlet
you use must be properly grounded.
b. Use a grounded extension cord which has 3
wires, each with a minimum 1.5 mm diameter,
and having a maximum length of 30 m. Longer
lengths or smaller diameter wires may affect
sprayer
performance.
5. Be sure your system is properly grounded be-
fore
operating it. Read and follow the warning sec -
tion,
FIRE AND EXPLOSION HAZARD , on page 5.
KEY
AON/OFF Switch
B
Pressure Adjusting Knob
C Secondary Hose Outlet;
1/4 npsm(m)
DW et–Cup;
Keep 1/3 full with TSL
E Outlet Nipple;
1/4 npsm(m)
FPressure Drain Valve
GSpray Gun
H
15.2 m Main Hose
J 0.9 m Hose
0481A
A
B
C
D
E
F
G
HJ
Fig. 2
6. Plug in the Sprayer .
a. Be
s ur e t h e O N/OF F s witc h ( A ) i s O FF . S e e F ig . 2.
b. Plug the power supply cord into a grounded elec -
trical outlet that is at least 6 m away from the
spray
area to reduce the chance of a spark ignit -
ing
the spray vapors.
7. Flush the pump to remove the lightweight oil which
was left in the pump to protect it from rust.
a. Before using water–base paint, flush with miner -
al
spirits, followed by soapy water , and then flush
with clean water .
b. Before using oil–base paint, flush with mineral
spirits,
only .
c.
Flush. See page 1 1.
8. Prepare the paint according to the manufacturer’s
recommendations.
a. Remove any skin that may have formed on top
of
the paint.
b. Stir the paint to mix its pigments.
c. Strain the paint through a fine nylon mesh bag
(available
at most paint dealers) to remove par -
ticles that could clog the filter or spray tip. This
is
probably the most important step toward trou -
ble–free
spraying.

307-913
8
Operation
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
1. Prime the Sprayer with Paint.
a. Close the pressure drain valve (C). See Fig. 3.
b. Don’t install the spray tip yet!
c. Put the suction tube (D) into the paint container .
d. Turn
the pressure adjusting knob (B) all the way
counterclockwise to lower the pressure setting.
e. Disengage the gun safety latch (E).
f. Hold a metal part of the gun firmly against, and
aimed into, a grounded metal waste container.
See
Fig. 4. Squeeze the trigger and hold it open.
T urn the ON/OFF switch (A) to ON. See Fig 8–1.
Slowly increase the pressure setting until the
sprayer
starts. Keep the gun triggered until all air
is forced out of the system and the paint flows
freely
from the gun. Release the trigger and en -
gage
the gun safety latch.
NOTE: If the pump is hard to prime, open the pressure
drain valve (C). When fluid comes from the
valve, close it. Disengage the gun safety and
proceed
as in Step 1f, above.
g. Check all fluid connections for leaks. If any leaks
are found, relieve the pressure before tighten -
ing
connections.
2. Install the Spray T ip and T ip Guard
a. Be sure the gun safety latch is engaged.
b. Install the spray tip. If you are using the RAC IV
tip guard, refer to manual 307–848, supplied with
the gun, for installation instructions.
KEY
AON/OFF Switch
B
Pressure Adjusting Knob
CPressure Drain Valve
D
Suction T ube
E
Gun Safety Latch
A
B
C
D
E
0482A
Fig. 3
0483
MAINTAIN FIRM
MET AL T O MET AL
CONT
ACT BETWEEN THE
GUN AND A GROUNDED
MET
AL CONT AINER
Fig. 4

