Graco Series B Operation manual

INSTRUCTIONS-PARTS LIST
'- ~
Thismanual contains important
warnings and information.
READ AND RETAIN
FOR REFERENCE
ORACO
Rev. G
Supersedes C
and PCN D & E (Rev F cancelled)
ELECTRIC, 230 VAC
ULTRAs 500
Airless Paint Sprayer
195 bar Maximum Working Pressure
Model 231 -079, Series B
Complete sprayer with upright cart, hose, gun,
RAC lV@J, Dripless" Tip Guard and SwitchTip".
Table of Contents
setup ........................ 5
Troubleshooting 11
Operation 6
Displacement Pump Repair 33
Repair ...................... 19
Displacement Pump Parts 36
Accessories ................. 37
Parts - Upright Sprayer ....... 38
Parts - Pressure Control ...... 40
E2% 8ata .44
ia ram 41
Dimensions 44
Warranty .................... 44
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NOTE This is an example of the DANGER label on your sprayer.
This label
is available in other languages, free of charge.
See PaQe
37 to order.
Use outdoors orinextremelywell
hoses. containers and objects be
as. Ground equlpment, Never stop leaks with any part dthe body.
oving parts.Avoid accident& triggering of
atch when not spraying.
d accidental sMn injection. seek immediate
follow this warning can resun in amputation or serious
GRACO INC. RO. BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1988, GRACO INC.

FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid through
yourskinandintoyourbodyandcauseextremelyseriousbodily
splashedintotheeyesorontheskincancauseseriousdamage.
injury, including the need for amputation. Also, fluid injected or
Never point the spray gun at anyone or at any part of the body.
Never put hand or fingers over the spray tip. Nevertry to "blow
back" paint;sthis is NOT an air spray system.
Alwayshavethetipguardinplaceonthespraygunwhenspray-
ing.
Always follow the Pressure Rellef Procedure, below, before
cleaning or removing the spray tip or servicing any system
equipment.
Never try to stop or deflect leaks with your. hand or body.
each use.
Besureequipmentsafetydevicesareoperatingproperlybefore
Medical Alert--Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
CUT. Tell the doctor exactly what fluid was injected.
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
Important to treat the Injury surglcally ES soon as pOSElble.
Note to Physlclam Injection in theskin isatraumaticinjury. It Is
Donotdelaytreatmenttoresearchtoxicity.Toxicityisaconcern
withsomeexoticcoatingsinjecteddirectlyintothebloodstream.
Consultation with aplasticsurgeon or reconstructive hand sur-
geon may be advisable.
Spray Gun Safety Devices
each use. Do not remove or modify any part of the gun; this can
Be sure all gun safev devices are operating properly before
cause a malfunction and resuil in serious bodily injury.
Safety Latch
Wheneveryoustopspraying,evenforamoment,alwayssetthe
gunsafetylatchinthedosedor'safe"position,makingthegun
triggering of the gun.
inoperative.Failuretosetthesafetylatchcanresultinaccidental
Diffuser
Thegundiifuserbreaksupsprayandreducestheriskoffluidin-
jection when the tip is not installed. Check diffuser operation
regularly. Follow the Pressure Rellef Procedure, below, then
remove the spray tip. Aim the gun into a metal pail, holding the
the gun. If the fluid emitted is not dflused into an irregular
gunfirmlytothepail.Usingthelowestpossiblepressure,trigger
stream, replace me diffuser immediately.
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. The tip guard ale- you to the fluid injection hazard
and helps reduce, but does not prevent, the risk of accidentally
tip.
placing your fingers or any part of your body close to the spray
Trigger Guard
Aiwayshavethetriggerguardinplaceonthegunwhenspraying
to reduce the risk of accidentally triggering the gun if it is
dropped or bumped.
Spray Tip Safety
Useextremecautionwhencleaningorchangingspraytips.1fthe
spray tip clogs while spraying, engagethe gun safety latch irn-
mediately.ALWAYSfollowthe Pressure Rellef Procedureand
then remove the spray tip to clean it.
fully reliwed and the gun safety latch is engaged.
NEVER wipe off build-up around the spray tip until pressure is
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid in-
jection,splashingfluidorsolventintheeyesorontheskin,or
injury from moving parts orelectricshock, alwaysfollowthis
procedurewheneveryoushutoffthesprayer,whenchecking
or servicing any part of the spray system, when installing,
cleaning or changing spray tips, and whenever you stop
spraying.
2. Turn the ON/OFF switch to OFF.
1. Engage the gun safety latch.
3. Unplug the sprayer.
4. Disengage the gun safely latch. Hold a metal part ofthe
gun flrmly to the side of a grounded metal pail, and trig
ger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressuredrainvalve, havingacontainerready
to catch the drainage. Leavethevalve open until you are
If you suspect that the spray tip or hose is completely
ready to spray again.
clogged,orthatpressurehasnotbeenfullyrelievedafterfol-
lowing the steps above, VERY SLOWLY loosen the tip guard
retaining nut or hose end coupling and relieve pressure
gradually, then loosen completely. Now clearthetip or hose,

MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers or other body fore checking or servicing any part of the sprayer, to prevent it
parts. Keep clear of moving parts when starting or operatingthe from starting accidentally.
sprayer. Follow the Pressure Rellef Procedure on page 2 be-
EQUIPMENT MISUSE HAZARD
General Safety System Pressure
Any misuse of the spray equipment or accessories, such as This sprayer can develop 195 bar Maximum Working Pressure.
overpresurizing, modtying parts, using incompatible chemi-
Besurethatallsprayequipmentandaccessoriesusedarerated
calsandfluids,orusingwornordamagedparts,cancausethem
towithstandthispressure.Donotexceedthemaximumworking
toruptureandresultinfluidinjection,splashingintheeyesoron
Pressureof any comPonentorac~ssoV used in the system.
theskin,orotherserious bodilyinjury,orfire,explosionorprop-
Fluid and Solvent Compatibility
erly damage.
