Graco Series A Operation manual

INSTR.UCTIONS/PARTS LIST 307-758
aRIco
Rev A
This manualcontains IMPORTANT
WARNINGS and INSTRUCTIONS
READ ANDRETAIN FORREFERENCE
120 VAC, 16 Amp.
ULTRA"500 AIRLESS PAINT SPRAYER
2750 psi (195 bar) MAXIMUM WORKINGPRESSURE
Basic, without hose, gun, spray tip kitor tip
Model 231-032. Series A
Model 231-041
spray tip kit, and spraytip of choice.
IncludedSprayer Model
231-034, hose, gun, RAC Ill
Same as 231-041 except is CSA certified
Model 220-409. Series B
PATENT NO. 4,397,610
PATENTED 1983, CANADA
BREVETE 1984
FOREIGNPATENTSPENDING
INDEX
Warnings ................................ 2, 3
Avertissement ..... ; .................... 4, 5
Advertencia ............................. 6, 7
Introduction ................................ 0
Setup ......................................... 9
Operation
.................................. 10
Shutdown
8 Care .......................
Troubleshooting Guide 13-20
FlushingGuidelines:.12
SDin Test
................................... 19
:,
11
....................
.............
Bridge Test ................................ 20
ReDair Section Index .................... 21
Sprayer
32, 33
HowToOrder Replacement Parts.33
Pressure Control
...................... 34
Paits List B Drawings
.............................
...........................
Technical Data BackCover
CircuitBoard
35
................
Warranty ....................... Back Cover
Aluminum and Zinc
Materlal Hazard
WARNING
such. solventsinthisequipment. Such usecouldreaultin a serious chemical reaction,withthe possiblllty of explo-
Never use 1.1.1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents.or fluids containing
sion, which could causa death, aerious bodily injury and/or substantial propertydamage.
Consult yourfluid suppliers to ensure that the fluids being used are compatiblewith aluminum and zinc parts.
GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55-1444
@COPYRIGHT 1988 GRACO INC.
i

WARNlNG
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates veryhighfluidpressure. Spray
from
the gun,leaks or ruptured components can injectfluid
through yourskinand into yourbodyand
cause extremely
serious bodilyinjury, includingthe needfor amputation. Also,
fluid injected orsplashed intothe eyes
or on the skincan
cause serious damage.
NEVER point the spray gun
at anyone or at any pen of the
body. NEVER put hand or fingers over the spraytip. NEVER
try to"blow back" paint; this
is NOT an air spray system.
ALWAYS have the tipguard in place onthe spray gun when
spraymg.
ALWAYqfoilow thePressureRellefProcedure, below,
before cleaningorremoving the spray tip
or servicingany
system equipment.
NEVER try tostop
or deflect leeks with your hand or body.
before each use.
Be sure equipmentsafety devicesareoperatingproperly
Medical Alert-Airless Sorav Wounds
If any fluidappears to penetrate your skin,
w-EMERGENCY
MEDICAL CARE AT ONCE.
DO NOTTREATAS A
.I
SIMPLE CUT. Tell the doctor exactly what fluid was injected.
Note to Physlclan: Injection in the skin is a traumatic in-
jury. It is Important to treat the Injury surgicallyassoon
aa
possible. Do not delaytreatmenttoresearch toxicily.
directlyinto the blood
stream. Consultationwith a plastic
Toxi& is a concern with some exotic coatings injected
surgeon or reconstructivehandsurgeon my be advisebla.
Be sure all gun dety devices are operating properly before
Spray Gun Safety Devices
each use.
Do not remove or modify any panof the gun; this
can cause
a malfunctionand result in serious bodily injury.
Safety Latch
Whenever you stop spraying, even for a moment, always set
the gun safety latchinthe closed
or "safe" position, making
thegun inoperative. Failuretosat the safetylatchcan resultin
accidental triggering of the gun.
DHuser
The gun diffuserbreaks up spray and reducesthe risk offluid
injectionwhenthe tip
is notinstalled. Check diffuser operation
then remove the spray tip. Aim the gun intoa metalpail,
regularly. Follow the Pressure RellefProcedure. below,
prassure, trigger thegun. If the fluidemittedis notdiffused in-
holdingthe gun firmly to the pail. Using the lowest possible
to an irregular stream, replace the diffuser immediately.
Tip Guard
ALWAYS have the tipguard in place onthe spray gun while
spraying. Thetip guard
alerts you to thefluid injectionhazard
and helps reduce,but does not prevent, the risk of accidental-
spray tip.
ly placing your fingers or any panof your body close to the
Trigger Guard
Alwayshavethe trigger guardinplace onthe gunwhen spray-
ing to reduce the risk
of accidentally triggeringthe gun if it is
dropped or bumped.
Spray
llp Safety
thespray tip clo
s whilespraying, engage the gun safety latch
Use extreme cautionwhen cleaning
or changingspray tips. If
immedlately. AaWAYSfollow the Pressure Relief
Pro-
cedure and then removethespray tip toclean it.
NEVER wipe off build-uparound thespray tip untilpressureis
fully relieved and the gun safety latch
is engaged.
I -
To reducethe risk of seriousbodilyinjury, includingfluid injection, splashingfluidor solvent intheeyes or on the skin, or injury
Pressure
Relief Procedure
from moving parts or electric shock, alwaysfollow this procedurewhenever you shut
off the sprayer. when checking or servic-
ingany panof thespray system,when Installing. cleaning or changing spray tips, and whenever you stop spraying.
(1 1 Engage
thegun safety latch.
12) Turnthe ON/OFF switch toOFF. 13) Unplugthe power supply cord. 14) Disengage thegun safety latch.
(5) Hold a metal panof the gun firmlytothe sideof a grounded metal pail,and trigger thegunto relieve pressure. (6) Engagethe
gun safetylatch.
17) Openthe pressure relief valve, having a container readyto catch thedrainage. (8) Leave the pressure relief
valve open until youare ready to spray again.
stepsabove,
VERY SLOWLY loosenthetip guard retainingnutor hose endcouplingand relieve pressure gradually, then loosen
If you suspect that the spray tip or hose is completely dogged, or thatpressure hasnotbeen fullv relievedafter followingthe
comoletalv. Now clear the
tio or hose.
TURN SWITCH TO OFF
LATCH UNPLUG
CORD AND TRIGGER GUN;
DISENGAGESAFETY
ENGAGE SAFETYAGAIN
OPENPRESSURE
REUEF VALVE
I
I I

EQUIPMENT MISUSE HAZARD
Any misuse of the spray equipment or accessories, such as
General Safety
overpressurizing, modifying parts, using incompatible
chemicalsandfluids, or using worn or damagedparts,can
causethem to ruptureand result
in fluid injection, splashing in
the eyesor onthe skin, or other seriousbodily injury, fire, ex-
plosion
or property damage.
could cause
it to malfunction.
NEVER alter or modify any
part of this equipment; doing 80
CHECK allsprayequipmentregularlyandrepair or replace
worn or damaged parts immediately.
Alwayswearprotectiveeyewear,glovesand clothing as
recommendedby the
fluid and solvent manufacturer.
System Pressure
Thissprayercandevelop 2750 psi I195 berl MAXIMUM
accessoriesare rated to withstand the maximum working
WORKING PR€.SSUR€. Be sure that all spray equipment and
pressureof this sprayer.
DO NOT exceedthe maximumwork-
ing pressure of anycomponent oraccessory used'in the
witem.
Fluid and Solvent Compatlbillty
Alwaysread the fluid andSolventmanufacturer'sliterature
before usingthem
in this sprayer.
HOSE SAFETY
Highpressurefluid in thehoses canbevery dangerous.If the
damage or misuse,the high pressure spray emittedfrom
it can
hose develops aleak, split or rupturedueto any kindof wear,
cause
a fluid injection injury or other serious bodily injury or
propany damage.
ALL FLUID HOSES MUST HAVESPRING GUARDS ON
kinks or bendsat or closeto thecoupling which can result
in
BOTH ENDS1 The spring guards help protect the hose from
hose rupture.
TIGHTEN allfluid connections securely before each use. High
pressure fluid can dislodgealoosecouplingor allow high
pressure sprayto be emitted from thecoupling.
NWER use a damaged hose. Before each use. checkthe en-
tirehosefor cuts, leaks, abrasion,bulging cover,ordamage or
movement of the hose couplings. If any of these conditions
exist, replace the hose immediately.
DO NOTtry torecouple
highpressure hoseor mend
it withtape or any other device. A
repairedhosecannot containthe high pressure fluid.
HANDLEAND ROUTE
HOSES CAREFULLY. Do not pull on
hosesto move equipment.
Do notusefluidsormlventswhich
are not compatiblewith the innertube and cover ofthe hose.
DO NOTexposeGracohose to temperaturesabove180°F
(82°C) or below
-4O'F I-4O"C).
Proper hosegroundlng contmulty IS essentialtomaintaining e
Hose Groundlng Contlnulty
grounded spray system. Checktheelectrical resistanceofyour
fluid hosesat least once a week.Ifyour hose doesnothave a
tag on
it which specifies the maximum electrical resistance,
contact the hose supplier or manufacturer for the maximum
resistancelimits.Usearesistancemeter
in the appropriate
range for your hoseto check the resistance. If the resistance
exceeds the recommended limits, replace
it immediately. An
ungrounded or poorly grounded hose canmake your system
hazardous.AlsoreadFIRE
OR EXPLOSION HAZARD.
FIRE OR EXPLOSION HAZARD
through the pump and hose. If every part of the spray equip-
Static electricity is created by thehighvelocity flow of fluid
ment is not properly grounded, sparking may occur, and the
systemmaybecomehazardous.Sparkingmayalsooccur
when pluggingin or unplugging a power supply cord. Sparks
can ignite fumes from solvents and the fluid being sprayed,
dust particles and other flammable substances, whether you
are spraying indoorsor outdoors, and can cause
a fire or ex-
plosionandseriousbodilyinjury
and property damage.
away from the sprayer
and the spray area. Do not plug in or
Always plug the sprayer into
an outlet at least 20 feet 16 ml
any chance of igniting fumes still
in the air.
unplug any power supply cordsinthespray areawhenthereis
while using this equipment.STOP SPRAYINQ
hEDL
If you experienceanystaticsparkingorevenasli ht shock
ATELY. Checktheentire systemfor proper grounding.
Do not
corrected.
usethe system againuntilthe problemhas beenidentified and
Groundlng
To reducethe risk of static sparking, ground the sprayer and
all other spray equipment used or located in the spray area.
CHECK yourlocalelectricalcode for detailedgrounding
in-
structions for your area and type of equipment. BE SUREto
ground allof this spray equipment:
1.
2.
3.
4.
5.
6.
7,
Spreyer: plug the power supply cord, or extension cord,
eachequippedwithan undamaged three-prong plug,into
a properly grounded outlet.Donotuse anadapter.
All ex-
tension cords musthave three wires andbe rated for
15
amps.
Fluid hoses: use only groundedhoses with a maximumof
500'feet
(150 m)combinedhoselengthtoensure ground-
ing continuity. Refer to Hose Groundlng Conrlnulty.
Spray
gun: obtaingroundingthroughconnection to a
properly groundedfluid hose and sprayer.
Objectbeing sprayed: accordingto local code.
Fluid supply container: accordingto local code.
All solventpails used when flushing, according to local
code. Useonlymetalpeils, which are conductive.
Do not
or cardboard, which interruptsthe grounding continuity.
placethe
pail ona non-conductivesurface, suchas paper
To maintaingroundingcontinuitywhenflushingorreliev-
ing pressure, alwaysholda metalpartof thegunfirmly to
the side of agroundedmetalpail, then trigger the.gun.
Flushing Safety
Reducethe riskofinjection injury, staticsparking, orsplashing
of this manual.Follow the Pressure Rellef Procedure on
byfollowing the specific flushing procedure givenon page 12
page 4, and removethespray tip befOr.9flushing. Holda metal
part of the gun firmly tothe side of a metal pail anduse the
lowest possiblefluid pressure during flushing.
MOVING PARTS HAZARD
Moving parts can pinch or amputateyourfingers or other
bodyparts. KEEPCLEAR of movingparts when starting or
operating the sprayer. Unplug the sprayer, and follow the
Pressure Rellef Procedure on aaae
2. beforecheckina or
servicing anipart of the sprayeitoprevent
it from stariing
accidentally.
IMPORTANT
ticularly the General Standards, Part 1910, and the Construction Standards, Part 1926-should be consulted.
UnitedStates Government safety standards have been adopted undertheOccupational Safety and HealthAct. These standards-par-
307-758 3