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Operation
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
3. Adjust the Spray Pattern
a. Turn the pressure adjusting knob (B) just until
spray
from the gun is completely atomized. See
Fig. 3. T o avoid excessive over–spray and fogg -
ing, and to decrease tip wear and extend the life
of the sprayer, always use the lowest possible
pressure
needed to get the desired results.
b. If more paint coverage is needed, use a larger tip
rather than increasing the pressure.
c. Test the spray pattern. T o adjust the direction of
the spray pattern, engage the gun safety latch
(E). See Fig. 3. Loosen the tip guard retaining
nut
(A). Position the tip guard (B) horizontally for
a horizontal pattern or vertically for a vertical pat -
tern. T
ighten the retaining nut. See Fig. 5.
4. To Clean a Clogged Tip
WARNING
T o reduce the risk of serious injury from injection,
use extreme caution when cleaning or changing
spray tips. If the spray tip clogs while spraying,
engage the gun safety latch immediately , and then
follow the procedure in Steps a. to e., below .
Never wipe of f buildup around the spray tip until
pressure is fully relieved and the gun safety latch is
engaged.
a. Clean t h e f ron t o f t h e t i p f requently d uring d aily
operation.
First , reliev e t he p ressure . T hen , u se
a
s olvent–soake d b rus h t o c lea n t h e t ip.
b. If
the spray tip does clog, release the gun trig -
ger,
and engage the gun safety latch.
c. If using the RAC IV Spray Tip Kit, rotate the
RAC
IV handle 180. S ee Fig. 5. Disengag e t he
gu
n s afet y l atch.Trigger th e g u n i nto a grounded
waste container. Engage the gun safety latch
again.
R etur n t h e h andl e t o t h e s prayin g p osition.
d. If you are using a spray tip kit which is not
self–cleaning, VERY SLOWLY loosen the tip
guard retaining nut or hose coupling to relieve
pressure gradually, and then loosen the fitting
completely. Clean the tip or hose, then reas-
semble.
e. Disengage the gun safety latch, and resume
spraying.
f. If
the tip is still clogged, engage the gun safety
latch, shutoff and unplug the sprayer, and open
the
pressure drain valve to relieve pressure. Re -
move
the spray tip and clean it.
g. Instructions for cleaning the RAC IV spray tip
are given in manual 307–848, supplied.

C
A
B
KEY
ATip Guard Retaining Nut
BRAC IV T ip Guard
C Rotate Handle 180  and
trigger gun to clear tip clog
Fig. 5
5. If the sprayer shuts itself off when you are spray -
ing at high pressure, Relieve the pressure. A
switch
in the pressure control box shuts of f the spray -
er
if it is operated at a pressure too high for the oper -
ating conditions. Before resetting the switch, deter-
mine
and correct the cause of over–pressurization.
6. Be sure the spray tip you use is properly sized for the
fluid being sprayed. Always use the lowest pressure
needed to obtain a good spray pattern. Higher pres -
sure does not improve the spray pattern, but does
cause premature tip and sprayer wear .
7. To reset the switch, be sure the fluid pressure is re-
lieved
and the power supply cord is unplugged. Re -
move
the pressure control cover . Press the reset but -
ton.
Reinstall the pressure control cover . See Fig 6.

A
KEY
AReset Button
Fig. 6



Maintenance
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
1. Check the packing nut/wet–cup (C) daily . Relieve
the pressure Keep packing nut/wet–cup1/3 full of
TSL
at all times to help prevent dried fluid from col -
lecting on the piston rod, and to reduce premature
wear of the packings. The packing nut/wet–cup
should
be tight enough to stop leakage, but no tight -
er. Over–tightening the packing nut/wet–cup may
cause binding and excessive packing wear. Use a
metal punch and a light hammer to adjust the nut.
See
Fig. 7.
2. Clean the fluid filter (B) often and whenever the
sprayer is stored. Relieve the pressure. Refer to
manual 307–273, supplied, for the cleaning proce-
dure
of the filter .
3. Flush
the sprayer at the end of each work day and
fill
it with mineral spirits to help prevent corrosion and
freezing of the pump. See FLUSHING on page 1 1.
CAUTION
T o prevent pump corrosion, and to prevent fluid from
freezing in the pump and pressure control, never
leave water or any paint in the sprayer . If water or
paint freezes in the pressure control, it may prevent
the sprayer from being started, cause loss of pres -
sure or stalling, and cause serious damage to the
pressure control. Always use mineral spirits for the
final flush and relieve the pressure . Leave the
mineral spirits in the sprayer .
4. For very short shutoff periods, leave the suction
tube in the paint. Relieve the pressure. Clean the
spray tip.
5. Coil the hose and hang it on the hose rack (A) when
storing it, even for overnight. Proper storage of the
hose helps protect it from kinks, abrasion, coupling
damage.
WARNING
Refer to the warning section INJECTION HAZARD
on page 4 for information on the hazard of using
damaged hoses.
TIGHTEN