Neveralterormodifyanypartofthisequipment; doingsocould -, your chemical supplierto compatibility,
cause it to malfunction.
Allchemicalsusedinthesprayermustbechemicallycompatible
with the welted parts shown in the TECHNICAL DATA on page
Checkallsprayequipmentregularlyand repairorreplaceworn logenated hydrocarbon solvents or fluids containing such sol-
Do not use 1,1,1 -trichloroethane, methylene chloride, other ha-
or damaged parts immediately. vents in this equipment, which contains aluminum andlor zinc
Alwayswearprotectiveeyewear,gloves,clothingandrespirator the possibility of explosion, which could cause death, serious
parts. Such usecould resuit in aseriouschemical reaction, with
as recommended by the Ruid and solvent manufacturer. bodily injury andlor substantial properly damage.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the Handle and route hoses carefully.
Do not pull on hoses to move
hose develops a leak, split or rupture due to any kind of wear, equipment. Keep the hoses clear of moving parts and hot sur-
damageor misuse, the high pressurespray emitledfrom itcan
faces.DonotuseRuidsorsolventswhicharenotcompatiblewith
cause a fluid injection injury or other serious bodily injury or
theinnertubeandcoverofthehose.DonotexposeGraco hose
properly damage. to temperatures above 82" Cor below -40" C.
All fluid hoses must have sprlng guards on both endsl The
sDrina auards helo orotect the hose from kinks or bends at or Hose Grounding Continuity
hose for cuts, leaks, abrasion, bulging cover, or damage or
' limits. Use a iesistance meter in the appropriate range for your
movementofthehosecouplings. Ifanyofthesecondtionsexist. hose to checkthe resistance,
If the resistance exceeds the rec-
replace the hose immediately. Do not try to recouple high pres- ommended limits, replace
it immediately. An ungrounded or
sure hose or mend it with tape or any other device. A repaired poorly grounded hose can make your system hazardous,
Also
hose cannot contain the high pressure fluid. read
FIRE OR EXPLOSION HAZARD.
FIRE OR EXPLOSION HAZARD
Staticelectricityiscreatedbytheflowoffluidthroughthepump
and hose. If every part of the spray equipment is not properly
grounded, sparking may occur, and the system may become
hazardous. Sparking may also occur when plugging in or un-
plugging a power supply cord or using a gasoline engine.
Sparks can ignite fumes from solvents and the fluid being
sprayed, dust particles and other flammable substances,
whether youarespraying indoors oroutdoors, andcan causea
fireorexplosionandseriousbodilyinjuryandpropertydamage.
Ifyouexperienceanystaticsparkingorevenaslightshockwhile
entiresystemforpropeigrounding.Donotusethesystemagain
using this equipment, Stop Spraylng Immedlately. Check the
until the problem has been identified and corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and all
yourlocalelectricalcodefordetailedgroundinginstNctionsfor
othersprayequipmentusedorlocatedinthesprayarea.Check
your area and type of equipment. Be sure to ground all of this
spray equipment:
1. Sprayer: connect a ground wire and clamp (supplied) to a
true earth ground.
2. Fluid hoses: use only rounded hoses with a maximum of
150 m combined hose B ength toensuregrounding continu-
ilv. See Hose Groundlna Contlnultv.
-
3. Spraygun:obtaingroundingthroughconnectiontoaprop-
<
erly grounded fluid hose and sprayer.
4. Object being sprayed: according lo local code.
6. All solvent pails used when flushing, according to local
5. Fluid supply container: according to local code.
code. Use only metal pails, which are conductive. Do not
placethepailonanonconductivesurface,suchaspaperor
cardboard, which interrupts the grounding continuity.
7. To maintain groundingcontinuitywhenflushing orrelieving
pfessure, always hold a metal part of the gun firmly lo the
slde of a grounded metal pail, then trigger the gun.
Flushing Safety
ReducetheriskofRuidinjectioninjury,staticsparking,orspiash-
ofthis manual. Follow the Pressure Rellef Procedure on page
ingbyfollowingthefiushingproceduregivenonpagegandlo
the gun firmly to the side of a grounded metal pail and use the
2,andremovethespraytipbeforeflushing.Holdametalpartof
lowest possible fluid pressure during flushing.
IMPORTANT
particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 - should be consulted.
United States Government Safety standards have been
adopted under the Occupational Safety and Health Act. These standards -
307-889 3
..
.,

Setup
NOTE When tightening fittings at the pressure con-
trol, hold one wrench firmly on the hex
of the pressure
control fitting to keep it from rotating.
Use another
wrench
to tighten the mating fitting.
1. Connect the hoses (6263) and gun (61). See Fig.
1. Don’t use thread sealant on the hose and gun
connections. Don’t install the spray tip yet!
WARNING
sure the hoses are electrically conductive, that the
If you supply your own hoses and.spray gun, be
at least’795
bar Working Pressure. This is to re-
gun has a tip guard, and that each part is rated for
duce the risk of serious bodily injury caused by
static sparking, fluid injection or over-pressuriza-
tion and rupture of the hose or gun.