A WEWTISSEMEIMT
La pulv6risation t4 haute pression peut causer des blessures trds graves.
RBserv6 exclusivement B I'usage professionnel. Observer toutes les consignes de s6curit6.
Bietvlire et blen comprendre tous les manuels d'instructions avant d'utlllser le mat6riel.
RISQUES D'INJECTION
Consignes g6n4rales de sdcuritd
Cet appareilproduit unfluide B trbhaute pression. Le fluide
pulveris4 par
le pistolet ou le fluide sous pression provenant de
fuites oude rupturespeutpenetrer sous
la peau ou B I'intbrieur
du corps et entrainer des blessures trh raves, voir mema une
amputation. MBme
sans &re sous presseon, le fluideBclabous-
sant ou entrantdans
Ies yeuxpeutaussientrainerdes
blessures graves.
NEJAMAIS pointer
le pistolet vers quelqu'unou vers unepar-
tie quelconque du corps. NE JAMAIS mettre
la main ou 185
doi ts sur I'bjutage du pulv6risateur. NE JAMAIS essayer de
%!ouler'*
la peintura. CetapparailN'est PAS un compresseur
pneumatique.
TOUJOURS garder
la protection de I'ajutage en place sur le
pistolet pendant la pulv6risation.
TOUJOURSObSeNer
la March B Sulvre pour DBtendre la
I'ajutage du pulv6risateur. ou d'effectuer un travailquelcon-
Presslon donnee plus loin, avant denettoyer ou d'enlever
que sur une partie de I'appareil.
NE JAMAIS essayer d'arraer ou de dbvier
18s fuites avec la
main ou le corps.
Avant chaqua utilisation, bien s'assurer que
le8 dispositifs de
sbcuritefonctionnent correctement.
Encas de penetration de fluide sous
la pew: DEMANDER
Soins medicaux
IMMEDIATEMENTDES
SOINS MEDICAUX
COMME UNE SIMPLECOUPURE.
D'URGENCE. NE
PAS SOIGNERCETTEBLESSURE
Avls au medecln: Le pdndtration des fluides sous le peeu
est
un treumetisme. II est Importantdetralter
pes retarder le treitement pour effectuerdes recherches sur
chlrurglcalernentcette bleasure lmmddlaternent. Ne
la toxicitti. Certeins rev@temenfs exotiques sonr dengereuse-
ment toxiquesquend
ils sontinject&directementdensle
sang.
I1 est souheiteble de consulter un chirurgien esthdtique
ou on chirurgien spdcielisd dens la reconstruction des mains.
DiSDOSitifS de sbcurit6 du Distolet
enlever nimodifier one oartie auelconauadooistolet: ceci rie-
querait d'entrainer un mauiais fonctionnement'
et des
blessures graves.
A chaque fois que I'on s'ardte de puldriser, mdme dl s'egit
Verrou de sdcuritd
dun court instant,toujoursmenre le verroudesecuritb du
pistolet sur
le position"ferm6e"ou"sBcurit6"("safe") pour
empecher
le pistolet de fonctionner. Si le verrou de skurite
Voir
la Fig. 3.
n'est pasmis, le pistolet peut sa ddclencher accidentellement.
Diffuser
Le diffuseur du pistolet sen B divisar le jet et B reduire les ris-
ques d'injectionaccidantellequandI'ajutagen'estpasen
place. Verifier
le fonctionnement du diffuseur r6gulibrement.
Pour cettev4rification.detendre
la pressionanObSeNBnt la
Marcha A Sulvre pour Ddtendre la Presslon donnkplus
loin puis enlever I'ajutage du pulvdrisateur. Pointer
le pistolet
dans unseau en metal, en le maintenant fermementcontre la
seau.Puis, en utilisant la pression la plus faible possible, ap-
puyer sur
la gachettedu pistolat. Si le fluide projete n'estpes
diffuse MUS forme dejet irregulier, remplacer immbdiatement
la diffuseur.
Protection de /'ejuaiuta e . .
TOUJOURS maintenir B a protectionde I'ajutage en place sur le
pistolet du pulverisateurpendant la pulv4risation:La protec-
tionde I'ajutage attire l'attention sur
18s risques d'injection et
contribue
8 rbduire, mais n'kite pas le risque, que le8 doigts
ou une partie quelconque du corps nepassentaccidentelle-
ment
A proximite immediatede I'aiutaae du pulv6risateur.
"
Consips de skurite concernantI'ajutage du
pulvhsateur
Faireextremement attention
B I'occasion du nettoyageou du
remplacement
des ajutagesdupulv8risateur. Si I'ejutage se
verrou de sdcuritd du pistolet.TOUJOURSbienobserver la
bouchependant le pulv6risation,mettreimmediatement le
I'ajutage du pulverisateur pour le nettoyer.
Marche
A Sulvre pour DBtendre la Presslon puis enlever
NEJAMAIS essuyer cequis'est accumule autourde I'ajutage
tombbe
et que le verrou de securitbdupistolet ne soit engage.
du puldrisateur avant que la pression ne soit compl&tement
Avant chaque utilisation, bien s'assure quetous
Ies dispositifs
de skurite du pistolet fonctionnent correctarnent.Nepas
I 1
Pour reduire les risques de blessuresgraves, y cornpris les blessurespar injection de fluiie ou celles causbs pardes
1 B suivre B chaque fois que I'on arrete le pulv4risateur. B I'occasion de la verification w de la reparationd'une piece de I'appareil
Bclaboussures dans
Ies yeux ou sur la peau, des pieces en mouvamentou par Blectrocution, toujours bienObSeNercenemarche
i que arrht. 1) Engager le verrou dedcuritbdupistolet. 2) MenreI'interrupteur Marche-Arret surARRET I"0FF"). 3) DBbrancher
de pulvdrisation,
B I'occasion de I'instelletion, du nettoyage ou du remplacement des ajutages et d'une rnenibre gBn6rale B cha-
le cordon d'alirnentation. 4) DBsengager le verrou de securitd du pistolet. 51 En maintenant une partie metallique du pistolet
fermement appuyeecontre
le cdtdd'un seau en metal, appuyer sur la gachenedupistolet pour liberer la pression. 6) Engager le
verrou deskuritedu pistolet. 7) Ouvrir la soupape de securite an prenant soin d'avoir un recipient pr6t B rkuperer le liquide.
81 hisser le soupape ouvertejusqu'8 ce que !e pulverisateur soit de nouveaupret B etre utilia4.
Sil'on soupconne queI'ejurage du pulvdriseteur ou le tuwuesr complbtement bouchd, ou que la pression n'a pes dt6complbtk
1 ment libdrde eprbsevoirprocdddeux opdrations ci-dessus, desaerrer TRES LENTEMENT I'4crou deretenuade la.protection de
I'ejutageou
le raccord dubout dutuyauet liberer progressivement la pression, puisterminer le desserrage. On peutmaifitenant
1 debaucher I'ajutage ou le tuya
I
2
3
7

