Graco Ultra 1000 Operation manual

INSTRUCTIONS-PARTS

LIST

.

<zf

307-926

Rev.

F

'I

This manual contains important

READ AND RETAiN

FOR

REFERENCE

PCN

DEF

warnings and information.

Supersedes

C

and

#IIIucIIo#

ELECTRIC,

220/240

VAC

Ultra.

1800

Airless

Paint

Sprayer

207

bar Maximum Working Pressure

Model

231

-082,

Series

C

Complete sprayer with hose, gun, RAC

IV?

DripLess" Tip Guard and SwitchTip".

NOTE:

See Table

of

Contents on page

2.

,I

NOTE:

This

is

an example

of

the DANGER label on your sprayer.

This label

is

available in other languages, free

of

charge.

See page

43

to order.

w712

.

,:

FIRE

AND

EXPLOSION

HAZARD

I

SKiN INJECTION

HAZARD

Spray ainting. flushing or cleaning equipment with flammable liquids

in conlned areas

can

result in fire or explosion. Uquids

can

be injected into the

body

by high pressure aides spray or

Keep body clear ofthe nozzle. Never slop leaks with any pMofthe

body.

US0

outdoors or in earemely well ventilated areas. Ground equipment.

Avoid

all

ignition sources such as static electricity from plmic drop gun

w

JLs sening ~ety latch when not sprwng.

hoses,

containers and objects being sprayed. Drain all ressure before removing parts. Avoid accidental triggering

of

cloths, open flames such as pilot lights. hot objects such

as

cigarettes. Never spray wiihout

a

tip

guard.

arcs from mnneaing or disconnecting wwer cords or turnlng light

switches

on

and

oft.

In

case

of

seek

immediate

Failure to follow this warning can result in death or serious injury.

'Surgical Treatment".

Failure to follow this warning can resun in amputation or serious

injury.

leaks

-

especially hose leaks.

READ

AND UNDERSTAND ALL LABELS AND iNSTRUCTlON MANUALS BEFORE USE

L

GRACO INC.

RO.

BOX

1441

MINNEAPOLIS, MN

55440-1441

@COPYRIGHT

1988,

GRACO

ING.

Table

of

Contents

Introduction

...................................

2

Warnings..

....................................

4

Setup..

.......................................

6

Operation

.....................................

8

Shutdown

&

Care

.............................

10

Troubleshooting Guide

Flushing Guidelines 11

Motor Won't Operate

.........................

13

Low Output

.................................

16

No Output

..................................

17

Excessive Pressure Fluctuations

...............

17

Electrical Short

..............................

18

Spin Test

...................................

19

Bridge Test., 20

General Repair Notes

........................

21

ON/OFF Switch Replacement

22

Power Supply Cord Replacement 22

Choke Replacement

24

Bridge Replacement

23

...........................

Motor

Is

Hot and Runs Intermittently

...........

18

................................

Repair

..............

.................

.........................

Filter Replacement

...........................

24

Circuit Board Replacement.. 26

Microswitch Replacement

25

Pressure Control Replacement

................

27

Pressure Control Adjustment

..................

28

Motor Capacitor Replacement 32

Displacement Pump

30

:'

Motor Brush Replacement

....................

33

Bearing Housing

&

Connecting Rod Replacement

.................

34

Drive Housing Replacement..

.................

35

Motor Replacement

36

Complete Sprayer

...........................

38

Pressure Control Assembly

...................

40

Displacement Pump

.........................

42

Accessories

..................................

43

Technical Data

................................

44

Warranty Back Cover

Dimensions

44

.....................

..................

.........................

.................

..........................

Parts Lists and Drawings

..................................

.............................

Introduction

Ultra@

1000

Basic

Components

Your new Ultra@

1000

Sprayer functions and oper-

ates differently than other airless paint sprayers. This

section will help you become familiar with the sprayer

before operating it.

Pressure Control

The pressure control

(43) includes an ON/OFF switch

(303) for the sprayer, the pressure adjusting control

knob

(A)

and

a

pressure sensing device.

Its

function

is

to

control the motor speed

so

that the sprayer

maintains constant fluid pressure at the pump outlet.

Motor

The DC motor (1) has sealed bearings and replace-

able motor brushes.

Its

function is

to

drive the dis-

placement pump at the rate needed

to

supply suffi-

cient paint volume at the selected pressure. Working

together, the pressure control and motor cause the

pump

to

cycle whenever there is fluid or pressure de-

mand. When the pump is cycling, the motor sounds

like an automobile starter cranking. When the pump is

not cycling, the motor may hum intermittently until the

fluid pressure stabilizes, then the motor will shut itself

off. However, there will still be power

to

the sprayer

you manually

shut

it

off

and relieve pressure.

and

it

will stay pressurized and ready

to

use unless

9

an7-o~~

Because the motor is DC, it is less sensitive to low

voltage or voltage fluctuations than an AC motor, and

an extension cord of up to

45

m can be used.

Drive

Assembly

the

DC

motor to the displacement pump.