I 1
To avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
1. Always use nylon spray hose at least 15.2 m
2. Never use a wire braid hose as it is too rigid to
act
as a pulsation dampener.
3. Never install any shutoff device between the
filter and the main hose. See Fig.
1.
4. Always use the main filter outlet for one gun
operation. Never plug this outlet.
2. Fill the packing nut/wet-cup (216) 1/3 full with
Graco Throat Seal Liquid
(TSL), supplied. See
Fig.
1.
3. Check the electrical setvice.
a. Be sure the electrical service
is properly rated
for your sprayer and that the outlet you use is
properly grounded.
b. Have a licensed electrician attach an appro-
priate plug to the power supply cord.
A Do not install any shutoff device here.
302.
Fig. 1
62 E358
c. Use an extension cord which has 3 wires of a
minimum
1.5 mm size, and a maximum of 45
m long. Longer lengths may affect sprayer
performance.
4. Be sure the ON/OFF switch (302) is OFF. Then
least
6 m away from the spray
area.
plug
the cord into a
grounded electrical outlet at
WARNING
the risk of fire or explosion which can result in seri-
Proper electrical grounding is essential to reduce
the warning section
FIRE OR EXPLOSION HAZ-
ous bodily injury and property damage. Refer to
ARD on page 3 for more detailed grounding in-
structions.
4 307-889

Setup
5: Flush the pump to remove the lightweight oil
6. Prepare the paint according to the manufacturer’s
which was lefl in to protect pump parts after fac-
tory testing.
recommendations.
a.
b.
C.
Before using water-base paint, flush with min-
era1 spirits followed by soapy water, and then
a clean water flush.
Before using oil-base paint, flush with mineral
spirits only.
C.
See FLUSHING on pages 9 and 10 for the
flushing procedure.
a.
b.
Remove any skin that may have formed.
Stir the paint to mix pigments.
Strain the paint through
a fine nylon mesh
bag (available at
most paint dealers) to re-
move particles that could clog the filter or
spray tip. This is probably the most important
step toward trouble-ree spray painting.
307-889 5

Operation
WARNING
To reduce the risk of serious bodily injury, includ-
ing fluid injection or splashing in the eyes or on
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure Warning on page
ting down the sprayer.
2 before checking, adjusting, cleaning and shut-
Startup
Use this procedure each time you start the sprayer to
you start
It safely.
help ensure the sprayer
is ready to operate and that
NOTE For the first time startup, be sure to flush the
sprayer first. See page
9 and 10 for FLUSHING.
1. Don't instail the spray tip yet!
2. Put the suction tube into the paint container.
3. Lower the pressure setting by turning the pres-
sure adjusting knob all the way counterclockwise.
See Fig. 3.
Fig.
2 m359
6 307-889
4. Disengage the gun safety latch. See Fig. 4.
..
5. To prime the pump, open the pressure drain
valve. Turn the ON/OFF switch to ON, and slowly
increase the pressure setting until the sprayer
starts. When fluid
is flowing freely, hold a metal
grounded metal waste container. See Fig.
2.
part of the
gun firmly against and aimed into a
Trigger the gun to prime the hose and gun. Keep
the gun triggered until ail air is forced
out of the
system and the paint flows freelyfrom the gun.
Release the trigger and engage the gun safety
latch.
6. Check all fluid connections for leaks. If any leaks
Warning on page
2 before tightening connec-
are found, follow the Pressure Relief Procedure
tions.
7. Install the spray tip and tip guard. You must use
a tip guard on the gun. Be sure the gun safety
latch
is engaged. See Fig. 4. Install the spray tip.
manual 307-848, supplied with the gun, for in-
If you are using the RAC IV tip guard, refer to
tip guard, refer to the instructions supplied with it.
stallation instructions.
If you are using some other
A when flushing
Maintainfirm metal-t&metaicontact
'A
Fig. 3 0143

Operation
8. Adjust the spray pattern.
a. Increase the pressure setting by turning the
pressure adjusting knob clockwise. Increase
pressure just until spray from the gun
is com-
pletely atomized.
To avoid excessive over-
spray and fogging, 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 coverage is needed, use a larger tip
rather than increasing the pressure.
c. Test the spray pattern.
To adjust the direction
of the spray pattern, engage the gun safety
the tip guard horizontally for a horizontal pat-
latch and loosen the retaining nut. Position
tern or vertically for a vertical pattern. Then
tighten the retaining nut.
Cleaning a Clogged Tip
WARNING
To reduce the risk of serious bodily injury from
fluid injection:
L
NEVER. operate the spray gun with the tip
guard removed.
DO NOT hold your hand, body, or a rag in front
of the spray tip when cleaning or checking a
clogged tip. Always point the gun toward the
ground or into a waste container when check-
ing to
see if the tip is clear.
DO NOT try to "blow back" paint; this is NOT
an air spray sprayer.
1. Clean the front of the tip frequently during the
day's operation. First, follow the Pressure Relief
Procedure Warning on page
2. Then use a
solvent-soaked brush to wipe away fluid build-
up, which helps prevent tip clogging.
2. If the spray tip does clog, release the gun trigger,
engage the gun safety latch, and rotate the RAC
IV handle 180". See Fig. 4.
3. Disengage the gun safety latch and trigger the
gun into a waste container. Engage the gun
safety latch again.
4. Return the handle to the original position, disen-
gage the gun safety latch, and resume spraying.