RlsauEs EN CAS DE MAUVAISE UTILISATION DU MATERIEL
Consignes gBn6reles de s6curit6
accessoirescomme,parexemple, la misesousunepression
Toute utilisation anormalede I'appareil depulverisation oudes
excessive,
les modifications depibces, I'utilisation deproduits
chimiques et dematibresincompatibles et I'utilisation de
pieces us&
ou ab?m&s peutcauser des d6gAts A I'appareilou
des ruptures de pieceset entrainer une injection de liquideou
Pression
Ce pulvbrisateur peut produire un PRESSIONMAXIMUM DE
TRAVAIL 195 bar 12750 Ib/po. 1 1. S'assurerquetous les
Bl4ments du pulverisateuret ses accessoiressontconcus pour
resister B la pression maximum de travail de ce pulvdrisateur.
NE PAS dbpasser la pression maximum de travail d'aucun des
Blementsou accessoires utilisbavec cet appareil.
d'autrtis blessuris s4rieuses.
un incendie, una expldsion ou Competibiiit6chimique des CDrPS
d'autres d6gAts.
NE JAMAIS altbrerou modifier une pibce de cet appareil; ceci Toujoursliresoigneusement
les documents et brochures du
fabricant des fluides et solvants utilises avant de s'an servir
risqueraitd'entra?nersonmauvais fonctionnement. danscepulv6risateur.
VERIFIER regulierementtout I'appareil de pulverisationet
ses
Bquipements et reparer ou remplacerimmediatement Ies
pibces us& ou abimbes.
MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXIBLES
trbs dangereux.Encasde fuite sur le tuyau,de fissure.
Le fluide
B hautepressioncirculant dans 1es tuyaux peut &reMANIPULERLES TUYAUX AVECPRECAUTIONET
dkhirure
ou rupture B lasuite de I'usure, de d4gAts ou d'une le fluide en tirant sur le tuyau. Ne pas utiliser de fluides ou de
CHOlSlR SOIGNEUSEMENT LEUR CHEMIN. Ne pas deplacer
mauvaise utilisation,
Ies projections de fluide haute pression solvants qui nesont pas compatibles avecI'enveloppe
in-
qui en proviennent peuvent entrainer des blessures graves par tbrieure ou exterieure du tuyau. NE PASexposer
le tuyau B
penetration sous la peauou par contact, ainsi quedes d6gAts des temperatures supdrieures
B 82°C 118O"Fl ou inferieures B
matQiels.
&PC ~-4o"Fl.
TOUS LES TUYAUX FLEXIBLES DOIVENTAVOlR DES
RESSORTS SPIRALE DE PROTECTION AUX
2 BOUTS!
Continuit6 de le mise B le term des tu eux
Unebonnecontinuitedelamise B la terre CY es tuyaux est
Lessoiralesde protectioncontribuent B Bviterla formation deessentiellepourmaintenirlamise B la terredeI'ensemblede
piUrLs, de bouclesou de nmudssur Ies tuyaux quipourraientvaporisation. VBrifiezlaresistanceBlectrique devostuyaux B
entrainerla rupture du tuyau B I'endroit du raccord ou B sonfluides et B air,au moinsunefoisparsemaine. Sivotre tuyau
ne comoorte oas d'6tiauene aui oreciselaresistanceBlectri-
unisinad.
~-.
SERRER FERMEMENT tous les raccords avant que mahum, prenez 'contaci a& le fournisseur de tuyaux
tion. Le fluide souspressionpeutfaire muter un raccord
Milisel un de resistance de gamme appropriee pour
ou la fabricant pour avoir 18s limit88 de resistance maximum.
desserreouproduireuniet hautepressions'bchappantpar10
votre tuyau et verifiez r8sistance, si ceiIe-ci depasse
raccord. limitesrecommand4es,remplacez
le tuyau immbdiatement.
utilisation,verifierentibrementchaquetuyaupourdeceler
Ies rectepeutentrainerdesrisquespourvotresystbme.Lisez
NE JAMAIS utiliser
un tuyau endommag6. AvantchaqueUn'tuyausansmise B laterreou avec unemise B la terreincor-
touteautre deterioration ou jeudes raccords. Si Sonconstate
coupures,fuites,abrasions,boursoufluresde I'enVelOPpe
OU aussiLES RISQUES DINCENDIEOU D'EXPLOSION ci-
I'une de ces det4riorations.
il fautremplacer le tuyau im- dessus.
haute pression
ni de reparer le tuyauavec du ruban adh4sifou
mediatement.NE PAS essayer derefaire
le raccordd'un tuyau
par toutautre moyen.Untuyau repar6 ne peut pas resister au
fluide sou8 pression.
RlSQUES D'INCENDIE OU D'EXPLOSION
De I'BIectricitB statique est produite par le passagedu fluide B
. ~ ~~
grande vitessedanslapompe et dans les tuyaux; Sitout88 Ies
pieces de I'appareil de pulverisation ne sontpas convenable-
mentreliees
B la masse ou B la terre, des Btincelles peuvent se
produire et I'appareilrisqued'8tredangereux. Des Btincelles
pewent 4galement
se produire B I'occasion du branchement
sont suffisantespour allumer
Ies vapeursdesolvantset le
oududdbranchement
ducordon d'alimentation.
Les Btincelles
fluide pulv4rist5,
185 finesparticules depoussibreainsique
d'autres substances inflammables. quand on pulvbrise
B I'in-
terieur ou B I'exterieur, et elles peuventcauser unincendie ou
uneexplosion,ainsiquedes blessures graves et des d4gAts
materiels. Toujours brancher
le pulverisateur dans une prise se
trouvant B aumoins 6 m I20 pieds) de I'appareiletdeI'endroit
oh
se fait la pulv4risation. Ne pas brancherou debrancher un
cordon d'alimentation que1 qu'il soit dans la zone
oir se fait la
pulverisation quand
il y a le moindre risque que des vapeurs
encore presentes dans I'air prennent feu.
S'il se produit des Btincelles d'blectricite statique, ou sivous
r-ntez la moindreddcharge, ARRETE2 IMMEDIATEMENT
LA PULVERISATION. VBrifiez que le syst&ne entier est bien
mis
B laterre. Ne vous WNBZ pasdusystbme avant que le pro-
blemesoit identifib et corrig6.
Mise B le term ou B le masse
statique, le pulverisateuret tous Ies Bquipements utili& ou se
Pour reduire lea risques de productiond'Btincelles d'blectricit4
trouvant dans la zone de pulverisation doivent &re relies
B la
terreou
B lamasse. Pourconnaitre le detaildes instructions de
ment, CONSULTER
le codeou 18s reelementations Blectriques
mise B la terre dans la region et le type partiCUlier d'dquipe-
tion suivants sont bien relies
B la terre:
locales. S'ASSURER que tous
les Bquipements de pulvbrisa-
1.Pulvdrisataur:Brancher
le cordon d'alimentation ou la
etat. dansuneprisedecourantconvenablementmise
B la
rallongequidoivent&re Bquipesd'une prise
B 3 fiches enbon
terre. Ne pas utiliser d'adaptateur. Toutes
Ies rallonges doivent
avoir
3 fils et Atre pr4vues pour 15 ampbres.
2. Tuyaux flexibles: Afin d'assurer la continuite de lamise B la
terre, n'utiliser que des tuyaux comportant une mise
B la terre
et avantunelongueurmaximum combink de 150 m
(1500 piedsl. Se reporter6galementauparagraphe "Con-
tinuit4
du circuit de mlse d la terre des tuwux".
3. pistolet:RBaliser la mise B la terreen le raccordant B un
tuyau flexibleet
B unpulvbrisateurdeja convenablement relib
4. Recipientd'alimentation: Observer le code ou Ies r4glemen-
B la terre.
tations locales.
5. Objets, materiel ou surfaces recavant la pulvdrisation:
observer
le code ou 18s reglementations locales.
6. Tousles seaux de solvants utilisdspour le rincage: Observer
mdtallquesconducteursde I'lectricite. Ne pasmettre
le seau
le code ou Ies reglementations locales. N'utiliser que des seaux
sur une surfacenon conductrice comme sur du papierou du
carton car cola intarromprait
le continuite le la mise B la terre.
rince
le matdriel ou quand onlibdm la pression; toujours
7. Pourconserver la continuitd de la mise B le terraquandon
maintenir une partie metalliquedupistolet fermement appuyee
contre
le cat6 d'un seau en metalpuis appuyer sur la d&ente
Mesures de SBcurit6 concernant le Rinceqe
du pistolet.
Pour reduire
Ies risquesdeblessurespar penetration de IS
peau et Ies risques dOs aux Btincelies d'electricitb statiqueou
aux Bclaboussures, Observer lamarche
B suivre pour le rincage
donnee
B la page 12 de ce manuel. Observerla "Marche d
Sulvra pour D4tendre la Pression" donnee B la page 4 en
enlever I'ajutage
du pulvdrisateur avant le rincage. Maintenir
une partie m4talliquedu pistolet fermementappuykcontre
10
cat6 d'un seau en mdtal et utiliserlapression la plus faible
possible pendant
le rincage.
307-750 5