The sealed drive assembly (18) transfers power from

Displacement Pump

The positive displacement, volume-balanced pump

(39) provides equal fluid delivery on both

the

up

and

which, when filled with Graco Throat Seal Liquid,

down pump strokes, The pump has a wet-cup

ton rod.

helps prevent damage

to

the throat packings and pis-

Fluid

Filter

The fluid filter

(48)

strains the paint

to

help avoid

clogs in the hose and spray tip. The filter includes a

reusable element and a pressure drain valve

(50)

for

relieving fluid pressure.

Hoses

The grounded, nylon spray hoses have spring guards

on both ends. The15.2

rn

(28) hose has a 1/4

in.

ID.

The 0.9 m,

3/16

in. ID whip hose (56) allows flexible

gun movement. The nylon hose material acts as a

pulsation dampener

to

absorb pressure fluctuations.

Fig.

1

Fig.

2

Observe All Warnings. Read and understand all instruction manuals before operating equipment.

High Pressure Spray Can Cause Serious Injury. For Professional

Use

Only.

This equipment generates very high

fluid

pressure. Spray from

General Safety

the gun, leaks or ruptured components can inject fluid through

yourskinandintoyourbodyandcauseextremelyseriousbodily

injury, including the need for amputation. Also. fluid injected or

splashedintotheeyesorontheskincancauseseriousdamage.

NEVERpointthespraygunatenyoneoratanypartofthebody.

NEVER put hand or fingers over the spray

tip.

NEVER

try

to

"blow

back" paint; this is NOT an air spray

system.

ALWAYS have the tip guard in place

on

the spray gun when

spraying.

ALWAYS follow the Pressurs Rellef Procedure, below, before

cleaning or removing

the

spray tip or servicing any SYStOm

equipment.

NEVER try

to

stop or deflect leaks with your hand or body.

each

use.

Besureequipmentsafehldevicesareoperatingproperiybefore

Medical Alert--Airless Spray Wounds

If

any fluid appears to penetrate your skin, get EMERGENCY

MEDICAL CARE AT ONCE.

DO

NOT TREAT AS A SIMPLE

CUT.

Tell the doctor exactly what fluid was injected.

Note

to

Physlclan:

Injection

in

the

skin

is

a traumatic

injuty

It

Is

Important

to

treat the

Injury

surgloally

as

soon

as

possl-

cern with

some

exotic coatings injected direct& into the blood

ble.

Do

not

delay treatment to research toxiciw Toxicityis a con-

stream. Consultation with a plastic surgeon or reconstructive

hand surgeon may

be

advisable.

Spray

Gun

Safety

Devices

Be

sure all gun safety devices are operating properly before

eachuse.Donotremoveormodifyanypartofthegun;thiscan

cause a malfunction and result

in

serious bodily injury.

Safety

Latch

Wheneveryoustopspraying,evenforamoment,alweyssetthe

gun safety latch in the closed or "safe" position. making thegun

inoDerative.Failuretosetthesafetylatchcanresultinaccidental

triggering of

the

gun.

Diffuser

Thegundi~serbreaksupsprayandreducestheriskolfluidin-

iection when the

ti0

is not installed. Check dfluser operation

kgulariy.

Follow

the

Pressure

Rellef Procedure,

below, then

remove the spray tip.

Aim

the gun into a

metal

pail, holding the

gunfirmlytothepail.Usingthelowestpossiblepressure,trigger

the

gun.

If

the fluid emitted

is

not

diffused into an irregular

stream, replace the diffuser immediately.

Tip

Guard

ALWAYS have the tip guard

in

place on the spray gun while

spraying. The tip guard alerts you

to

the fluid injection hazard

placing your fingers or any part of your body close

to

the spray

and heips reduce,

but

does

not

prevent, the risk of accidentally

tip.

nigger Guard

Alwayshavethetriggerguardinplaceonthegunwhenspraying

to reduce the risk of accidentally triggering the gun

if

I

is

dropped or bumped.

Spray Tip

Safety

UseextremecautionwhencleaninporchanainQspraytips.lfthe

spray tip clogs while spraying, engage the gun safe@ latch

im-

then remove the spray tip to clean it.

mediately.ALWAYSfollowthePressureRellelProcedureand

fully relieved and the gun safety latch

is

engaged.

NEVER wipe

off

build-up around the spray tip until pressure is

-

-.

Pressure Relief Procedure

Toreducetheriskofseriousbodiiyinjury,includingfluidinjec-

tion, splashing fluid or solvent

in

the eyes or on the skin, or in-

juryfrommovingpartsoreiectricshock,alwaysfoilowthispro-

cedure whenever

you

shut

off

the sprayer, when checking or

servicing any pa

rf

ofthe spraysystem, when installing, clean-

ing 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 sprayer.

4.

Disengage the gun safety latch. Hold a metal.part.of the

the gun to relieve pressure.

gunfirmlytothesideofagroundedmetalpail,andtrigger

5.

Engage

the

gun

safety latch.

6.