5. lf the tlp Is still clogged, engage the gun safety
the pressure drain valve
to relieve pressure. Clean
latch, shutoff and unplug the sprayer, and open
the spray tip
as shown in manual 307-848, sup-
plied with
the RAC W.
A
RAC IV handle shown
in spraying position.
Gun salety latch
A shown engaged.
Fig. 4 0137
307-889 7

Maintenance
r
WARNING
To reduce the risk of serious bodily injury, includ-
the skin, or injury from moving parts, always follow
ing fluid injection or splashing in the eyes or on
the Pressure
Relief Procedure Warning on page
2 before checking, adjusting, cleaning and shut-
ting down the sprayer.
~~~
1. Check the packing nutlwet-cup daily. First follow
the Pressure Relief Procedure Warning on page
2. Be sure the wet-cup is 113 full of TSL.at all
times to help prevent fluid buildup on the piston
rod and premature wear of packings. The packing
nut should be tight enough
to stop leakage, but
no tighter. Over tightening may cause binding and
excessive packing wear.
Use a round punch or
brass rod and light hammer to'adjust the nut.
See
Fig. 5.
2. Clean the fluid filter often and whenever the
sprayer is stored. First follow the Pressure Relief
307-273, supplied, for the cleaning procedure.
Procedure Warning on page
2. Refer to manual
3. Lubricate the bearing housing after every 100
hours of operation. Fill the connecting rod cavity
with
SAE No. 10 non-detergent oil. See Fig. 6.
4. Flush the sprayer at the end of each work day
and
fill it with mineral spirits to help prevent pump
corrosion'and freezing. See FLUSHING on page
10.
r
CAUTION
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump or pressure
control in cold weather, never leave water or any
type of paint in the sprayer when it is not in
use.
Freezing can seriously damage the sprayer or re-
sult in a loss of pressure or stalling.
5. For very short shutoff periods, leave the suction
tube
in the paint, follow the Pressure Relief Pro-
cedure Warning on page
2, and clean the spray
tip.
6. Coil the hose and hang it on the hose rack when
storing
it, even for ovemight, to help protect the
hose from kinking, abrasion, coupling damage,
etc.
IWARNlNGl
Refer to the warning section HOSE SAFETY on
page
3 for Information on the hazard of using
damaged hoses.
A Turn pacWng nul in direction of arrow to lighten.
Fig. 5
I I
KO1
Fill with SAE No. 10
Q nondetergent oil
Fig. 6 02w

MOTE Several flushes are often required to thor- "Use this category for flushing a brand new sprayer
oughly clean the system and prepare it for the next
fluid
to be sprayed, or to store the sprayer. Use this
and flushing after storage.
chati to determine the required flushes for the fluids
you are using, and then follow the procedure below
for flushing.
Prepare to use the sprayer
System has
sprayed.
this fluid in it: Flushing order:
Next fluid
to be Before you spray or store
sprayer:
Flush
1 I Flush 2 I Flush 3
*Oil-based
Oil-based
new color
solvent or paint
Prime with oil-based paint none
none
Mineral spirits
Oil-based paint
-
solvent or paint paint
Water-based
.
Mineral spirits Warm soapy
water
based paint
Prime with oil Mineral spirits
Clean water
Warm soapy
Oil-based paint
Water or water-
Prime with water none
Clean water
Warm soapy
water
paint
- new color
based paint
Water-based Water or water-
Prime with water-based Clean water
water paint
Prepare the sprayer
for storage
Oil-based
Leave drain valve open
water
storage
based paint Relieve pressure,
Mineral spirits
Clean water
Warm soapy Prepare for Water or water-
Leave drain valve open
Relieve pressure,
storage
solvent or paint
none
none Mineral spirits
Prepare for
307-889 9

Flushing
CAUTION -1
NEVER allow water to freeze in the pressure
control. Doing
so prevents the sprayer from being
started and causes serious damage to the pres-
sure control. Pump the water out with mineral
spirits.
WARNING
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
he side
of a grounded metal pail.
he gun
and hold a metal part of the gun firmly to
1
0143 I
1. Follow the illustrated Pressure Relief Procedure
on page
2. Engage the gun safety latch.
2. Turn the pressure adjusting knob fully counter-
clockwise
to the minimum pressure.
3. Remove the spray tip from the gun. Remove the
filter bowl
(A) and screen (B); leave the filter
support
(C) in place. Clean the screen separately
and install the bowl without the screen
to flush it.
See Fig 7.
4. Put the suction tube into e grounded metal pall .
with 2 liters of compatible solvent.
5. Start the sprayer. See Steps 1 to 5 on page 6. To
save the fluid still in the sprayer, trigger the gun
into another container until the next fluid appears,
then trigger the gun back into the fluid you are
pumping. Circulate the flushing fluid a couple of
minutes
to thoroughly clean the system.
6. Do not run the pump dry for more than 30
seconds to avoid damaging the pum packings!
7. Follow the illustrated Pressure Relief Procedure
on page
2. Engage the gun safety latch.
8. Unscrew the filter bowl and reinstall the clean
screen. Install the bowl and hand tighten.
B
C
Fig. 7 mJM
10 307-889

Troubleshooting.
I w
ARNING
To reduce the risk of serious bodily injury, includ-
ing fluid injection or splashing in the eyes or on
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure Warning on page
ting down the sprayer.
2 before checking, adjusting, cleaning and shut-
-
Motor Won't Operate
Type of Problem
Basic fluid pressure
problems
Basic mechanical problems
I
I
Check everything in the gL
the sprayer.