AD VERTENCIA
EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES.
SOLO PARA US0 PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.
Lea y entienda todo ai manual de instrucciones antes de manejar ai equipo.
PELIGRO DE INYECCION DE FLUID0
Seguridad general
€me equipo genera un fluido a unapresi6n muy aka. El
rociado de lapistola, 10s escapesde fluido o roturasde 10s
componentes pueden inyectar fluido en la piel y el cuerpo y
causar lesionesextremadamente raves, incluyendo aveces la
necesidaddeamputaci6n. Tam~iBn, e1 fluido inyectado o
salpicado en 10s ojos puedecausar graves daflos.
NUNCAapuntar la pistola hacia alguien
o algunapartedel
cuerpo. NUNCA colocarla mano
o 10s dedos encima de la bo-
quilla. NUNCA tratar de "hacer retornar la pintura"; este NO
es un sistema de rociado de aire.
SiEMPRE tenercolocado
el protector de ia boquilla en la
pistola mientras
se est4 pulverizando.
SIEMPRE seguir
e1 procedimianto dedescargadepresl6n.
dado
m4s abjo, antes de lirnpiar o sacar la boquilla o de dar
servicio
e cualiquier equipo del sistema.
cuerpo.
NUNCA tratar de parar
o desviar 10s escapescon ia mano o el
Asegurarque todos
10s aparatosdeseguridaddelequipo
estan funcionando bien antes de cada
USO.
Tratamianto medico
Si pareciera queun poco de fluido penetr6 la piel, conseguir
TRATAMIENTOMEDICO DEURGENCIADE IN-
MEDIATO. NO TRATAR LA HERIDA COMO UN SIMPLE
CORTE.
Deciralmedico exactamentecuafluido fuel
. Avlso a1 medico: Si sellega e inyectar estefluido en la piel
'se causa unelesidntraum8tica. Es importantetratar
qulrfirglcamente
la lesi611 a la brevedadposible. No
de171Or8re/ tratamiento pare investigar la toxicided. Le tox-
icidad es algode
sum importenciaenalgunes pinturas
exdticascuando se inyecfandiractamente
a/ torrente
sangulneo. Sir4 conveniente consultar e
un especielistaen
ciruglapldstice
o reconstructiva de /as manos.
Aparatos de seguridad de la pistola puiverizador
Asegurerque todos
10s aparatosprotectoresde la pistola
ea4n funcionandobienantes decadauso. No sacar ni
modificarninguna piezadela pistolapuespodriaceusar e1 ~.
malfuncionamiento de la misma con las consiguientes lesiones
Pestillo da seguridad
personeles.
Cada vez que
se deje de pulverizar, aunque sea por un breve
momento,siemprecolocar
e1 pestillodeseguridad en la
posici6n "cerrada",
lo que deja lapistolainoperante. El no
hacerlo puede ilevar a1 disparo imprevistode le pistola.
Difusor
El difusor dela pistola dispersa e1 chorro pulverizado y reduce
el riesgo deinyecci6ncuando no est4instaladalaboquilla.
Revisarcon regularidad
el funcionamiento del difusor. Seguir
e1 procadlmlanto dedescarga depresibn. dado m4s abajo,
y despub sacarla boquilla.Apuntar la pistolaa un balde
rnet4lico.sosteniendolabienfirmecontra
61. Utiiizandola
presi6n
mas bejoposible,dispararlapistola. Si el fluido,
emitidonosale disperso
en un chorro irregular, reemplazar de
inmediato
el difusor.
Rotector de la boquilla
SIEMPRE tener el Drotector de ia boauiiiacoiocadoen la
pistola mientras
se est4 pulverizando. E& protector llama la
atenci6n contra e1 peligro de inyecci6n y ayude a reducir, pero
no evita, lacolocaci6n accidental de 10s dedos o cualquierotra
parte del cuerpo cerca de
le boquilla.
Segurldad de la boquilla pulverizadora
Tenermuchocuidado a1 limpiar o cambiar 18s boquillas. Si
llegara a obstruirse mientrasesta pulverizando, enganchar e1
pestillodelapistola de inmediato. SIEMPRE seguir el pro-
cedlmlento dedescarga depres1611
y despuk sacar la bo-
quilla para limpiarla.
NUNCA limpiar la acumulaci6nde pintura alrededor de labo-
quiilaantes de que
se hayadescargado porcompleto la
presi6n
y el pestillo est6 enganchado.
Marche B Suivre pour Dbendre Is Presslon
Pour reduire 18s risquesdeblessuresgraves, y compris Ies blessures par injection de fluideou celles causbs pardes
Bclaboussures dans
19s yeux ousur la peau. des pieces en mouvementoupar Blectrocution, toujours bienobserver cene marche
B suivre B chaquefois que l'on arrete la pulv&isateur, B l'occasion de la verification ou de la reparation d'unepiece de I'appareil
de pulv4risation.
B l'occasionde finstallation, du nettoyage ou duremplacement des a'utageset d'une manibre gBn6rale B cha-
la cordon d'aiimentation.
41 DBsengagar le verrou de skuritedu pistolet.
51
En maintenant une partie m4tallique
du pistolet
que arr8t.
1) Engagerleverroudesecuritedu pistolet.
2) MettreI'interrupteur Marche-Arretsur ARRET POFF"). 3)
Debrancher
fermementappuybcontrelacbt6
d'un seau en metal, appuyer sur la gachettedupistolet pour liberer la pression. 6) Engager le
verrou de securit6du pistolet. 71 Ouvrir la soupape de securite en prenant soin d'avoir un recipient pret B rkuperer le liquide.
81 hisser la soupape ouverte jusqu'a ca que !e pulverisateur soit de nouveeu pr&t B &re utili&.
Sil'on soupconne
que I'aiutage du pulv4risateur ou letuvauest compl&tementbouch4, ou que la pression n 'e pas Bt4 compli)te-
mentIib&& epr& avoirprocdd4 eux operetions ci-dessus, desserrer TRES LENTEMENT 1'4crou de retenue de la protection de
I'ajutage ou
le raccord du bout du tuyauet liberer progressivernent la pression,puisterminer le desserrage. On peut maintenant
deboucher I'aiutaoeou
le tuvau.

PELIGRO POR MAL US0 DEL EQUIP0
Seguridad general
comosobrepresurizaci6n.modificaci6nde piezAs, us0de
Cualquier mal us0 del equipo pulverizador
o 10s accesorios, tal
materiales
y productos qulmicos incompatibles, o utilizaci6n
depiezasdaiiadas
o desgastadas, puede hacenque se rompan
y cauSen lainyecci6nde fluido uotrasIesionescorporales
graves, incendio, explosi6n
o danon a la propiedad.
NUNCA alterar
o modificar ninguna pieza de este equipo; el
hacerlo podrla causar una averla.
REVISAR con regularidad a1 equipo pulverizador
y reparar o
reemplazar de inmediato Ias piezasdaiiadas o desgastadas.
Presi6n del sistema
Esta pulverizadora puede desarrollar 195 barlas 12750 psi) de
PRESION DE TRAEAJO MAXIMA. Asagurarque todo el
equipo pulverizador y sus accesoriostienen la capacidad para
aguantar
le presidn mexima de trabajo de esta pulverizadora.
NOexceder lapresi6nmaximadetrabajodeningdn com-
ponente
o accesorio de este sistema.
ComDatibllidad de fluldn
Siempre leer 18s instruccionesdelfabricantedel fluido y
mlvente antes de usarlosen asta pulverizadora.
SEGURIDAD EN EL US0 DE LAS MANGUERAS
El fluido que escapa a alta presi6n por Ias mangueras puede
ser muypeligroso. Sien
la manguera se desarrollaunescape,
unarotura
o rajaduradebidoacualquier tip0 de desgaste,
daiio
o maltrato, e1 chorro a aka presi6n emitido por all1 puede
causaruna lesi6nporinyecci6nuotras lesiones corporales
graves
o daflos ala propiedad.
lTODASLASMANGUERASPARA FLUIDOS TIENEN
QUETENER GUARDAS DE RESDRTEEN AMBOS EX-
TREMOSl Estas protegen Iasmangueras contradobleces
o
podrlan traducirse en roturasde la manguera.
retorceduras
en 10s acoplamientos o cercade ellos, 10s que
Antesde usarlas, APRETARbien firmes todas las conexiones.
El fluido a aka presi6n puede desalojarunacoplamiento suelto
o dejar que por 41 escape un chorro a alta presi6n.
NUNCAusarunamangueraque
est& dafiada. Siempre,
revisarla
en busca de cortaduras, escapes, abrasi6n. cubierta
abultada,
o acoplamientos sueltos o daflados. Siilegara a en-
contrarse cualquiera de estas condiciones, reemplazar de in-
mediatola manguera. NO intentar reacoplar una manguera de
aka presi6n
o enmendarla con cinta adhesiva u otro material
similar. Una manguera que ha sido remendada
no aguante e1
fluido a aka presi6n.
MANEJAR
Y PASARCUIDADOSAMENTELAS
equipo.No usar fluidos
o solventesque Sean incompatibles
MANGUERAS.Notirardelasmanguerasparamover
el
con el tub0 interno y la cubienadela manguera. NO exponer
18s mangueras
a temperaturassobre 82'C (180°F) o bajo
-40°C
bW").
Continuidad del circulto de puesta a tierra de la
rnanguera
La continuidaddel circuito de puma a tierra apropiado es
esencialpara mantenerconectadoatierra e1 sistema
pulverizador.
Es indispensablerevisarlaresistencia elktrica
maxima de las mangueras de aire
y defluido por lo menos una
veza
la semana. Si la manguera no tiene una etiqueta en la
cual
se especificaia resistencia el4ctrica maxima, ponerse en
contact0con al proveedor o fabricantedela manguera para la
informacidn sobre
10s limitesde resistencia. Usarunmetro de
resistencia
en la gama apropiada para comprobar la resisten-
cia; si excede
10s llmitesrecomendados,reemplazarladein-
tierra
o con la puasta a tierra en malascondlciones. Leer tam-
mediato. Es muyarriesgado tener una manguera sin puesta
a
SION. mas arriba.
bi4nla informaci6n sobre RIESGODE INCENDIO
0 EXPLO-
PELIGRO DE INCENDIO 0 EXPLOSION
mangueracrea electricidadestdtica. Si todas 18s panesdel
El flujo a akavelocidaddel fluido a1 pasar por labomba y
equipopulverizadornotienenbuenatierra,puedenocurrir
chispas, convirtiendo alsistemaanalgopeligroso. Tambibn,
pueden producirse chispas al enchufar
o desenchufar el cor-
d6n elktrico. Estaschispaspueden inflamar
10s vaporesde
10s solventes y e1 chorro de fluido pulverizado, partlculas de
polvo
y otrassustanciasinflamables, sea al airelibre o bajo
techo,
lo que podrlacausar una explosidn o incendio y graves
Iesiones corporales
y daflos ala propiedad. Enchufar siempre
la pulverizadora aun tomacorriente que
se encuentre a por lo
menos 6 m (20 piesl delamdquina y del Area que se vaa
el lugardonde se est4rociandocuandotodavlaexistala
rociar. No enchufar
o desenchufar ningdn cord6nektrico en
posibilidad de que quedenvapores inflamables en e1 aire.
Siocurre
una chispa de electricidad estAtica o inclusounligero
choqueelbctricomientras
88 usa el equipo,DEJARDE
PULVERIZAR
DE INMEDIATO.Revisar todo e1 sistema en
buscadeunatierraapropiada.Nousardenuevo e1 sistema
hasta haber identificado
y solucionado e1 probiema.
Puesta a tiarra
Para reducir el riesgo de chispas estdticas, conectar a tierra la
pulvarizadora
y todo al otro equipo de pulverizar que se use o
se encuentreen el lugar que se va a rociar. CONSULTAR e1
c6digo el4ctrico dela localidadpara Iasinstrucciones sobre Ias
conexionesatierraexigidasparalazona
y tip0 deequipo.
ASEGURARdeconectaratierra todo esteequipo
pulverizador:
sor, cada uno con un enchuf de tres patas enbuen estado, a
1. Pulverizadora: enchufar el
corddn el4ctrico. o cable exten-
un tomacorrienteconpuestaatierraapropiado.Nousar un
adaptador. Totos
10s cables extensores tienen que tener tres
hilos
y una capacidad de 15 amperios.
2. Manguerasparefluidos: usarsolamentemangueras con
puestaatierradeuna longitud combinadade
150 m
1500 pies), para asegurar buenacontinuidad a tierra. Referirse
tambibn a1 pArrafosobre continuldad a tlerradela
3. Pistola: hacerlapuestaa tierraconectAndolaauna
manguers.
manguera de fluido
y pulverizadora bien conactadas a tiarra.
4. Suministrarunrecipiente: deacuerdo a1 c6digo de la
localidad.
5. Objeto quese est6 rociendo: de conformidad con el c6digo
local.
6. Todos /os baldes de solvenre usados durante e1 lavado, de
conformidadcon
el c6digolocal. Usar solamentebaldesde
metal, que Sean conductivos.Nocolocar e1 balde en una
superficie
no conductiva, como papel o can6n.queinter-
rumpela continuidad a tierra.
7. Para mantener la continuidad a rierradurante el lavado o
descargade presidn, siempre apoyar una parte methlica de la
pistolabienfirmecontra
el costadodel baldedemetal,
despu6s apretar el gatillo.
Seguridad durante el lavado
piel, o que ocurra una descarga de electricidad estatica, siem-
Para reducir
e1 riesgo de que se inyecte o salpique fluido en la
preseguir las INSTRUCCIONES PARA EL LAVADO, dadas en
lapAgina
12. Seguir el procedimientode dascargade
presibn en la pdgna 6, y quitar la boquilla rociadora antes de
lever.
Apoyar una parte mettJicade la pistole bienfirmecontra
e1 costado de un baldede metal y usar le presi6n mds baja
posible defluido durante
el lavado.
PELIGRO DE LAS PlEZAS MOVILES
otraspartesdelcuerpo.MANTENERSEALEJADOdeIas
Las piezas en movimiento pueden pinchar o amputar dedos u
piezas
en movimientodurante e1 arranque o funcionamiento
de
Is pulverizadora. Desenchufar la putverizadora y descargar
la presi6n antes de revisar
o dar servicio, e cualquier parte de
pulverizadora, para impedir que arranque inesperadamente.
IMPORTANT
Se han edoptado las normasde seguridad del gobierno de 10s
Estados Unidosde Norteambrica bajo e1 Acta de Seguridad y
SaludOcupacional.DeberAn consultarseestasnormas.en
especial las Generales,Pane
1910, y Ias Normas de Construc-
ci6n,Parte
1926.
307-758 7