A
B
C
KEY
AHose Rack
B
Fluid Filter
CPacking Nut/Wet-Cup
Fig. 7

 
Flushing
When To Flush
1. New Sprayer . Y our new EM5000 sprayer was facto -
ry
tested in lightweight oil,which was left in to protect
the pump parts.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean
water flush.
Before using oil–base paint, flush with mineral spir -
its,
only .
2. Changing Colors. Flush with a compatible solvent
such
as mineral spirits or water .
3. Changing from water–base to oil–base paint.
Flush
with warm, soapy water , then mineral spirits.
4. Changing from oil–base to water–base
paint.Flush with mineral spirits, followed by warm,
soapy water , and then a clean water flush.
5. Storage.
Water base paint: flush with water , then mineral spir -
its and leave the pump, hose and gun filled with min -
eral spirit. Shut off the sprayer, and open the pres-
sure drain valve to relieve pressure. Leave the drain
valve open.
Oil base paint: flush with mineral spirits and leave the
pump, hose and gun filled with mineral spirits. Shut
off
the sprayer , and open the pressure drain valve to
relieve pressure. Leave the drain valve open.
CAUTION
Never leave water in the sprayer if there is the
slightest chance it could freeze. Flush with mineral
spirits to push the water out of the sprayer . W ater left
in the pressure control tube may freeze, which can
prevent the sprayer from being started, and may
cause serious damage to the pressure control.
6. Startup after storage.
Before using water–base paint , flush out the mineral
spirits with soapy water, and then with clean water.
When using oil–based paint, flush out the mineral
spirits
with the paint to be sprayed.
Continued on page 12



Flushing
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
How To Flush
1. Relieve the pressure .
2. Remove the filter bowl (A), screen (B) and support
(C).
Clean the screen and support separately . Install
the bowl, without the screen and support, to flush it.
See Fig. 8. See instruction manual 307–273,
supplied,
for detailed instructions.
0486
A
B
C
D
KEY
AFilter Bowl
B Filter Screen
C Filter Support
DPressure Drain Valve
Fig. 8
3. Close the pressure drain valve (D).
4. Pour 2 liters of compatible solvent into a grounded
metal
pail. Put the suction tube in the pail.
5. Remove the spray tip from the gun.
WARNING
T o reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
the gun, and hold a metal part of the gun firmly to
the side of, and aimed into, a grounded metal pail.
6. Disengage the gun safety latch. Point the spray gun
into a metal waste container . With a metal part of the
gun firmly touching the metal container , squeeze the
gun trigger . See Fig. 9. This procedure helps reduce
the risk of static sparking and splashing. Start the
sprayer,
trigger the gun, and slowly turn the pressure
adjusting knob clockwise, just until the pump starts.
Keep the gun triggered until clean solvent comes
from
the nozzle. Release the trigger . Engage the gun
safety latch.
7. Check all fluid connections for leaks. If any connec -
tions leak, first relieve the pressure. Tighten the
connections. Start the sprayer . Recheck the connec -
tions
for leaks.
8. Remove the suction tube from the pail. Disengage
the
gun safety latch. T rigger the gun to force solvent
from the hose. Do not let the pump run dry for more
than 30 seconds, to avoid damaging the pump pack -
ings!
Relieve the pressure .
9. Leave the pressure drain valve open until you are
ready to use the sprayer again. Unscrew the filter
bowl and reinstall the clean screen. Reinstall the
bowl,
hand tight only .
10. If
you flushed with mineral spirits and are going to use
a water–base paint, flush with soapy water followed
by a clean water flush. Relieve the pressure .
0483
MAINTAIN FIRM
METAL-TO-METAL
CONT
ACT BETWEEN THE
GUN AND A GROUNDED
MET
AL CONT AINER
Fig. 9