What to Check
If check is OK, go to the next check
1. Check the pressure control knob setting.
Themotorwillnotrunifitisattheminimum
2. Check for a clogged spray tip. Refer to the
setting (fully counterclockwise).
separate gun or tip instruction manual.
Check for frozen or hardened paint in the
tube. arefully W to rotate fan at back of
pump 19)andlorpressurecontroIbourdon
~ ~~~~ ~ ~ ~~ ~
Li
motor by had. See page 17.
2. Checkdisplacementpumpconnectin rod
pin (20). It must be completely pushe8into
should be firm1 in groove of connecting
connectingrod(9)andretainingspnng(Zl)
rod. See page i5.
3. Check for motor damage. Remove drive
housing assembly (6). See page 28. Try to
rotate fan bv hand.
1. Checkelectricalsuppl withvokmeter.Me-
~,~~ ~~~
ter should read 190-g50 volts.
2. Check extension cord for visible dama
Use a volt meter or test lamp at extenspi
cord outlet to check.
3. Check sprayer powersupply cord 31 1) for
visibledamagesuchasbrokeninsulationor
1. Check motor brush leads, terminals and
wires.
brush length. Brush length should be 10
mm minimum. See page 32.
lide before disassembling
What to Do
If check is not OK, refer to this column
17 Slowly increase the pressuresetting tosee
if the motor starts.
2. Relievepressure,refertoyourseparategun
or tip instruction manual for tip cleaning.
pump packings (see page 33)'andlor re-
lace the bare pressure control box (300).
ee page 25. g
2. Push pin into place and secure with the re-
taining spring.
3. Replace motor (2) if fan won't turn.
See page 30.
1. Reset buildin circuit breaker; replace
building fuse. Try another electrical outlet.
2. ReDlace extension cord.
3. Replace power supply cord. See page 20.
4. lighten terminal screws; replace brushes.
See page 32.
..
Thaw the sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm area.
should operate. If paint hardened (dried) in the sprayer, the pump packmgs andlor bare pressure control must be replaced. See
Do not try to start the sprayer until it has thawed completely. If the bourdon tube was not damaged by the freezing, the pump
page 33 or 25.
307-889 11

1
Type of Problem
Dlagnoslng clrcult board
indlcator lamps.
The normal
condition is red lamp on,
telling pump to run.
clear lamp on when board is
Follow Pressure Rellef Pro-
gun from hose. Remove
cedure Warning. Remove
pressure control cover and
check for faulty condRion of
circuit board lamps.
Condltlon A
Both lamps on; pump
won't operate and motor
is notrunning
What to Check I
What to Do
If check is OK, go to the next check
1. Check leads from bridge 308) to motor to
be sure they are securey I fastened and
1.
properly maied.
2. CheckGlandG2connectionsbetweencir-
tions and terminals. See page 32.
or loose terminals.
3.
3. Check for loose motor brush lead connec-
cuitboard (72)and bridge(308)fordamage 2.
4. CheckbrushlengthwhichshouldbelOmm
minimum. See page 32.
NOTE The brushes do not wear at the
samerateonbothsidesofthemotor.Check
4.
both brushes.
5. Check for broken or misali ned motor
brushsprings.Rolledportiono?springmust
rest squarely on top of brush. See page 32.
6. Check motor brushes for binding in brush
6.
holders. See page 32.
5.
7. Checkmotorarmaturecommutatorforburn
spots,gougesandextremeroughness.Re-
7.
move motor cover and brush inspection
8.
plates to check. See page 32.
8. Check motor armature for shorts using ar-
maturetester(growler)orperformspintest.
See page 17.
9. Check bridge (308) by substituting with a
page18or21.
good bridgeor performing bridgetest. See
CAUTION: Do not perform this check until ar-
mature is determined to be good. A bad ar-
mature will immediately burn out a good
bridge.
9.
If check is not OK, refer to this column
leads. Be sure male terminal blades are
Replace any loose terminals and crimp to
straight and firmly connected to mating
Dart.
Cleancircuitboardmaleterminals.Replace
loose or damaged terminals. Securely re
Tightenteflinalscrews.Replacebrushesii
connect leads.
leads are damaged. See page 32.
Replace brushes. See page 32.
Replace spring if broken. Realign spring
with brush. See page 32.
Clean brush holders. Remove carbon with
Smallcleanin brush.Alignbrushleadswith
slot in brush 1 older to assure free vertical
brush movement.
Remove motor and have motor shop resur-
face commutator if possible. See page 30.
Replace motor. See page 30.
Replace bridge. See page 21.
. swmn
12 307-689

Type of Problem
:ondlUon B (continued)
loth lamps off
IEFER TO THE WIRING DIA.
:RAM ON PAGE 12
'0 IDENTIFY TP POINTS.
:ondltlon C
led lamps on,
Xear lamp off
Jnplug sprayer!
I
What to Check
If check is OK, go to the next check
1. Checkelectricalsuppl Connectvoltmetel
to electrical outlet. iieter should reac
2. Check power supply to circuit board witt
spra erturnedON. MeasurevoltageatTPl
andtb2.Metershouldread190-250Volts.
190-250 Volts.
3. Checkallterminalsandwiresfordamageol
loose ft.
4. Checkmotorthermalcutoutswitch.Unplug
motor thermal switch leads at TP9 ana
sprayer. Allow motor to cool. Diconnec!
TP10. Use ohmmeter to check continuity.
Switch should be closed when motor IS
5. Check microswitch (306). Wah no fluid
cool.
pressure in the pressure control, discon.
nectwiresTP16andTP19,Checkcontinuity
across switch terminals with an ohmmeter.