Openthepressuredrainvalve.Leavethevalveopenunti1

you

are

ready

to

spray again.

lfyoususpectthatUlespraytiporhoseiscompletel).clogged.

orthatpressurr,hasnotbeenlu~relievedaffertollowingthe

steps above, wrap

a

rag around the tip guard retaining

nut

or

hose end coupling and

VERY

SWWLY

loosen

the pan

to

re-

lieve pressure gradually, then loosen completely.'Now clear

the

tiD

or hose.

EQUIPMENT MISUSE

HAZARD

General Safe

Any misuse oft

3;

e spray equipment or accessories, such

as

Allchemicalsusedinthesprayermustbechemicallycompatible

ovemressurizina. modifvina Darts, usina incompatible chemi- with'the wetted parts given

in

the TECHNICAL DATA

on

page

Fluid

and

Solvent Compatibility

calsandfluids,o);singwornordamage~parts,cancausethem

44.

Consult your chemical supplier to ensure compatibility.

.

-.

toruPtureandresuitinfluidinjection,splashingintheeyesoron

Donotuse1,1,l~trichloroethane,methylenechloride,otherha~

the skin, or other serious bodily injury, or fire, explosion or prop-

logenated

hydrocarbon

em/ damage.

or

fluids

containing

such

vents

in

this equipment, which contains aluminum and/or zinc

oarts. Such usecould

resuitinaseriouschemicalreaction,

with

Alwayswearprotectiveeyewear,gloves,clothingandrespirator

mumworkingpressureofanycomponentoraccessoryusedin

as recommended by the fluid and solvent manufacturer. the system.

HOSE

SAFETY

High pressure fluid

in

the hoses can be very dangerous.

If

the Handle and route hoses carefully.

Do

not pull

on

hosesto move

damageormisuse,thehighpressuresprayemittedfromitcan ofthepumpandgasengine.Donotusefluidsorso1ventswhich

hose develops a leak, split or rupture due to any kind of wear, equipment. Keep hoses clear of moving parts

and

hot surfaces

cause a fluid injection injury or other serious bodily injury or

arenotcompatiblewiththeinnertubeandcoverofthehose.DO

property damage.

NOTexposeGracohosetotemperaturesabove82D

Corbelow

All

tluld

hoses

must have sprlng guards on both endsl The

-40"

spring guards help protect the hose

from

kinks or bends at

or

closet6 the coupiing which can result in hose rupture.

Hose

Grounding Continuity

all

fluid

securely

before

each

use,

High

Proper hose grounding continuity is essential to maintaining

a

groundedspraysystem.Checktheelectricalresistanceofyour

onitwhichsoecifiesthemaximumelectricalresistance.contact

pressurefluidcandislodgealoosecouplingorallowhighpres-

~uidhosesatleastonceaweek~,,your~~se~o~sn~~~a~~atag

sure spray to be emitted from the coupling.

NEVER useadamaged hose. Beforeeach use, checktheentire the hosesupplier or manufacturer for the maximum resistance

hose for cuts, leaks, abrasion, bulging cover, or damage or limits. Use a resinance meter

in

the appropriate range for your

replacethehoseimmediatelv.DONOTtrytorecouplehighDres-

ommended limits, replace

it

immediately.

An

unarounded or

.

i

movementofthehosecouplings.

lfany oftheseconditionsexist, hose to check the resistance. If

the

resistance exceeds the rec-

sure hose or mend

it

with tape or any oiher device.

A

&paired 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

and hose. If every part of the spray equipment is not properly

Staticelectricityiscreatedbytheflowoffluidthroughthepump

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 you are spraying indoors or outdoors, and can cause

a fire or explosion and serious bodily injury and property dam-

age.

Ifyouexperienceanystaticsparkingorevenaslightshockwhile

the entire system for proper grounding.

Do

not use the system

usingthisequipment,STOPSPFlAYlNGIMMEDIATELY.Check

again until the problem has been identified and corrected.

To reduce the risk of static soarkina. around the soraver and all

Grounding

other spray equipment used or-located in the sljray area.

tions for your area and type

of

equipment. BE SURE

to

ground

CHECKyourlocalelectricalcodefordetailedgroundinginstruc-

all of this spray equipment:

1.

Sprayer: connect a ground wire and clamp (supplied) to a

true earth ground.

2.

Fluidhosest use only grounded hoses with a maximum of

150mcombinedhoselengthtoensuregroundingcontinu-

ity. See Hose Groundlng Contlnulty.

3.

Spraygun:obtaingroundingthroughconnectiontoaprop-

erly grounded fluid hose and sprayer.

4.

Object being sprayed: according to local code.

5.

Fluid

suppby

container: according to local code.

6.

All

solvent pails used when flushing, according to local

code.

Use

only metal pails, which areconductwe.

Do

not

placethepailonanon-conductivesurface,suchaspaper

or cardboard, which interrupts the grounding continuity.

7.

To

maintain

grounding

continuify when flushing

or

relieving

prsssure, always hold a metal pati of the gun firmly to the

side of a grounded metal pail, then trigger the gun.

Flushing

Safety

AeducetheriskofRuidiniectioniniurv,staticsparkina,orsplash-

ing byfollowing

theflushhgprocediregivenonpa~e

11 iind 12

ofthis manual. FollowthePressure

Rsllef

Procedureon page

the gun firmly to the side of a grounded metal pail and use the

4,

and remove thespray tip beforeflushing. Holdametal partof

lowest possible fluid pressure during flushing.