 
Application Methods
Always hold the gun perpendicular to the surface and
keep
the gun at an even to 300–356 mm from the surface
you are spraying. See Fig. 10.
Begin moving the gun in a horizontal direction at a steady
rate. Start the spray stroke of f the target surface and pull
the trigger as the gun is moving. Then, while the gun is
still
moving, and as you approach the other edge, release
the trigger. This method avoids excess paint buildup at
the
end of each stroke.
0277
Fig. 10
The
correct speed for moving the gun will allow a full, wet
coating to be applied without runs or sags. Lapping each
stroke 50% over the previous stroke produces uniform
paint thickness. And spraying in a uniform pattern alter-
nately
from right to left, then left to right, provides a pro -
fessional
finish. See Fig. 1 1.
0487
Fig. 11
The best way to control the rate of coverage is with the
gun tip size. A small tip orifice applies less paint and a
narrower pattern. A larger tip orifice applies more paint
and
a wider pattern.
Do not try to increase coverage by increasing the fluid
pressure!
Using the lowest pressure necessary to get the
desired results will help prolong the life of your sprayer
and
minimize paint lost by over–spray .
For interior corners, such as on a bookcase or inside
a
cabinet, aim the gun toward the center of the corner to
spray. By dividing the spray pattern this way, the edges
on
both sides are sprayed evenly . See Fig. 12.
048
8
Fig. 12
If there is a wind, angle the spray pattern into the wind
to minimize drifting. Paint from the ground to the roof.
Shrubs. When next to the house, tie back shrubs from
the
surface to be painted with rope and stakes. Then cov -
er them with a canvas drop cloth as the painter ap-
proaches the area. Remove the canvas drop cloth as
soon
as the area is painted, to prevent possible damage
to the shrubs.
Concrete walks. If the walkways will be walked on, cov -
er
them with a canvas drop cloth to avoid slipping. Other -
wise
a plastic drop cloth is all that is needed.
Electrical outlets and lamps. Protect electrical outlets
with masking tape. Cover lamps with plastic bags se-
cured with masking tape.
Nearby objects. Move objects such as automobiles, pic -
nic
tables, lawn furniture, etc. upwind of the surface to be
sprayed. In the case of a nearby home, make a protective
barrier by hanging plastic between two long poles. 4

307-913
14
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Check everything in the chart before disassembling the sprayer .
PROBLEM CAUSE SOLUTION
Motor won’t run, or the
motor stops while spraying
Power cord or extension cord unplugged,
or damaged, or building circuit breaker or
fuse has tripped
Check, reset or replace.
Motor overload switch opened Unplug power supply cord, relieve pressure, al-
low motor to cool. See NOTE A, page 15.
Over–pressure switch opened Reset. Correct cause of over–pressure. See
page
9, Step 5., and NOTE C, page 15.
Pressure setting too low Increase.
Pressure control frozen or damaged by
over–pressurization. Try to thaw, or replace pressure control. See NOTE
B and C, page 15.
Spray tip or filter plugged Remove and clean.
W rong type extension cord Use maximum 30 m, 3 wires, 1.5 mm gauge mini -
mum,
grounded extension cord.
Motor labors when starting, and
trips
building circuit breaker or fuse
Circuit board has failed Replace the circuit board inside
electrical junction box. See page 27.
Motor capacitor has failed Replace the capacitor . See page 28.
Motor runs, but displacement
pump
doesn’t operate
Pressure setting too low Increase pressure.
Displacement pump outlet filter dirty Clean filter .
T ip or tip filter clogged Clean tip or tip filter .
Paint dried on the displacement rod Service pump. See page 32.
Connecting rod worn or damaged Replace. See page 19.
Drive housing worn or damaged Replace. See page 21.
Clutch worn or damaged Service. See page 25.
Pinion assembly worn or damaged Service. See page 22.
Motor runs, but there is little or no
paint
output and pump does stroke
Sprayer is not primed. Prime sprayer . See page 8.
Spray tip too big or worn Change the spray tip.
Piston ball check not seating Service. See page 32.
Piston packings worn or damaged Replace. See page 32.
Intake valve ball check not seating Service. See page 32.
Displacement pump worn or damaged Replace. See page 32.
Clutch worn or damaged Service. See page 25.
Drive assembly damaged Replace. See page 21.