ULTRATM WO BASIC COMPONENTS
Model
231-041 shown
PRESSURE CONTROL KNOB
ELECTRICMOTOR
RUlDFlLT
DRIVEASSEMBLY
FLUID ounm
CIRCUIT BREAKER
RESET BU'ITON
PAILHANOER
DISPLACEMENTPUMP
PRESSURERELIEFVALVE
MAINFLUIDHOSE
--SPRAY OUN
Your new UltraTM 500 Sprayer functions andoperates
differentlythan other airless paint sprayers. This section
will help you become familiar with the sprayer before
operating
it.
PressureControl
The pressurecontrolincludesen
ON/OFF switchforthe
sprayer, the pressureadjustingcontrolknob,
a pressure
with a manual resetbutton. Its functionis to controlthe
sensingdevice,and e current overload circuit breaker
motor speed
so that the sprayermaintains constant
fluid pressure
at the pumpoutlet.
Motor
. ..
TheDC motor hassealedbearingsandreplaceable
motor brushes.
Its function is to drivethe displacement
pump et the rate needed to supplysufficient paint
volumeet the selected pressure.
Workingtogether, the pressure control end motor
cause the pump to cyclewheneverthereis fluid or
pressure demand.Whenthe pumpiscycling, the motor
sounds like an automobile atartercranking. When the
tently,
or appearstohaveshut itself off. However, there
pump is not cycling, the motor hums,hums intermit-
will still be Dower to the sDraver end it will stay
pressurized and readytouse unlessyoumanuallyshut k
off and relieve pressure.
voltage or voltage fluctuations than anAC motor, end
a
Because the motor is DC, it is less sensitive tolow
heavygaugeextension cord of up to
150 feet (46 m)
can be used.
The sealed drive assembly transfers powerfromthe DC
Drive Assembly
motor tothe displacement pump.
Displacement Pump
The positivedisplacement, volume-balancedpumppro-
videsequal fluid deliveryon both the up and down
pump strokes. The pump has
a wet-cup which, when
filled with Graco Throat SealLiquid,helps prevent
damage tothe throat peckings endpistonrod.
fluid Filter
The fluid filter providesthe final paint straining'to help
avoid clogsinthe hose and spraytip. The filter includes
a reusable element and a pressure relief valvefor reliev-
ingfluid pressure when shuttingoff the sprayer.
Hoses
The grounded,nylonspray hoses havespring guards on
The 3 foot (0.9 ml, 3116 in. ID whiphoseallowsflexi-
bothends. The
50 foot (15.2 m)hose has e 114 in. ID.
pulsationdampener toabsorb pressurefluctuations.
ble gun movement. The nylon hose material acts es e
Spray Gun
B Reverse-A-Clean 111 Spray Tlp
Graco high pressurespreygunshave a trigger safety
which prevents accidental triggering when
it isengaged
(seebelow).The Reverse-A-Clean
111 spraytip uses high
without removing
it fromthegun.
It includes a safetytip
pressure fluid to removeclogs from the spray tip
guardwhich helps reducethe risk of injectioninjury.

SETUP
1. Connect Hose and Gun (Refer to Fig 1.)
e. Remove the plasticcap plug from the filter
outlet nipple and screwthe
50 ft (15.2 m)main
fluid hose onto the nipple.
r
b. Connect the whip hose between the fluid hose
andthe
gun inlet connection.
c.Don't
use threadsealant,anddon't installthe
spray tip yet1
WARNING
gun,besure they are electricallygrounded and
If youare supplyingyour own hosesandspray
rated for
at leest 2750 psi 1195 bar)Working
kassura, andthat the gunhas
a tip guard. This is
to reducethe risk of serious bodilyinjury caused
.pressurizing end rupturingthe equipment.
by staticsparkingand fluid injection or over-
r
CAUTION
To avoiddamagingthepressurecontrol, which
may result in poorequipmentperformanceand
componentdamage, follow these
1 precautions:
1. Always use nylon sprayhose of at least
50 ft (15.2 m) long.
2. Never use
a wire braidhose as it istoo rigid
to ect
es a pulsationdampener.
3.Never
install any shutoff device between
the filter and the main hose.
See Fig 2.
4. Always use the main filter outlet for one-
gun operation. Never plug this outlet.
2.
Fill PackingNutlWet-Cup (See Fig2.)
Throat
Seal Liquid ITSL), supplied.
Fill the packing nutlwet-cup 1/3full with Grato
3. CheckElectrlcalService
a. Be sure the electricalservice is 120 V,
60 HrAC, 15 Amp (minimum)and that the
outlet you use is properly grounded.
b. Use anextensioncord which has 3 wires'of e
minimum 12gaugesize,and a maximum of
sprayer performance.
150
ft (45 milong. Longer lengths may affect
a.
b.
C.
4. Plug In the Sprayer
Be sure the ON/OFF switch is OFF.Refer to
Fig
3.
Plug the powersupply cord into a grounded
electricaloutletthat
is at least 20 ft I6 m) away
from the spray area
to reduce the chance of e
spark igniting the spray vapors.
Do not remove the third prong of the power
supply cord plug, which
is the grounding
prong, and do not use
an adapter.
5. Flush thepumpto remove the lightweight oil
which wes left in to protect pump parts after fac-
tory testing.
a. Beforeusing water-basepaint, flush with
mineralspirits followed by soapywater,and
then
a clean water flush.
b. Before usingoil-basepaint, flush with mineral
spirits only.
Fig
3
c.Sea FLUSHINGGUIDELINESon page 12for
6. Preparethe paintaccordingtothe manufacturer's
recommendations.
a. Removeanyskin that mayhaveformed.
b. Stir thepaint to dissolvepigments.
c. Strain the paintthrough
a fine nylon meshbag
(available
at most paintdealers) to remove per-
ticlesthat couldclog thefilter or spraytip. This
is probablythe most important step toward
trouble-free spray painting.
flushing procedure.