-

MOVING PARTS

HAZARD

-

Moving parts

can

pinch or amputate your fingers or other body

parts. KEEP CLEM of moving parts when starting or operating

the sprayer. Follow the Pressure

Rsllef

Procedure

on

page

4

before checking or servicing any part ofthe sprayer, to prevent

it

from starting accidentally.

-

IMPORTANT

-

UnitedStatesGovernmentsafetystandardshavebeenadopted

undertheOccupati0nalSafetyandHealthAct.Thesestandards

struction Standards, Part 1926

-

should be consulted.

-

particularly the General Standards, Part 1910,

and

the Con-

.."

"*

c

1.

Connect hose and gun. Refer

to

Fig.

4.

trol, hold one wrench firmly on the hex

of

the pressure

NOTE:

When tightening fittings at the pressure con-

wrench

to

tighten the mating fitting.

control fitting

to

keep it from rotating. Use another

a. Remove the cap from the filter

outlet

nipple

and screw the

15.2

m main fluid hose

(28)

onto the nipple.

b. Connect the whip hose

(56

-

not shown)

between the fluid hose and the gun inlet

connection.

c. Don’t

use

thread sealant, and don’t install the

spray tip yet!

If

you are supplying your own oses and spray

gun, be sure the hoses are electrically conductive,

that the gun has a tip guard and that each pari is

rated for at

least

207

bar

Working

Pressure. This is

to reduce the risk of serious bodily injury caused

by static sparking, fluid injection or over-pressuri-

zation and rupture of the hose or gun.

WARNIfG

I

2.

Two

gun hookup. Remove the cap from the

1/4

accessory hose

(C) and gun.

See

Fig.

4.

npsm(m) nipple

-

See Fig.

3.

-

and attach an

CAUTION

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

long.

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

(48)

and the main hose

(28).

See Fig.

3.

4.

Always use the main filter outlet

(46)

for one

gun operation. Never plug this

outlet.

See Fig.

3.

5.

Fill packing nut/wet-cup

(216).

See

Fig.

3.

Fill the packing nut/wet-cup

1/3

full

with Graco

Throat Seal Liquid

(TSL),

supplied.

fi

m7-07fi

6.

Check the Electrical Service

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,

c. Use

an

extension cord which has

3

wires of

a

45

m long. Longer lengths may affect sprayer

minimum

1.5

mm size, and

a

maximum

of

performance.

A

DO

not

install

any

shutoff device here

Fig.

3

m7u

A

Fig.

4

-

7.

Plug

in

the

sprayer. Be sure the

ON/OFF

switch

(A)

is

OFF.

See Fig.

4.

Then plug the cord into a

grounded electrical outlet at least

6

m away from

the spray area.

WARNING

Proper electrical grounding is essential

to

reduce

the

risk

of

fire or explosion which

can

result

in

seri-

ous

bodily injuty and property damage. Refer to

the warning section

FIRE

OR

EXPLOSION

HAZ-

ARD

on page 5 for more detailed grounding in-

structions.

8.

Flush the

pump to remove the lightweight

oil

which was left

in

to

protect pump parts after fac-

toty

testing.

’

“a.

.~ Before-using water-base paint,Jiush

With

then a clean water flush.

mineral spirits followed by soapy water, and

b. Before using oil-base paint,

flush

with

min-

eral spirits only.

c. See Flushing on pages

11

and

12

for the

flushing procedure.

9.

Prepare

the

paint according

to

the manufactur-

er’s recommendations.

a. Remove any skin that may have

formed.

b. Stir the paint

to

mix pigments.

c. Strain the paint through a fine nylon mesh

bag (available

at

most paint.dealerd,.to.re-

,

spray tip. This is probably the most imporlant

move particles that could clog the filter or

step toward trouble-free spray painting.

Operation

WARNING

Pressure Relief Procedure

To

reduce the risk of serious bodily injury, includ-

ing fluid injection, splashing fluid or solvent in the

eyes or on the skin, or injury from moving parts or

electric shock, always follow this procedure when-

ever you shut

off

the sprayer, when checking or

stalling, cleaning or changing spray tips, and

selvicing any part of the spray system, when in-

whenever you stop spraying.

1.

Engage the gun safety latch.

2.

Turn the ON/OFF switch

to

OFF.

3.

Unplug the sprayer.

4.

Disengage the gun safety latch. Hold a metal

part of the gun firmly

to

the side of a grounded

metal pail, and trigger the gun

to

relieve

pressure.

5.

Engage the gu.n safety latch.

6.

Open the pressure drain valve. Leave the

If

you

suspect that the spray tip

or

hose

is

com-

pletely clogged, or that pressure has not been fully

relieved after following the steps above, wrap a

coupling and

VERY

SLOWLY loosen the part to

rag around the tip guard retaining nut or hose end

relieve pressure gradually, then loosen completely.

Now clear the tip or hose.

valve open until you are ready

to

spray again.