Switch contact should be closed. Depress
actuatorbutlon.Anaudible'click"indicates
the contacts have opened. Ohmmeter
should read iniinitv.
~ ~ ~. ..~~
6. Checkcircuiboar~(72)bysubstitutingwitt
a good board.
1. Check circuit board (72) by removing from
boxwithoutdisconnectmg wires; seepage
24 for removal procedure.
should be on now - removing the circuil
Plug in and turn on sprayer. Clear lamp
and unplug the sprayer.
boardoverridestheopticaldetector.Tumofi
-
"
rl
I
I2
'3
14
t
I
15
16
-_
I1
-
~~ ~~ ~ ~
What to Do
If check is not OK, refer to this column
. Resetcircuitbreakerorreplaceoutletfuse.1
circult breaker or fuse continues to open
see "Electrical Short", page 18.
I. Unplug s rayer Check continuity of bot)
oles of 8NIOFF switch (302) from TP3 t(
~P4andTP6toTPG.Replaceswitchiffaulty
See page 20.
to TPB and TP9 to TP10. Replace filter i
CheckcontinuityofRFIfitter(310)fromTPi
bully. See page 22.
Checkpowersu plycord 3ll)forcontinu
pace v cord if faulty. See page 20.
frOmTP11tOfPl2and'/P13toTP14.Re
Check for any loose connections.
,. Replacedamagedterminalsandreconnec
securely.
. Replace electric motor if switch does no'
dose when motor is cool. See page 30.
. Replace the microswitch. See page 23.
. Replace circuit board. See page 24.
. Replace circuit board. See page 24.
WARNING: Removing the circuit board while still wired overrides the
optical detector which could cause the sprayer to over-pressurize, if the
microswitch does not function properly. Turn the sprayer on ONLY long
enough to check lamp condition. then shut off immediately.
WARNING To reduce the risk of electric shock, handle board by edges
only1 Do not allow any metal objects to come in contact with the boardl
307-889 13

Low output
Type of Problem
,ow output
What to Check
If check is OK, go to the newt check
1. Check for worn spray tip.
2. Check to see that pump does not continue
tostrokewhenguntriggerisreleased.Plug
Trigger gun momentaril then release and
in and turn on sprayer. Prime with paint.
engagesafetylatch. Rekvepressure, turn
off and unplug sprayer.
3. Checkelectrical supplywithvolt meter. Me-
ter should read 190-250 Volts.
4. Checkextensioncordsizeand1ength:must
than 45 m.
be at least 1.5 mm dia. wire and no longer
5. CheckGlandG2leadsfrombridge(308)to
circuit board (72 fordamageorloosewires
or connectors. A efer to page 24.
6. Check stall pressure. Refer to Pressure
7. Check bridge (338) + and - leads and ter-
Control Adjustment on page 26.
minals to motor. Inspect wiring insulation
and terminalsfor signs of overheating. See
page 21. '
E. Check for loose motor brush, leads and ter-
minals. See page 32.
9. Check for worn motor brushes which
should be 10 mm minimum. See page 32.
10. Check for broken and misali ned motor
brushsprin s Rolledportionokpringmust
rest sauarei: on toD of brush.
11. Checkmotor brushes for binding in brush
holders. See page 32.
12. Checkcircuitboard(72 bysubstitutingwith
a good circuit board. B ee page 24.
13. Check motor armature for shorts by using
anarmaturetester(grow1er)orperformspin
test. See page 17.
14. Check bridge (308) by substituting with a
test. See page 18 or 21.
good bridge or by performing the bridge
Do not perform this check until armature is
CAUTION
determined to be good. A bad armature will
immediately bum out a good bridge.
What to Do
If check is not OK, mfer to this column
1. Follow Pressure Rellef Procedure Warn-
1ngthenreplacetip.Seeyourseparategun
or tip manual.
2. Service pump. See page 33.
3. Reset buildin circuit breaker; replace
building fuse. Wepair electrical outlet or try
4. Replacewithacorrect,groundedextension
another outlet.
cord.
5. Cleancircuitboardmaleterminals.Replace
loose or defective lead terminals. Securely
reconnect lead terminals to board.
8. Adjust pressure control. See page 26.
7. Be sure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or dama ed
wiring. Securelyreconnectwiresto brilge.
8. l7ghtenterminalscrews.Replacebrushesif
9. Replace brushes. See page 32.
leads are damaged. See page 32.
10. Re lace spring if broken. Realign spring
wit{ brush. See page 32.
11. Clean brush holders, remove carbon dust
with smallcleaning brush.Align brush lead
with slot in brush holdertoassure freeverti-
cal brush movement.
12. Replace circuit board. See page 24.
13. Replace motor. See page 30.
14. Replace bridge. See page 21.
14 ~307-009

No Output
Type of Problem
What to Check
If check is OK, go to fhe next check
What to Do
If check is not OK, refer to this column
Motor runs and pump
strokes
1. Check paint supply.
2. Check for clogged intake strainer.
1. Refill and reprime pump.
3. Check for loose suction tube or fittings. 3. Tighten; us8 thread sealant or sealing tape
2. Remove and dean, then reinstall.
4. Check to see if intake valve ball and piston 4. Rem0veintakevalveandclean.Checkballs
ball are seating properly. See page 33. and seats for nicks; replace if necessary.
on threads if necessary.
See page 33.
5.