307-913 15
PROBLEM CAUSE SOLUTION
Motor runs, but there is little or no
paint output and
pump does not
stroke
Filter element installed upside down Correct. See page 12 or manual 307–273.
Pressure control frozen or damaged by
over–pressurization. Try to thaw, or replace pressure control. See NOTE
B and C, below
. Pump is frozen Thaw . See NOTE B, below .
Paint leaks into wet–cup Loose wet–cup T ighten just enough to stop leakage.
Throat packings worn or damaged Replace packings. See page 32.
Displacement rod worn or damaged Replace rod. See page 32.
Excessive surging from spray gun Spray tip or fluid filter is plugged Disassemble and clean.
Spray tip too big or worn Change the spray tip.
Paint too viscous Thin.
Intake valve ball stuck Remove and clean intake valve.
W rong type hose Use minimum 15.2 m, static–free nylon hose
(wire braid hose is unacceptable).
Not enough paint pressure Pressure setting too low Increase.
Pressure control frozen or damaged by
over–pressurization. Try to thaw, or replace pressure control. See NOTE
B and C, below .
Displacement pump worn or damaged Replace. See page 32.
T ails or fingers in spray pattern Pressure setting too low Increase pressure.
Fluid outlet filter is dirty or clogged Clean. See page 12 or manual 307–273.
Spray tip too big or worn Change the spray tip.
Fluid supply is low or empty Refill and prime the pump. See OPERATION,
page
8. Check fluid supply often to prevent run -
ning
the pump dry .
Paint too viscous Thin.
W rong type hose Use minimum 15.2 m, static–free nylon hose
(wire braid hose is unacceptable).
Paint runs or sags Spray tip too big or worn Change the spray tip.
Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake and
tighten. Them prime the pump.
See OPERATION, page 8.
T ip partially clogged Clear.
Fluid supply is low or empty Refill and prime the pump. See OPERATION,
page
8. Check fluid supply often to prevent run -
ning
the pump dry .
Static sparking from the gun Spray or work being sprayed is not prop -
erly
grounded
Correct problem before continuing. Follow the
warning section, FIRE OR EXPLOSION HAZ-
ARD
on page 5.
A. The motor has an over–temperature switch which
automatically
resets upon cooling. If it opens, and the
motor shuts itself off, unplug the power supply cord
and
let the sprayer cool for 30 to 60 minutes. Always
use the lowest pressure setting needed when
spraying.
B. Freezing results from failure to replace the water–
base
paint or flushing water with mineral spirits, and
usually causes permanent damage to the pressure
control.
C. Over–pressurization
results from (1) using less than
15.2 m of nylon spray hose, (2) from using a wire
braid
spray hose, (3) from adding a shutof f device be -
tween
the pump outlet and the spray gun, (4) from at -
taching
a spray hose to the pressure drain valve, or
(5) from using a clogged or incorrectly assembled fil -
ter.