Startup

Use this procedure each time you start the sprayer

to

help ensure the sprayer

is

ready

to

operate and that

you start

it

safely.

NOTE:

For the first time startup, be sure

to

flush the

sprayer first. See Flushing on pages

11

and

12

for

the flushing procedure.

1.

If

you have not installed a secondary hose, be

sure the nipple

is

firmly plugged with the cap. See

Fig.

5.

2.

Don’t install the spray tip yet1

3.

Put the suction tube into the paint container.

4.

Open the pressure drain valve (50).

5.

Lower the pressure setting by turning the pres-

sure adjusting knob

(6)

all the way counterclock-

wise. See Fig.

5.

6.

Disengage the gun safely latch. See Fig.

7.

To

prime the pump, turn the ON/OFF switch

(A)

to

ON,

and slowly increase the pressure setting

from the pressure drain valve

(50),

close

it.

until the sprayer starts. When fluid flows freely

8.

To

prime the hose and gun, hold a metal part of

the gun firmly against and aimed into a metal

waste container, See Fig.

6.

Squeeze the trigger

and hold

it

open, Keep the gun triggered until all

air

is

forced

out

of the system and the paint flows

freelyfrom the gun, Release

the

trigger and en-

gage the gun safety latch.

9.

Check all fluid connections for leaks. If any are

found, follow the Pressure Relief Procedure

Warning,

to

the left, before tightening connec-

tions.

10.

Install the spray tip and tip guard. Be sure the

gun safety latch is engaged.

See

Fig.

7.

Install the

spray tip.

if

using the

RAC

IV

tip guard, refer

to

manual

307-848,

supplied with the gun, for

installation instructions.

11.

Adjust the spray pattern

a. Increase the pressure adjusting knob

(6)

set-

ting just until spray from the gun

is

completely

atomized.

To

avoid excessive overspray 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

latch and loosen the tip guard retaining nut

(C).

See Fig.

5.

Position the tip guard horizon-

tally for a horizontal pattern or vertically for a

vertical pattern. Then tighten the retaining nut.

.

Operation

50

m745

A

Maintain firm metal-to-metal

metal pail when flushing.

Contact

between gun and grounded

Fig.

6

0143

Cleaning a Clogged Tip

WARNING

To

reduce the risk of serious bodily injury from

fluid injection:

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 checking

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

8.

Then use a

sol-

vent-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 (D) 180". See Fig. 7.

3.

Disengage the gun safety latch and trigger the

gun into a waste container. Engage the gun

safety latch again. See Fig.

7.

4.

Return the handle

(D)

to

the original position,

disengage the gun safety latch, and resume

spraying.

5.

If

the tip is

still

clogged, engage the gun safety

latch, shutoff and unplug the sprayer, and open

the pressure drain valve

to

relieve pressure. Clean

the spray tip

as

shown in manual

307-848,

sup-

plied with the RAC

IV.

Trigger

safety

shown engaged

A

Trigger safety shown disengaged

A

RAG

N

tip handle shown in spraying position.

Turn

180".

disengage

safety

latch and trigger

gun

to

clear clog.

AD

Shutdown

and

Care

WARNING

sure Relief Procedure Warning on page

11

to

Before doing these procedures, follow the Pres-

I.

Check the packing nutfwet-cup

(216)

daily. First

follow the Pressure Relief Procedure Warning

TSL

at all times

to

help prevent fluid buildup on

on page

11.

Be sure the wet-cup is 1/3

full

of

the piston rod and premature wear of peckings.

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.

8.

2.

Clean the fluid filter

(48)

often and whenever the

sprayer

is

stored. First follow the Pressure Relief

307-273, supplied, for the cleaning procedure.

Procedure Warning on page

11.

Refer

to

manual

3.

Lubricate the bearing housing after every

100

hours of operation. Fill the connecting rod cavity

See Fig.

9.

(A)

with

SA€

No.

10

non-detergent oil.

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

11.

.CAUTION

1

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

11,

and clean the spray

tip.

storing

it,

even for overnight,

to

help protect the

hose from kinking, abrasion, coupling damage,

etc.

6.

Coil the hose and hang

it

on

the hose rack when

Refer

to

the warning section

HOSE

SAFETY

on

page

5

for information on the hazard of using

damaged hoses.

A

Remove cap to

fill.

Keep

filled

with

TSL

To

tighten the packing nut turn

ii

in the

direction shown

by

the

arrow.

Use

a punch and light hammer

lo

turn

the

notched

ring

of

the pacldng

nut

A

48

..

.

Fig.

8

a743

A

non-deter

entoll

Fill

cavm

with

?+E

No.10

after

every

$M)

hours

of

operation

Flushing

WARNING

Pressure Relief Procedure

To

reduce the risk

of

serious bodily injury, including

fluid injection, splashing fluid or solvent in the eyes

or

on

the skin, or injury 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 safely latch.

2.

Turn the ON/OFF switch

to

OFF:

3.

Unplug the sprayer.

4. Disengage the gun safety latch. Hold a metal

part of

the

gun firmly to the side of a grounded

metal pail, and trigger the gun

to

relieve

pressure.

5.

Engage

the

gun safety latch.