OPERATION WARNING
Pressure Rellef Procedure
cludingfluid injectionorsplashing inthe
eyes or on
Toreduce the risk of serious bodilyinjury,in-
the skin,or injury from movingparts or electric
shock, always follow this procedure wheneveryou
any part of thespray system,
when installing,
shut
off the sprayer, when checking or servicing
cleaning or changing spray tips, and whenever you
stop spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFFswitch to OFF.
3. Unplugthe power supply cord.
4. Disengagethe gun safety latch.
5. Hold a metalpartof the gunfirmlytotheside of
e metal pail,andtrigger the gun to mlieve
6. Engage the gun safety latch.
pressure.
7. Open the pressurereliefvalve,having a con-
8. Leave the pressurereliefvalveopen until you
tainer readyto catch thedrainage.
are readyto operate the sprayer again.
plete4 clogged,
or thatpressure hasnot beenfulk
if you
suspect that the spraytip
or
hose is com-
relievedafterfollowingthestepsabove, VERY
SLOWLY loosenthe tip guardretaining nut or
hose end couplingand relieve pressure gradually.
Then loosenthe nutcompletely. Now clear the
tip
or hose obstruction.
1. Prime the Sprayer wlth Pelnt.
a. Close the filter's pressure relief valve. See Fig 1.
b.Don'tinstallthespray tip yet1
c. Put the suction tube into the paint container.
d.Turnthe pressure adjusting knob all the way
counterclockwisetolower the pressure setting.
e. Disengagethe gun safetylatch.
f. Hold
a metal part of the gun firmly against and
aimed into
a metal waste container. See Fig 4.
ON/OFFswitch to ON, and slowlyincrease the
Squeeze the trigger and hold it open, turn the
pressure setting until the sprayerstarts.This
procedurereduces the risk of
static electric
dischargeandsplashing.Keepthegun trig-
gered until
all air is forcedoutof thesystem and
the paintflowsfreelyfromthe gun. Release
the
trigger and engage the safety.
NOTE: If the pump is hard toprime, place e con-
tainer under the pressure
relief valve and
open
it. Whenfluid comesfrom thevalve,
close
it. Thendisengage the gun safety
latchand proceed
as in Step If, above.
g. Check
all fluid connectionsfor leaks. If any are
found, follow the Pressure Relief Procedure
Warnlng, above, then tighten connections.
2. Install theSpray Tip end Tip Guard
(Referto Fig
5.1
a. Be sure the gun safety latch isengaged.
METALTO METAL
MAINTAIN FIRM
GUN AND CONTAINER
CONTACT BETWEEN
Fig 4
IS ENGAGED1
BE SURE GUN SAFETY LATCH
TIGHTEN SNUGGED
RETAINER NUTlI8TO
l/BTURN WITHWRENCH
Fig 5
c. Install the Reverse-A-ClesnTM 111 spray housing
withtip installed.
See the RAC 111 packaging
label for instructions.
d. Tighten the retaining nut byhanduntil snug.
e.
Use a wrenchtotightenthe retainingnutabout
r"cAuT~oN 1
1/0 to 1 /6 turn.
Overtighteningthe retainingnut will damage the
seat gasket and resultin leakage.
~~~ ~~ ~~~
3. Adjustlngthe SprayPattern
__~ ~
a. Increase the pressure adjusting knob setting
just until spray from theguniscompletely
atomized.To avoid excessiveoverspreyand
fogging, and to decrease tip wear and extend
the
life of the sprayer,alwaysuse the lowest
possiblepressureneeded
to get the desired
results.
b.
If morecoverageisneeded,use a larger tip
rather than increasing the pressure.
c.Test the spraypattern. To adjust the direction
of the spraypattern,engage the gun safety
tiD so the aroove is horizontalfor e horizontal
latchand loosenthe retaining nut. Positionthe
b. Unscrewthe
tip guardretaining nutfrom the pattern or;erticel for a verticalpattem.-Then
gun. tighten theretainingnut.

4. Operatino Tips. These suggestionswill helppre-
vent the motor from runningtoo hot or operating
intermittently.
a. Decreasethe pressure whenusing a smalltip.
b. Keep
the sprayer in a shaded area when spray-
ing outdoors.
whenever you stop spraying.
c.Turn
off the sprayerandrelievepressure
5. Cleanlng a CloggedTip
r
ARNING
To reduce the risk of serious bodily injury from
fluid injection or splashing in the eyes or on the
skin,
use extremecautionwhencleaningor
changing spray tips. if the spray tip clogs while
spraying, engage the gun safety latch immediate-
ly, fhen follow the procedure in Steps 9-5e.
below.
I
NEVER wipe off builduparound the spraytip until
pressure isfully relieved and thegunsafetylatch
is
enaaaed. I
1.
2.
3.
a. Clean the front of the tip frequently duringthe
day'soperation.
First, follow the Pressure
Rallef Procedure Warnlngon page
10. Then
buildingup and clogging thetip.
use a solvent-soaked brushto keep paint from
b.
If the spray tip doesclog, release the gun trig-
ger,
engage the gun safw, and rotate the
spray tip handle
1M0. See Fig 6.
e. Disengagethe gun safety latch and trigger the
gun into
a wastecontainer. Engage the gun
safety latch again.
d. Returnthe handle to theoriginalposition,
disengage thegunsafety,andresumespray-
mg.
e. If the tip is still clogged, engage the gun safety
open the pressurereliefvaiva to relieve
latch,shut
off andunplugthesprayer,and
pressure. Clean the spray tip.
SHUTDOWN AND CARE
follow the Pressure RellefProcedureWarning
Check thepacklngnutlwet-cup dally. First
on page
10. Be sure the wet-cup is 1/3 full ofTSL
at
ell times to helppreventpaintbuildupon the
piston rod andprematurewear of psckings.The
packing nut shouldbe tight enough to stop
leakage, but no tighter. Overtightening may cause
bindingand excessive packing wear.
Use a screw-
driverand light hammer to adjust the nut.
See
Fig 7.
CAUTION
Never leave water or anypaintinthe sprayer over-
night to: (1) prevent pump corrosion; (2) to pre-
vent the paint or waterfrom freezinginthe pump
andpressure control which cancauseloss
of
Always use mineralspirits for the final flush.
pressure, stalling orserioussprayerdamage.
of min6ral spirits in the sprayer.
Relieve pressure. This leaves
a protectivecoating
4. For very short shutoff perlode, leavethe suction
tube in the paint, follow the Pressure Relief Pro-
cedure Warningon page 10, and clean the spray
tip.
5. Coli thehose and hang it on the hose rack when
storing
it, wen for overnight, to help protect the
hosefrom kinking, abrasion, couplingdamage, etc.
HANDLE
ROTATE
?/- I le,
Clean the fluid fllteroften andwhenever the
sprayer is stored. First follow the Pressure Relief
Procedure Warnipg on page 10. Refer to manus1
307-273, supplied, for the cleaning procedure.
W
Flush the sprayer at theend of eachwork day
end fill
it with mineral spiritsto help preventpump
corrosion and freezing.
See "FlushingGuidellnes"
on page
12.
m 7
307-758 11

FLUSHING GUIDELINES
When
to Flush
1: NewSprayer. Your new UltraTM 500 Sprayerwas
factoly tested inlightweightoil whichwas
left in to spiritsendleave the pump,hoseand gunfilledwith
Water-base palnt: flush with watar, thenmineral
protectpumpparts.mineralspirits. Shut
off and unplug the sprayer,
Before
uslng water-base palnt, flushwith mineral
spirits, followed by soapy water, and then
a clean open the pressurereliefvalve to relievepressure
water flush. and leave open.
Oil-base pelnt: flush with mineral spirits. Shut off
Before uslng olbbase palnt, flush with mineral
spiritsonly. valve to relievepressureandleaveopen. and unplug the sprayer,open the pressurerelief
2. Changing Colors. Flushwith ecompatiblesolvent 6. Startupafter storage.
such
as mineralspiritsorwater. Before uslng water-basepalnt,flush out mineral
3. Changing from water-base to oli-basepaint. spirits with soapy water and then
a clean water
Flushwith soapy water, then mineral spirits. flush.
When uslng oll-base pelnt, flush out the mineral
4. Changing from oil-base to water-bdsepalnt. spiritswith thepaint to besprayedand the sprayer
Flushwith mineral spirits,followedbysoapy water,
then
a clean water flush. isreadyto
use.
5. Storage.
How toFlush
1. Follow the PressureRellefProcedureWarnlng
on page
2 or 10.
2. Remove the filter bowl andscreen; see manual
307-273 supplied. Clean the screen separately and
installthe bowl withoutthe screen toflush it. See
Fig
8.
mJ 8
3. Close the filter pressurereliefvalve.
4. Pour one-half gallon (2 liters)of compatible solvent
into e bare metal pail. Put the suction tube in the
pail.
5. Remove the spray tip from the gun.
6. Disengagethe gun safety latch. Point the spraygun
into
a metal waste container endwith a metal part
of the gun firmly touchingthemetalcontainer,
squeeze the gun trigger. See Fig 9. Thls prcr
cedure helps reduce the rlsk of sratlc sparklng
and splashlng. With theguntriggered, turn the
adjusting knob clockwise just
untll
the sprayer
ONlOFFswitch to
ON and slowlyturnthepressure
starts. Keep the gun triggered until clean solvent
comes from the nozzle.
Release thetrigger and
engage the gun safety latch.
MAINTAIN FIRM
CONTACT BETWEEN
GUN AND CONTAINER
7. Check all fluid connections'for leaks. If anyleak,
first follow the Pressure Relief Procedure Warn-
start the sprayer, end recheck the connectionsfor
ing on page 2 or 10. Nowtightenthe connections,
leaks.
8. Removethesuctiontube from thepail.Disengage
the gun safety end trigger the guntoforcesolvent
from the hose.
Do not letthe pump run dry for
more than
30 seconds to avolddamaglng the
pump packlngslThenturn ON/OFFswitchtoOFF
and engagethe gun safety.
9. Unplugthepowersupply cord.Open the pressure
the sprayeragain.Unscrew the filter bowl and
relief velve and leave openuntil
you are readyto use
tight only.
reinstallthe clean screen. Reinstall the bowl, hand
10. If you have flushedwith mineral spirits and are go-
water followedby
a clean water flush. Then repeat
ing to use a water-basepaint, flush with soapy
Step
1.

TROUBLESHOOTING GUIDE
WARNING
Preeeure Rellef Procedure
To reduce the risk of serious bodily injury, including fluid injection, splashingfluid in the eyes or on the skin, or in-
jury from moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when
checking
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. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to the.side of a metal pail, and trigger the gun to relieve pressure.
6. Engage the gun safety latch.
7. Open the pressure relief valve.
8. Leave the pressure relief valve open until you are ready to spray again.
If you suspect that the spray tip or hose is completely clogged, or thatpressure has not been fully relieved efter
following tha steps
abova, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve
pressuregradually,
then loosen completely. Now clear the tip or hose.
TYPE OF PROBLEM
MOTOR WONT OPERATE
BasicFluidPressureProblems
Basic Mechanical Problems
-
Br
-
lsicElectricalProblems
WHAT TO CHECK
If check Is OK, go to next check
1. Check the pressure control knob setting. Thc
motor will not run if
it is at the minimum set
ting (fullycounterclockwise).
2. Check for a clogged spray tip. Refer to your
separate gun or tip instructionmanual.
1. Check for frozen or hardened paint in the
pump
(391 andlor pressure control bourdon
tube. Using a screwdriver, carefully try to
rotate fan
at back of motor by hand. See
page19.
2. Checkdisplacement pump connectingrod
pin
(201. It must be completely pushed into
should be firmly in groove of connecting
rod
connecting rod (3) and spring retainer (35)
See page 28.
3. Check for motor damaae. Remove drive
~~~ ~~
rotate fan by hand.
housingassembly
(2). gee page 29. Try to
1. Checksprayer circuit breaker 13091 button tc
be sure
it has not popped up.
2. Check electrical supply with volt meter.
Meter should read 105 to
125 VAC.
3. Check extension cord for visible damage.
cord outletto check.
Use
a volt meter or test lamp
at extension
4. Check sprayer power supply cord (311) for
visible damage such as broken insulationor
wires.
5.Check motor brush leads, terminals and
brushlength. Brush length should
be ll2”
minimum. Seepage 22.
A
it, due to exposure to low temperatures, by placing it in a
‘Thaw the sprayer if waterorwater-based paint hasfrozen inWhen re
warm area. Do not try to start the sprayer until it has thawed remove
tt
board anc
freezing, the pumpshouldoperate. Ifpainthardened (dried1
in
completely. If the bourdon tube was not damagedby the bare box.
the sprayer, the pump packingsandlor bare pressurecontrol
must be replaced.
See page 26 or manual 307-793.
WHAT TO DO
When check Is not OK refer to thls columr
I. Slowly increase the pressure settingto see if
the motor starts.
1. Relievepressure,refer to youiseperate gun
or tip instructionmanual for tipcleaning.
1. Thaw‘.Plug in sprayerand turn on. Slowly
increase pressure settingto see if motor
starts. If
it doesn’t, replace the displacement
pump packings
(see manual 307-793) andlor
replacethe bare pressure control box
1301)‘.
See page 26.
2. Push pin into place and secure with the
spring retainer.
2. Redace motor If) if fan won’t turn.
T
1
.
-
-
cing the barepressure control box (item 301).
circuit breaker,
ON/OFF switch, bridge, circuit
ectrical hardware and reinstall these parts in the
1.Depress circuit breaker button to reset. If
trical Short“, page-18.
circuit breaker continues to open, see “Elec-
2. Reset buildingcircuit breaker;replace
buildingfuse.
Try another electrical outlet.
3. Replaceextension cord.
4. Replace power supply cord. Seepage 23.
5. Tightenterminalscrews;replacebrushes.
sw page n.
Troubleshooting continued on nextpage.
307-758 13