Checkforleakingaroundthroatpackingnut
pislonvahreseatforhardenedpaintornlcks whichmayindicatewornordamagadpack-
5. Replacepackings.Seepage33.Alsocheck
and replace if necessary. ings. See page 33.
Motor runs but pump does 1. Checkdisplacementpumpconnectingrod 1. Replace pin if missing. Be sure retaining
not stroke .pin
(20). See page 35.
3.
Checkdrivehousingassemblyfordamage
13. %surecrankindrivehousingrotates;plug
2. Replace connecting rod assembly. See 2. Check connecting rod (9) assembly for
spring (21) is fully in groove all around con-
necting rod. See page 35.
damage. See page 28.
check. {urn off and unplug sprayer. See
page 28.
Daae 28.
and replace if necessary. See page 28. In spra er and turn on momentarily to
Excessive Pressure Fluctuations
Type of Problem
Spray pattern variations
What to Check
If check is OK, go to the next check
I. Be sure both 01 and 62 leads from bridge
(308) to circuit board (72) are firmly con-
?, Check sta!l pressure. Refer to Pressure
nected. See page 24.
5. Check bourdon tube flag (A) and detector
Control Adjustment on page 26.
position. Turn pressure setttng to maxi-
detector (6) slot of circui board.
mum:flagshouldnotdra$orbindinoptical
72
A
I. Checkcircuitboard (72) bysubstiiutingwith
i. Check LOW OUTPUT section on Daae 14.
a good board. See page 24.
If check is not OK, refer to this column
?. Adjust pressure control. See page 26.
3. Car~fully bend flag (A) into alignment with
detector(6)slottoseeifthatcorrectsprob-
lem. If not, replace bare pressure control
ter reassembly.
assernbly(300).Adjustpressurecontrolaf-
I. Replace circuit board. See page 24.
307-889 15

Motor Is Hot and Runs Intermittently
1 Type of Problem What
to Do
What to Check
If check is OK, go to the next check
1. Check to see if sprayer has been operatin!
If check is not OK, refer to this column
1. Decrease pressure setting or increase tip
at high pressure with small tips. whic size.
causeslowmotorRPMandresultsinexces-
sive heat build up.
sprayer is located is more than 32" C or if sible.
sprayer is located in direct sun.
2. Checktoseeifambienttemperaturewhere 2.
Movesprayertoshaded,coolerareaifpos-
3. Check to see if sprayer has been left in a
3. Turn off spra er whenever ou stop spray-
stalled condition (sprayer turned on, pres-
surized, but not operatmg) for long periods ing for a whi
Y e and relieve iuid pressure.
of time.
Electrical Short
Type of Problem
Building circuit breaker opens
turned on.
as soon as sprayer switch is
CAUTION
Any short in any pari of the
motor power circuit, which is
connected to the output side
of the bridge, will cause the
ately. Correctly diagnose and
bridge to burn out immedi-
repair all shorts before check-
ing and replacing bridge.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.
What to Check I What to Do
If check is OK, go to the next check 1 If check is not OK, refer to this column
1. Check all electrical wirin for damaged in- 1. Repair or replace any damaged wiring or
sulation, and all termin% for loose fit or I terminals. Securelv reconnect all wires.
damage. Be sure to checkwires between
pressure control and motor which are en-
cased in conduit (41). See page 30.
2. Check for missing inspection plate gasket 2. Correct faulty conditions.
metal to metal contact points which
could
(see page 32),
bent terminal forks or other
cause a short.
test. See page 17. Inspect windings for
anarmaturetester(grow1er)orperformspin
burns.
3. Check motor armature for shorts by using 3. Replace motor. See page
30.
4. Replace bridge. See page 21.
~~
eepage18or21.
CAUTION
Do not perform this check until armature is
determined to be good. A bad armature will
immediately burn out a good bridge.
1. Check 'Basic Electrical Problems'on page
11.
2. CheckON/OFFswitch (302).See page20.
Be sure the sprayer is unplugged! Discon-
2
with ohm meter. The ohm meter should
nect wires from switch and check switch
and zero with the switch ON.
read infinity with the ONIOFF switch OFF,
A short in the motor circuit will bum the bridge
CAUTION
out immediately, which in turn usually causes
the ONIOFF switch to fail in the closed mode.
.Replace ONIOFF switch.
See page 20.
16 307-009

Spin Test
WARNING
To reduce the risk of serious bodily injury, includ-
the skin, or injury from moving parts, always follow
ing fluid injection or splashing in the eyes or on
the Pressure Relief Procedure Warning on page
2 before checking, adjusting, cleaning and shut-
ting down the sprayer.
I I
For checking armature, motor winding and brush
electrical continuity.
Setup
1. Remove the drive housing from the sprayer as
described in DRIVE HOUSING REPLACEMENT,
Steps
1-7, page 20.
2. Remove the pressure control cover
(48) and
cover
(F), and the inspection covers (J). See Fig.
screws
(79). Remove the motor cover (I), the fan
8.
3. Disconnect the two leads from the motor to the
bridge
(308). See Fig. 9.
1.
2.
Armature Short Circuit Test Fig. 8 mi
..
..
Quickly turn the motor fan by hand; If there are no
shorts, the motor
will coast two or three revolu-
tions before coming to a complete stop.
If the motor does not spin freely and resists rota-
tion, the armature
is shorted and the motor must
be replaced. See page
30.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Connect the two black motor leads together with
a test lead.
2. Turn the motor
fan by hand at about two revolu-
tions per second.
.3.