6.

Open the pressure drain valve. Leave the valve

open until you are ready

to

spray again.

If

you

suspect that the spray

tip

or

hose is com-

pletely clogged,

or

that pressure

has

not been fully

relieved after fo1low;ng

the

steps above, wrap a rag

around the tip guard retaining nut or hose end cou-

pling and

VERY

SLOWLY loosen the part

to

relieve

pressure gradually, then loosen completely. Now

clear the tip or hose.

1.

New Sprayer. Your new sprayer was factory

tested in lightweight

oil

which was

left

in to protect

pump parts.

Before

using water-base paint, flush with mineral

water flush.

spirits followed by soapy water, and then a clean

Before

using

oil-base paint, flush with mineral

spirits only.

2.

Changlng Colors. Flush with a compatible

sol-

vent such as mineral spirits or water.

3.

Changing from water-base to oil-base paint.

Flush with warm, soapy water, then mineral

spirits.

4.

Changing from oil-base to water-base paint.

Flush with mineral spirits, followed by warm,

soapy water, then

a

clean water flush.

5.

Storage.

Wafer-base paint: flush with water, then mineral

with mineral spirits. Shut

off

the sprayer, open the

spirits and leave the pump, hose and gun filled

pressure drain valve

to relieve pressure and leave

it

open.

Oil-base

paint:

flush with mineral spirits. Shut

off

the sprayer, open the pressure drain valve to re-

lieve pressure and leave

it

open.

,I

CAUTION

slightest chance

it

could freeze. Push

the

water

NEVER

leave water in the sprayer

if

there

is

the

out with mineral spirits. Water left

to

freeze in the

pressure control tube prevents the sprayer from

being started and causes serious damage to the

pressure control.

6.

Startup after storage.

Before using water-base paint, flush out mineral

spirits with soapy water and then

a

clean water

flush. When using oil-base paint, flush out the

mineral spirits with the paint

to

be sprayed and

the sprayer is ready

to

use.

Continued

on

page

12.

Flushing

How

to Flush

I.

Follow the Pressure Relief Procedure Warning

onpagell.

2.

if the sprayer has been

used

befwe,

remove the

filter bowl (C) and screen

(D);

see manual

307-273,

supplied. Clean the screen

(D)

sepa-

rately and install the bowl (C) and support

(E)

without the screen to flush

it.

See Fig.

10.

A

50

Fig.

10

3.

Close

the pressure drain valve (50). See Fig.

10.

4.

Pour

2

liters of compatible solvent into a grounded

metal pail.

Put

the suction tube in the

pail.

5.

Remove the spray tip from the

gun,

if

it

is

installed.

WARNING

To

reduce the risk of static sparking and splash-

ing, always remove the spray

tip

from the gun,

and hold a metal part of the gun firmly to the side

of and aimed into a grounded metal pail when

flushing.

See

Fig.

11,

6.

Lower the pressure setting by turning the pres-

sure adjusting knob

(B)

all the way counterclock-

wise.

7.

Open the pressure drain valve

(50).

Turn

the

ON/

OFF switch

(A)

to

ON,

and slowly increase the

pressure setting until the sprayer

starts.

When

solvent

is

flowing freely, close the pressure drain

valve.

8.

Hold a metal part

of

the gun firmly against and

aimed into a metal waste container. See Fig.

11.

Squeeze the trigger and hold

it

open until all air is

forced

out

of the system and the solvent flows

freely from the gun. Release the trigger and en-

gage the gun safety latch. This procedure helps

reduce the

risk

of

static sparking and splashing.

9.

Remove the suction tube from the pail. Disengage

the gun

safely

latch and trigger the gun to force

solvent from the hose.

Do

not let the pump run

dry for more than

30

seconds to avoid damaging

the pump packings! Then follow the Pressure

Relief Procedure Warning on page

11

.'

10.

Leave the pressure drain valve open until you are

ready to use the sprayer again. If the screen was

removed, unscrew the filter bowl and reinstall the

clean screen. Reinstall the bowl, hand tight only.

11.

Remove the suction tube and clean

it

separately.

Flushing may not be sufficient to clean the tube.

12.

If you flushed with mineral spirits and are going to

followed by a clean water flush. Then follow the

use a water- base paint, fiush with soapy water

Pressure Relief Procedure Warning on page

11.

A

Maintain Rrm metal-lo-metal

contact between gun

and

grounded

metal

pail

when

Rushing.

Fig.

11

Pi43

Troubleshooting

WARNING

Pressure

Relief Procedure 4. Disengage the

gun

safety latch.

Hold

a

metal

To

reduce the risk

of

serious bodily injury, including part of the gun firmly to the side of a grounded

fluid

injection, splashing fluid or solvent

in

the eyes

or

on the

skin,

or injury from moving parts

or

electric

metal

pail,

and trigger the gun to relieve pres-

shock, always follow this procedure whenever you

sure.

shut

off

the sprayer, when checking or servicing any

5.

Engage the

gun

safety latch.

part of the spray system, when

installing,

cleaning

6.

Open the pressure drain valve. Leave the valve

or

changing spray tips, and whenever you stop

spraying.