YPE OF PROBLEM
IOTOR WON7 OPERATE
iagnosing circuit board in-
cator lamps. The normal
mdition is red lamp on,
ear lamp
on whenboard is
luing pump
to run.
dlow Pressure Relief Pro-
dura. Remove gunfrom
DW. Remove pressurecon-
01 cover and check for faulb
mdition ofcircuit board
mps.
ondition A bothlamps on;
ump won't operate and
lotor
is not running
:ondition
B
loth lamps off
WHAT TO CHECK
Ifcheck Is OK, to to next check
. Check leads from bridge (308) to motor to be
,sure theyare securely fastened and properly
mated.
!. Check G1 and 62 connectionsbetweencir-
cuit board
(23) and bridge (3081 for damage
or
loose terminals.
I. Check for loose motor brush lead connec-
tions and terminals. See page
22.
1. Check brushlengthwhich should be 1/2"
' minimum. See page 22.
the sarna rate on both sides of the motor.
NOTE
also that the brushes donot wear at
i. Check for broken or misaligned motor brush
springs. Rolled portion ofspring must rest
squarely on top of brush. See page
22.
i. Check motor brushes for binding in brush
holders. See page
22.
1. Check motor armaturecommutatorfor burn
spots, gouges and extreme roughness.
platesto check. See page
22.
Remove motor cover and brush inspection
mature tester (growler)or performspin test.
See page 19.
good bridge or performingbridge tat. See
page 20.
armature is determinedto be good. A bad
CAUTION: Do not performthis check until
armature will immediately burn out
a good
bridge.
1.Check circuit breaker
(3091 bunon to be sure
it has not popped up.
3. Check motor armature for shorts using ar-
3. Check bridge (308) by substitutingwith a
2. Check sprayer power supply cord (3111.
connect volt meter to these leads. Plug in
DisconnectTP6 female end TP1femaleand
sprayer. Meter should read 105 to 125 VAC.
Unplug sprayer. ReconnectTP1.
3. Check ONlOFF switch (3031. DisconnectTPi
and connectvolt meter to TP6 female and
TP2 male. Plug in sprayer and turn on. Metel
should read 105 to 125 VAC. Turn
off and
unolua sDraver. Reconnect TP2.
1. Check jumper wire (306). Disconnect TP3
and
conneci volt meter to TP6 female and
__ ~~ ~. . ~~ ~~
TP3 female. Plug insprayer and turn on.
Meter should read 105 to
126 VAC. Turn off
and unplug sprayer. Reconnect TP3.
5.Check circuit breaker
(309). Connect volt
meter to TP6 female and TP4. Plug in
sprayer and turn on. Meter should read105
to 125VAC. Turn
off and unplug sprayer.
WHAT TO DO
When check Is not OK refer tothis columl
Replaceany
loose terminals and wimp to
straight and firmly connectedto mating part
leads.
Be sure male terminal blades are
Clean circuitboard male terminals. Replace
loose or damaged terminals. Securely recon-
nect leads.
Tightenterminal
screws. Replace brushes if
leads are damaged.
See page 22.
Replace brushes. See page 22.
Replace springif broken. Realign springwitt
brush. See page
22.
Clean brushholders. Remove carbonwith
small cleaning brush. Align brush leadwith
slot in brush holderto assure free vertical
brushmovement.
Remove motor and have motor shop resur-
face commutator if possible. See page
30.
Replace motor. See page 30.
Replace bridge. See page 24..
Depress circuit breaker button toreset. If cil
trical Short", page 16.
cult breaker continues to open, see "Elec-
Replace power supply cord. See page
23.
Replace ONlOFF switch. See page 21.
Replace jumper wire. See page 25.
Replace circuit breaker. See page
24.
(Continued)
(Continued)
Troubleshooting continued onnextpage

tndition B
ontinued)
Dndition
C
3d lamp on, clear lamp off
nplugspreverl
CCheckmotor thermal cutout switch.
~~
female. Plug in arid turn onsprayer. Meter
Connect volt meter to TP6 female and
TP9
should read 106 to 125 VAC. Turn off end
unplugsprayer.
7. Check microswitch (302). Reconnect TP6
connectors. Connect volt meter v) TP16
male and TP4. Meter should read 50-125
VAC.
8. Visuallyinspect microswitch 1302 button.
M{uatmant
stud (QI should mt dapress tha
microswitchbuttonwhen fluid pressure is
with small screwdriver; an audible click in-
zero. Manually check by depressing button
dicates microswitch is in normal position.
9. Check microswitch 13021 continuity withohm
should read zero ohms with no fluidpressure
meter. Be
sure sprayer is unplugged1 Meter
in the sprayer.
10.Check all terminalsfor damage or loose
fa.
Reconnect TP6 connectors.
11.Check circuit board
(23) by substitutingwith
a
spzd board. See page 25.
1.Check circuit board
I231 by removingfrom
25 for removal procedure.
box without disconnecting wires;
see page
WARNING: Removingthe circuit board
while
still wired over-ridesthe optical detac-
tor which could causa the sprayer to over-
pressurize,
if the microswitchdoes not func-
tion properly. Turn thesprayer
on ONLY
long enough to check lamp condition, then
shut
off immediately.
WARNING: To reduce the risk of electric
shock, handle board by edgesonly1
Do not
with the board1
allow any metal objectsto coma in contact
Plug in and turn on sprayer. Clear lamp
shouldbe on now
- removing the circuit
off end unplug sprayer.
board over-ridesthe optical detector. Turn
2. Check bourdontube flag and detector posi-
tion. Reinstall circuit board (sea page
25).
Turn pressure setting to maximum; flag
should extend less then half way into optical
detector slot from thebottom.
TYPE OF PROBLEM
WHAT TO CHECK
If check Is OK, 80 to next check
WHAT TO DO
When check Is not OK referto this column
-
-
cc
(C
6
7
0
IC
I
1
1
-
" "
-
CI
Rt
U,
1
I
-
L -
When replacingthebarepressurecontrol box 13011,remove the circuitbreaker.
bridge,
circuit board and electrical hardware end reinstall in the new bare box.
~~
VIEW OF OPTICAL DETECTOR AND FLAG
i. Allow motor to mol. Correct cause of over-
heating. If switch remains open after motor
cools, checkcontinuitybetweenTP9 female
and TPlO with ohmmeter. If open, replace
motor.
'. Clean microswitchmale terminals. Replace
loose or damaged terminals. Securely recon-
nect leads.
I. Microswitch is faulty. Return sprayer for
capair.
I. Micmswitchis faulty. Return sprayer for
repair.
lO.Replace damaged terminals and reconnect
securely.
l1.Replace circuit board.
See page 25.
i . Replace circuit board. See page 25.
2. Calibrate pressurecontrol to see if that cor-
rects problem.
See page 27.
If not, replace bare pressure control box
(301P. See page 26.
Troubleshooting continuedon nextpege