If there is uneven or no turning resistance, check
the following and repair parts
as needed. See
page 32.
a. broken brush springs
b. 'broken brush leads
c. loose brush terminal screws
d. wom brushes
e. broken motor leads
f. loose.motor lead terminals
4. If there is still uneven or no turning resistance,
replace the motor. See page
34.
Fig. 9 txb
307-889 17

Bridge Test
Remove the bridge from the pressure control box and
tional. See
BRIDGE RECTIFIER REPLACEMENT,
perform this test to determine if the bridge is func-
set on the X1 ohms scale.
page 21. Use a continuity tester, such
as multi-meter
All tests must be performed. If the bridge fails even
one test,
it must be replaced.
Fig.
10 shows the position of the wires on the bridge.
Using the chart at the right, connect the meter wires
as indicated and then check the continuity.
5
0
I I
000
I
Fig. 10
:heck For
I. tine short
Connect meter + to bridge ACI
Connect meter - to bridge AC2
?. Diode 1
Connect meter + to bridge -
Connect meter - to bridge ACI
Connect meter
+ to bridge AC1
Connect meter
- to bridge -
.........................................
3. Diode2
Connect meter
+ to bridge -
Connect .meter - to bridge AC2
Connect meter
+ to bridge AC2
Connect meter
- to bridge -
.........................................
1. Gate 1
Connect meter + to bridge +
Connect meter - to bridge AC1
5. Gate2
Connect meter
+ to bridge
Connect meter
- to bridge AC2
5. Diode 3
Connect meter + to bridge -
Connect meter - to bridge +
Connect meter + to bridge +
Connect meter - to bridge -
.........................................
Ohmmeter
Reading
No continuity
Continuity
..................
No continuity
Continuity
..................
No continuity
NO continuity
No continuity
Continuity
..................
No continuity
18 307-889

General Repair Information
WARNING
To reduce the risk.of serious bodily injury, includ-
ing fluid injection or splashing in the eyes or on
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure Warning on page
2 before checking, adjusting, cleaning and shut-
ting down the sprayer.
1. When disconnecting wires in the pressure control
assembly, use needle nose pliers to separate
mating connectors.
When reconnecting the wires, be sure the flat
in the wrap-around blade of the female connec-
blade of the insulated male connector is centered
tor.
r
CAUTION -1
To reduce the risk of a pressure control malfunc-
tion, be sure to properly mate connectors, and
never pull on a wire to disconnect
it. Pulling on a
wire could loosen the connector from the wire.
2. Route wires in the pressure control assembly
carefully through the legs of the U-shaped bour-
bourdon tube, which moves as the pressure set-
don tube. This is to avoid interfering with the
ting changes, and to avoid pinching the wires be-
tween the pressure control box and cover.
CAUTION -1
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
3. Keep all screws, nuts, washers, gaskets, and
dures. These parts are not normally provided with
electrical fittings removed during repair proce-
replacement assemblies.
4. Test your repair before regular operation of the
sprayer to be sure the problem
is corrected.
If the sprayer does not operate properly, review
the repair procedure again to verify that every-
thing was done correctly.
If necessary, refer to the
Troubleshooting Guide, pages
11 -18, to help
identify other possible problems and solutions.
WARNING
To reduce the risk of serious bodily injury, includ-
ing electric shock,
DO NOT touch any moving
parts or electrical parts with your fingers or a tool
while inspecting the repair.
Shut
off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
rCAuTIoN 1
Do not run the sprayer dry for more than 30 sec-
onds to avoid damaging the pump packings.
5. Reinstall the motor cover before regular operation
of the sprayer and replace it if it is damaged. The
cover directs cooling air around the motor to help
risk of burns, fire or explosion; see the
WARN-
prevent overheating. It can'also help reduce the
ING, below.
WARNING
During operation, the motor becomes very hot
and could bum your skin
if touched. Flammable
materials spilled on the hot, bare motor could
cause a fire or explosion. Always have the motor
cover in place during regular operation to reduce
the risk of burns, fire'or explosion.
307-009 19

Power Supply Cord
WARNING
Before doing this procedure, follow the Pressure
Relief Procedure Warning
on page 2 to reduce
the risk of serious bodily injury, including fluid in-
jection or splashing In the eyes or on the skin, or
injury from moving part.
2
NOTE Refer to Fig. 11 and 12.
1. Remove the nut (337) from the filter stud (310).
2.
Remove the three screws (4) holding the pressure
control
to the frame.
3. Remove the pressure control mounting bracket
(50) and screws (51).
4. Disconnect the power supply cord wires from the
control box terminal strip
(336) using a screw-
driver.
5. Install the new power supoly cord (31 1) in the re-
verse order of disassembly.
6. Have a licensed electrician install a new plug on
the other end
of the cord. Be sure to follow all lo-
cal codes regarding the type of plug to use.
65
Fig. 11
\
31 0
Fig. 12 02362
On/Off Switch
WARNING ~ ' 6. Reconnect the wires.
Before doing
this procedure, follow the Pressure
Relief Procedure Warning
on page 2 to reduce
jection or splashing in the eyes or on the skin, or
7. Reinstall the pressure control cover and screws.
the risk
of serious bodily injury, including fluid in-
injury
from moving part.
NOTE Refer to Fig. 13.
1.
Remove the pressure control cover and screws.
2. Disconnect the wires from the ON/OFF switch
302
(302).
3.
Pry off the retaining clip (303).
4. Remove the ON/OFF switch.
5. Install the new switch as shown in Fig. 13. Fig. 13 0"
20 307-889