If

you

suspect that the spray

tip

or hose

is

com-

plete& clogged, or that pressure has not been

fu/&

relieved after following the steps above, wrap a rag

1.

Engage the gun safety latch. around the tip guard retaining nut or hose end cou-

2.

Turn the ON/OFF switch to OFF. pling and

VERY

SLOWLY

loosen the part to relieve

pressure gradually, then loosen completely. Now

3.

Unplug

the sprayer. clear the tip or hose.

open until you are ready to spray again.

Check everything

in

the guide before disassembling the sprayer.

Tj’pe

of

Problem What

to

Check

If check is

OK,

go

to

the next check

Basic Fluid Pressure

Problems

1.

Checkthepressurecontrolknobsetting.The

motor will not run

if

It

Is

at the minimum setting

(fully counterclockwise).

2.

Check for a clogged spray tip. Refer

to

the

separate gun or tip instruction manual.

Basic Mechanical Problems

1.

Check

for

frozen or hardened paint in the

tube. Carefully try

to

rotate fan at back of motor

pump

(39)

and/or pressure control bourdon

by hand. See page

19.

What to

Do

If check

is

not

OK,

refer

to

this column

the motor starts.

1.

Slowly increasethe pressure setting

to

see

if

2. Relieve pressure,

refer

to your separate gun

or tip instruction manual for tip cleaning.

1.

Thaw. Plug in sprayer and turn on. Slowly in-

doesn’t, replace the displacement pump pack-

crease pressure setting

to

see

if

motor

starts.

If

it

ings

(seepage30)andlorreplacethe

barepres-

sure control box

(300).

See page 27.

2. Check displacement pump connecting rod

pin (20).

It

must be completely pushed into con-

nectingrod (29) andretainingspring (35)should

34,

page 32.

be firmly in groove of connecting rod.

See

Fig.

2. Push pin into place and secure with

the.re-

taining spring.

I

3.

Check for motor damage. Remove drive

housingassernbiy(2).Seepage34,Trytorotate

fan by hand.

3.

Replace motor (1)

if

fan won’t turn.

I

Basic Electrical Problems

1.

Checkelectrikalsupplywithvoltmeter.

Meter

1.

Reset

building circuit breaker: replace buiid-

I

should read 190-250

Volts.

~~

I

ing fuse. Try another electrical outlet.

I

2. Check extension cord for visible damage. 2. Replace extension cord.

Use a volt meter or

test

lamp

at

extension cord

outlet

to

check.

I

3.

Check sprayer power supply cord

(31

1)

for

3.

Replace power supply cord.

See

page 22.

visible damage such as broken insulation or

wires.

I

4.

Check motor brush leads, terminals and

4.

Tighten terminal screws; replace brushes.

brush length. Brush length should be 10 mm See page

35.

minimum. See page 35.

I

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.

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

27

or page

30.

should operate.

If

paint hardened (dried) in the sprayer, the pump packings and/or bare pressure control must be replaced.

See

”-

”^

”

Motor Won't Operate

Type

of

Problem

dlcator lamps. The normal

What

to

Check

leads.

loose terminals.

Follow Pressure

Rellel

Pro-

looseordamagedterminals.

Securelyreconnect cuit board

(25)

and bridge

(308)

for damage or

te/hg

pump

to

run.

2.

Clean circuit board male terminals. Replace

2.

Check G1 and G2 connections between cir-

'Iear

lamp

On

when

and firmly connected to mating part.

mated.

condition is red lamp

on,

1. Replace any loose terminals and crimp to

1.

Check leads from bridge

(308)

to motor to be

Dlagnoslng clrcult board

In-

leads. Be sure male terminal blades are straight

sure they are securely fastened and properly

cedure Warnlng. Remove

3.

Check for loose motor brush lead connec-

3.

Tighten terminal screws. Replace brushes

if

gun from hose. Remove lions and terminals. See page

33.

leads are damaged. See page

33.

pressure

control

'Over

and

4.

Check brush length which should be 10mm

4.

Replace brushes. See page 33.

check for faulty condition of

See

page

33,

circuit board lamps.

N0TE:Thebrushesdonotwearatthesamerate

on

both sides

of

the motor. Check both brushes.

Condltlon A

Both lamps

on;

pump

won't operate and springs. Rolled portion of spring must rest brush. See page

33.

5.

Check for broken or misaligned motor brush

5.

Replace spring

if

broken. Realign spring with

is

not running squarely on top of brush. See page

33.

If

check is

OK,

go to the nert check

What

to

Do

If

check is not

OK,

refer to this column

6.

Check motor brushes for binding in brush

in brush holder to assure free vertical brush

small cleaning brush. Align brush leads with slot holders. See page

33.

6.

Clean brush holders. Remove carbon with

movement. . .. .

7.

Check motor armature commutator

for

burn

check. See page

33.

motor cover and brush inspection plates to

face commutator if possible. See page

36.

spots, gougesand extreme roughness. Remove

7. Remove motor and have motor shop resur-

ture tester (growler) or perform spin test. See

8.

Checkmotorarmatureforehortsusingarma-

8.