YPE OF PROBLEM
40 OUTPUT
Aotor runs and pump stroke
~~ __ ~~~ ~~~~ __~
WHAT TO CHECK
If check Is OK. go to next check
1. Check,for worn spray tip.
2. Check to see that pump does not continue
to stroke when gun trigger is released. Plug
Trigger gun momentarily, then release and
in and turn on sprayer. Prime with paint.
engage safely latch. Relieve pressure, turn
off and unplug sprayer.
3.Check electrical supply with volt meter.
Meter should read 105 to
125 VAC.
4.Check extension cord size and length: must
be
at least 12 gauge wire and no longer than
150
h 115.2 m).
5.CheckG1and 62leads from bridge
(308) to
circuit board
I231 for damage or loose wires
or connectors. Refer to page 25.
6. Checkstallpressure.Refer to Calibration
7. Checkbridge 13081 + and - leadsand ter-
minals to motor. Inspectwiring insulation
and terminals for signs
of overheating. See
page 20.
Procedure on page 27.
8. Check for loose motor brushleads endter-
minals. See page
22.
9. Check for worn motor brushes whichshould
be112" minimum. See page
22.
10.Check for broken and misaligned motor
brush springs. Rolled portion of spring must
rmt squarely on top of brush.
11.Check motorbrushes for binding
in brush
holders.
See page 22.
12.Check circuit board I231 by substitutingwith
a good circuitboard. See page 25.
13.Check motor armature for shorts by using an
armature tester (growler1 or performspin
.test. Seepage 20.
14.Check bridge (3081 by substituting with a
good bridge or by performingthe bridge
test. Sae page19.
CAUTION: Do not perform thischeck until
: armature is determinedto be good. A bad
armature will immediatelyburn out
a good
bridge.
1.Check paintsupply.
2. Check for clogged intakestrainer. See page
29.
3.Check for loose suction tube or fittings. See
page
29.
WHAT TO DO
When check la not OK refer to thla column
1. Follow Pressure Relief Procedure Warn-
~~
or tip manual.
Ingthen replace tip.
See your separate gun
2. Selvicepump. See manual 307-793,
3. Reset building circuit breaker;replace
another outlet.
buildingfuse. Repair electrical outlet or try
4. Replacewith a correct, grounded extension
cord.
5. Clean circuit boardmale terminals. Replace
loose or defectivelead terminals. Securely
reconnectlead terminals to board.
6. Calibrate pressure control. Seepage 27.
7. Be sure male terminal blades are centered
and firmly connectedto female terminals.
Replaceany
loose terminalor damaged wir-
ing. Securely reconnect wiresto bridge.
8. Tightenterminalscrews. Replace brushes if
leads are damaged. See page
22.
9. Replacebrushes.Seepage 22.
10.Replace spring if broken. Realign spring with
brush. See page
22.
11.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holderto assure free ver-
tical brush movement.
12.Replacecircuit board. See page
25.
13.Replace motor. See page 30.
14.Replace bridge. See page 24.
1. Refillandreprime pump.
2. Remove andclean, then reinstall.
3. Tighten; use thread Sealant or sealing tape
on threads if necessary.
Troubleshooting continuedon nextpege

(Continued)
TYPE OF PROBLEM WHAT TO CHECK
If check Is OK, go to next check
NO OUTPUT I 4. Check to see if intake valve bail and Piston 4,
Motor runs but pump does
not stroke
EXCESSIVE PRESSURE
FLUCTUATIONS
Spray patternvariations.
MOTOR IS HOT e
RUNS INTERMITTENTLY
307-793.
ball are seating property. See manuai
, Check for leaking around throat packing nut
which may indicateworn or damaged pack-
!ngs.See manual 307-793.
, Check &lacement pumpconnectingrod
pin. Seepage
28.
, Check connectingrod assembly for damage.
See page
28.
, Be sure crank indrive housingrotates; plug
Turn
off and unplug sprayer. See page 29.
in sprayer and turn on momentarilyto check.
. Be sure both 01and 62 leads from bridge
(3081 to circuitboard (23) are firmly
connected. See pege
25.
procedure on page 27.
. Check bourdontube flag and detector posi-
tion. Turn pressure settingto maximum; flag
slot of circuit board.
should not drag
or bind in optical detector
. Check stall pressure.Refer to Calibration
,-CIRCUIT BOARD
OPTICAL
DETECTOR
I I" FLAa
VIEW OF OPTICAL DETECTOR AND FLAG
.. Check circuit board (23) by substituting with
a good board. See page 25. f
. Check LOW OUTPUT section on page 16.
. Check to see ifsprayer has been operating a
high pressure with small tips, which cauw
low motor RPM and results in excessive hea
buildup.
!. Check to see if ambient temperature where
sprayer is located is morethan
WF (32OC)
or
if sprayer is located in direct sun.
I. Check to see ifsprayer has been left in a
stalled condition (sprayer turned on,
pressurized, but notoperating)for long
periods of time.
Wen replacing the bare pressure control box *m, remove the circult board, brldge.
circuit board, and electrical-hardware and reinstall
in the new bare box.
, Remove intake vab end dean. Check ba\b
and seats for nlcks; replace
if necessaty. Sea
manual 307-793.
, Replacepackings.Seemanual 307-793. Also
check pistonvalve nest for hardened paint 01
nicksandreplaceifnacessary.
Replace pin if missing. Be sure reteiner
spring isfully
in groove all aroundconnect-
ing rod.
See 28.
, Replaceconnecting rod assembly.Seepage
28.
, Check drive housingassembly for damage
and replace
if necessary. See page 29.
, Rewnnectsecurely. See page 24 and 25.
, Calibrate pressure control. See page 27.
, Carehlly bend flag into alignmentwith
detector slot to
see if that correctsproblem.
If not, replace bare pressurecontrol
assembly (301)'. Calibrate pressure control
after reassemblv.
. Replace circuit board. See page 26.
. Decreasepressure m'ng or increesa tip
size.
:. Movesprayer to shaded, cooler area if
possible.
I. Tum off sprayer whenever you stop spraying
for
a while end relieve fluid pressure.
Troublashooting continuedonnexf page

TYPE OF PROBLEM
ELECTRICALSHORT
Buildingcircuit breaker opens
as
noon as sprayer switch is
turned
on.
Any short in any part of ths
CAUTION
motor power circuit, which i
of the bridge, will cause ths
connected to theoutput sid
bridge to burn out immediate
ly. Correctlydiagnose ant
repairall shorts before check
ing and replacing bridge
es
soon es sprayer is plugged
Buildingcircuit breaker opens
into outletand sprayer is
NO
turned on.
Sprayer circuit breaker opens
after sprayer operates for
on1
5 to 10 minutes.
L
WHAT TO CHECK
If check Is OK, go to next check1
I. Check all electrical wiring for damaged in-
damage. Be sure to check wires between
suletion, and
all terminals for loose fit or
pressurecontrol and motor which are encas-
ed inconduit (22). See page 29.
1. Check for missinginspectionplategasket
(see pege 221, bent terminal forks or other
metalto metalcontact points whichcould
cause
a short.
3. Check motor armaturefor shorts by using ar
armature tester (growler)or performspin
test.
See page19. Inspectwindingsfor
burns.
4. Check bridge (308) by substituting with a
good bridge or by performingbridge test.
See page 20: '
CAUTION: Do not performthis check until
armature is determinedto be good. A bad
armature will immediatelybum out
e good
bridge.
1. Check'BasicElectricalProblems' on page 14
2. Check ONlOFF switch (303) Seepage 23.
Be sura the sprayer is unplugged1Disconnec
wires from switchand check switch with
ohm meter. The ohm meter should read in-
with
the switch ON.
finity with the ONlOFF switch OFF, endzert
CAUTION: A short inthe motor circuit wi
burnthe bridgeout immediately.which in tur
usually causesthe
ONlOFF switchto fail in th
closedmode.
1. Check electrical supply with volt meter.
Meter should read 105to 125 VAC.
2.Check tightness of pump packing nut. Over-
tightening nut tightens packingson rod,
restrictspump action, and damages
packings. See page 28.
3. Checkstallpressure.Remove the plug from
the top of the fluidfilter, and installa
5Mx)
psi (350 bar)fluid-filled pressure gauge. See
pege
27. Plug inand turn on sprayer. Slowli
increase pressure setting
to maximum. Puml
shouldstall
at 2550-2750 psi (178-195 bar).
Turn
off and unplug sprayer.
system, reset circuit breaker button.
4. After determiningthat there is no short in
WHAT TO DO
When check la not OK refer to this column
1. Repair or replace any damaged wiring or ter-
minals. Securely reconnectall wires.
2. Correct faulty conditions.
3. Replace motor. See page 30.
1. Replacebridge. See pege 24.
2. Replace ONlOFF switch. Seepege 23.
1. If voltageistoo high, do not operate sprayer
until corrected.
2.
Loosen packing nut. Check for leaking
eroundthroat. Replace pump packings,
if
necessary. See manual 307-793.
3. Calibrate pressure control. See page27.
4. If circuit breaker continuesto open (button
pops up), replace the circuit breaker.
See
page 24.
~~
Troubleshootingcontinuedonnextpege
~~ ~ ~~~~ ~

~ ~~~~~~~~~~~~~ ~~~~~~~~~~ ~~
SPIN TEST
WARNING
Beforedoingthis procedure, follow the Pressure
the risk of
a fluid injection injury,injuryfrom mov-
Rellef Procedure Warnlngonpage
13 toreduce
trical continuity.
For checkingarmature, motorwinding and brushelec-
setup
cribed in ”DriveHousing Replacement”,Steps 1-6,
Remove the drivehousing from the sprayer as des-
page
29.
motor cover, the fan cover (F), end the inspection
Remove the pressure control coverand
screws, the
covers
(J). SeeFig 10.
Disconnectthe two leads from the motorto the bridge
(308). see fig 11.
Armature Short CircuitTest
shorts, the motor will coast two or threerevolutions
Quickly turn the motor
fan by hand. /f there ere no
before comingto e complete stop.
If the motordoes notspin freely and resists rotation,the
armature is shorted and the motor
must bereplaced;
See page
30.
Armature, Brushes, and MotorWlrlng Open
Clrcult Test IContInulty)
Connect the
two blackmotor leadstogetherwith a test
lead.
Turn the motor fan by hand
at about two revolutions
per second.
If there is uneven or no turning resistance,check the
following:.
a) brokenbrush springs; b) brokenbrush
leads; c) loose brush terminal screws;dlworn brushes;
e)broken motor leads; fl loose motor leadterminals.
Repair parts
as needed. See page 22.
the motor. Seepage 30.
If there is still unevenor no turning resistance, replace
ng 10
Flg 11

BRIDGE TEST
performthistest todetermineif the bridge is functional.
Remove the bridge from the pressure control box and
See BridgeRectlfier Replacement, page 24. Use a
continuity tester,such as multi-meter set on the X1
ohmsscale ( 0 1.
the bridge failseven one.test, it
must bereplaced.
Eight individualchecks, or tests, must be performed. If
Fig
12 showsthe positionofthe wires onthebridge. Us-
ingthe chartat the right, connectthe meter wiresas in-
dicated bythe black dots for each test, then check the
continuity.
In
Tests 1, 2 and 3, there should be NO continuity.
In
Tests 4,5 and 8, connect the + and - meter wiresas
indicated, check continuity, thenswitchthe meter wire
get
NO continuity one way, and YES continuity the
connectionsandcheck continuity again.Youshould
other way.
In
Tests 7 and 8. connect the meter wires as indicated
bythe black dots.Touchthe indicated
"G" wire toone
meter wire, and then to the other. You should get
NO
continuity one way, and YES continuitythe other way.
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