307-913
16
Pressure Control Replacement
WARNING
To reduce the risk of serious injury , including fluid
injection or splashing in the eyes or on the skin, or
injury from moving parts, always follow the Pres-
sure Relief Procedure W arning on page 6
before checking, adjusting, cleaning, or shutting of
the sprayer . Unplug the power supply cord!
1. Disconnect both hoses (59) at the pressure control
(63). Hold the hex of the nipple (304) firmly with a
wrench
to prevent turning the elbow (303). T ake note
of the original location of each hose to be sure you
reassemble them correctly at the end of this proce-
dure. See Fig 13.
CAUTION
Do not allow the elbow (303) to turn when removing
or connecting the hoses. T urning the elbows can
damage the sensitive bourdon tube in the pressure
control box.
2. Remove the pressure control cover (76). Disconnect
the + and – leads from the rectifier (310). These
leads
go to the clutch field. Disconnect the five motor
leads. These leads go through the conduit to the mo -
tor.
See Fig. 15.
3. Remove the three nuts (61) and lockwashers (9)
from
the capscrews (62). See Fig 14.
4. Unscrew the nut on the conduit elbow (308). Careful -
ly
guide the wires through the elbow as you pull the
conduit (94) away from the pressure control.
5. Reassemble. Perform the PRESSURE CONTROL
CALIBRATION PROCEDURE on page 17 before
regular
operation of the sprayer .
59
63
303 320
302
304
76
0489
90
Fig. 13
VIEW FROM UNDER ENGINE MOUNTING
62, 9, 61
308
63 1
87
90
94
0490
Fig. 14
– LEAD
+ LEAD
310
323
MOT OR LEADS
0485
90
Fig. 15

 
Pressure Control Adjustment
WARNING
Use extreme caution when performing this calibra -
tion procedure to reduce the risk of a fluid injection in -
jury or other serious bodily injury , which can result from
component rupture, electric shock, fire, explosion or
moving
parts.
This procedure sets the sprayer to 18.0–20.7 MPa,
182–207
bar Maximum W orking Pressure.
Perform this procedure whenever the pressure control
assembly is removed and reinstalled, or replaced, to be
sure the sprayer is properly calibrated.
Improper calibration can cause the sprayer to over–
pressurize
and result in component rupture, fire or ex -
plosion.
It may also prevent the sprayer from obtaining
the maximum working pressure, resulting in poor
sprayer
performance.
NEVER attempt to increase the fluid outlet pressure by
performing these calibrations in any other way. Never
Exceed
20.7 MPa, (207 bar) Maximum W orking Pres -
sure. Normal operation of the sprayer at higher pres-
sures could result in component rupture, fire or explo-
sion.
ALWAYS
use a new 50 foot (15.2 m) spray hose, rated
for at least 20.7 MPa, (207 bar) Maximum Working
Pressure,
when performing this procedure. A used, un -
der–rated hose could develop a high pressure leak or
rupture.
Service Tools Needed:
NEW 15.2 m, 21.0 MPa, 210 bar , flexible nylon, airless spray hose, p/n 223–541
 0–350 bar fluid–filled pressure gauge, p/n 102–814
NEW spray tip, size 0.025 to 0.029
 3/8 in. ignition wrench or nut driver
 5 gallon pail and water or mineral spirits
 Swivel, p/n 156–823
 Nipple, p/n 162–453
T ee, p/n 104–984

307-913
18
Pressure Control Adjustment
Set Up
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
1. Relieve the pressure .
2.
Set up the system as shown in Fig. 16.
Set the Dead Band (Pressure Dif ferential)
NOTE: Do not alter this adjustment if the wheel is al-
ready
set as shown in Fig. 17.
1. Turn off and unplug the sprayer. Remove the pres-
sure
control cover .
2. Set the white differential wheel (A) on the micros-
witch.
T urn the wheel so the letter F is concealed be -
hind
the switch and the letter A is the first letter seen.
Pressure Up
1. Start the sprayer and prime it.
2. Adjust the pressure to 18.0 MPa, 180 bar .
3. Turn off and unplug the sprayer. If the pressure
drops, replace the pump packings before proceed-
ing.
See page 32.
Adjust the Pressure
1. Remove the plug (326) in the bottom of the pressure
control.
2. Turn and hold the pressure control knob (B) at the
maximum
pressure setting.
3. Engage the nut (C): insert the nut driver through the
pressure control hole, or use the ignition wrench from
the front of the pressure control.
a. Loosen the nut just until you hear a click. ST OP.
b. Slowly tighten the nut just until another click is
heard.
ST OP.
4.
Replace the plug (D) and pressure control cover .
0474
102–814
156–823
104–984
162–453
223–541
Fig. 16
0475
A
Fig. 17
AB
CCCW 
D
Fig. 18

 
Bearing Housing & Connecting Rod
WARNING
To reduce the risk of serious injury , including fluid
injection or splashing in the eyes or on the skin, or
injury from moving parts, always follow the Pres-
sure Relief Procedure W arning on page 6
before checking, adjusting, cleaning, or shutting of
the sprayer . Unplug the power supply cord!
NOTE: Refer to Fig 19 for this procedure.
Disassembly
1. Remove the front cover and screws (23,68). Re-
move
the spring clips (100,102) and the bypass hose
(101).
2. Disconnect the pump outlet hose (59) from the dis-
placement
pump outlet nipple (49).
3. Use a screwdriver to push aside the retaining spring
(26) at the top of the pump. Push the pin (25) out the
rear.
4. Loosen the jam nut (27) with an adjustable wrench.
Unscrew and remove the displacement pump.
5. Use a hex key wrench to remove the four screws (73)
and lockwashers (74) from the bearing housing.
6. While pulling the connecting rod (22) with one hand,
lightly tap the lower rear of the bearing housing (21)
with a plastic mallet to loosen it from the drive hous -
ing
(20). Pull the bearing housing and the connecting
rod assembly (22) of f the drive housing.
Reassembly
1. Evenly lubricate the inside of the bronze bearing (C)
in the bearing housing (21), and the inside of the con -
necting
rod link (D), with high–quality motor oil. Liber -
ally
pack the roller bearing (E) in the connecting rod
assembly (22) with bearing grease.
2. Insert the connecting rod (22) into the bearing hous -
ing (21).
3. Clean the mating surfaces of the bearing and drive
housings
(21 and 20).
4. Align the connecting rod with the crank (A) and care -
fully align the locating pins (F) in the drive housing
(20) with the holes in the bearing housing (21). Push
the bearing housing onto the drive housing or tap it
into
place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screw (73) to align
or seat the bearing housing with the drive housing.
These parts must be aligned using the locating pins
(F), to help avoid premature bearing wear .
5. Install the screws (73) and lockwashers (74) on the
bearing
housing. T ighten evenly to16–18 N.m.
procedure continued on page 20
20
73
TORQUE T O
(16–18 N.m)
23
74
26 59
49
25
E
D
A
F
C
68
11
24
22

21
27
100
101
102
Fig. 19



Bearing Housing & Connecting Rod
NOTE: Refer to Fig. 20 for Step 6..
6. Screw the displacement pump about 3/4 of the way
into the bearing housing (21). Hold the pin (25) up the
pin hole in the connecting rod assembly (22) and
continue screwing in the pump until the pin slides
easily into the hole. Back off the pump until the top
threads of the pump cylinder are flush with the face
of the bearing housing and the outlet nipple (49)
faces back. Push the retaining spring (26) into the
groove
all the way around the connecting rod. T ight-
en
the locknut (27) to 90 to 100 N.m, using a 57 mm
open end wrench and a light hammer .
WARNING
Be sure the retaining spring (26) is firmly in the
groove, all the way around, to prevent the pin (25)
from working loose due to vibration.
If the pin works loose, it or other parts could break
of f due to the force of the pump action. These parts
could be projected through the air and result in
serious injury or property damage, including dam -
age to the pump connecting rod and bearing hous -
ing.
7. Install the front cover and screws (23, 68). Connect
the
suction tube (30) and pump outlet hose (59). See
Fig 19.
8. Install the bypass hose and spring clips.
25
26
21
27
22
FACE OF
BEARING
HOUSING
TORQUE TO
90–100 N.m
0031
Fig. 20