Replace motor. See page

36.

page

19.

9.

Check bridge

(308)

by substituting with

a

9.

Replace bridge. See page 23.

good bridgeor performing bridgetest. Seepage

20

or

23.

tureisdeterminedtobegood.Abadarmaturewill

CAUTION:

Do

not perform this check until arma-

immediately burn out a good bridge.

Motor

Won't

Operate

Volts.

WE'

THE

wlRING

'Ip-

3MM

ON

PAGE

14

D'DfNTIFYTfsTPOINTS

TP2. Meter should read 190-250 Volts.

2. Check power supply to circuit board with

sprayer turned ON. Measure voltage

at

TP1 and

loose fit.

sprayer. Allow motor to cool. Disconnect motor

thermal switch leads atTP2 and TP10. Use ohm-

meter to check continuily. Switch should be

closed when motor is cool.

5.

Check microswitch (306). With no fluid pres-

sure in the pressure control, disconnect wires

TPl8 andTP19. Checkcontinuityacross switch

terminals with an ohmmeter. Switch contact

should be closed. Depress actuator button. An

audible "click" indicates

the

contacts have

opened. Ohmmeter should read infinity.

:ondltlon

C

led lamps on,

:lear lamp

off

lnplug

sprayer!

6. Check circuit board (25) by substituting with

a

good board. See page 26.

1.

Check circuit board (25) by removing from

boxwifhoutdisconnectingwires;seepage26for

removalprocedure.

Placethincardboardinopti-

caldetectorslot.Pluginandturnonsprayer0NLY

LONG

ENOUGH

TO

CHECKUMP

CONDITION.

sprayer.

Remove

cardboard.

C1earlampshouldbeonnow.Turnoffandunplug

WARNING:

Removing the circuit board while

still wired over-rides the

optical

detector which

couldcausethesprayertoover-pressurize,ifthe

microswitch does not function properly.

WARNING:

Toreducetheriskofeiectricshock,

handle board by edges only1

Do

not allow any

metal objects to come in contact with the board!

2. Check bourdon tubeflag (A) anddetector(6)

26). Turn pressure setting to maximum:

flag

position. Reinstall circuit board (25 -see page

should extend less than halfway into optical de-

tector slot from the bottom.

f

check

is

not

OK,

refer to this column

. Reset circuit breaker

or

replace outlet fuse.

:ircuit breaker or fuse continues to open,

se,

Electrical

Short".

page

18.

!.

Unplug sprayer. Check continuity

of

bot1

Ioles

of

ONlOFF switch (302) from TP3 to TP.

Ind TP5 to TP6. Replace switch if faulty.

:heck continuity

of

RFi filter (310) from TP7 tc

'P8 and TP9 to TP10. Replace filter if faulty.

:heck power supply cord (311) for continuit

rom

TP11 to TP12 and TP13 to TP14. Repiacl

:ord if faulty.

:heck for any loose connections.

I.

Replace damaged terminals and reconnec

ecurely.

I.

Replace electric motor if switch does

no

:lose

when motor

is

cool. See page 36.

;. Replace the microswitch. See page 25.

i.

Replace circuit board. See page 26.

.

Replace circuit board. See page 26.

'.

Calibrate pressure control

to

see if that cor

ects problem. See page 28.

'not, replace bare pressure control box (300)

iee

page 27.

Low

output

ype

of

Problem

1.

Check for worn spray tip.

ow output

What

to

Do

What

to

Check

If check is

OK,

go

to

the next check

If

check is not

OK,

refer

to

this column

then replace tip.

See

your separate gun or tip

1.

Follow

Pressure

Rellef

Procedure Warnlng

manual.

2.

Checkto seethat pump does not continueto

turnonsprayer.Primewithpaint.Triggergunmo-

2.

Service pump.

See

page

30.

stroke when gun trigger is released. Plug in and

mentarily, then release and engage safety latch.

Relieve pressure, turn

off

and unplug sprayer.

I I

let.

I

3.

Checkelectricalsupplywithvoltmeter. Meter

3.

Reset building circuit breaker; replace build-

should read 190-250

Volts.

ingfuse.Repairelectricaloutletortryanotherout-

4.

Check extension cord size and length; must

cord.

beatieast12gaugewireandnoiongerthan15.2

4.

Replace with

a

correct, grounded extension

Im.

5.

Check

G1

and

G2

leads from bridge

(306)

to

connectors. Refer

to

page 26.

5.

Clean circuit board male terminals. Repiace

cedure

on

page 28.

6.

Calibrate pressure control.

See

page26.

6.

Checkstailpressure.RefertoCaiibrationPro-

iooseordefectiveleadferminals.Secureiyrecon-

circuit board (25) for damage or

loose

wires or

7. Check bridge

(306)

+

and

-

ieadsand termi-

7.

Be sure male terminal blades are centered

nalsto motor. inspectwiring insulationandtermi- and firmly connected

to

female terminals.

Re-

nals for

signs

of overheating.

See

page 23. place any

loose

terminal or damaged wiring.

Se-

nect lead terminals to board.

curely reconnect wires

to

bridge.

6.

Checkforloosemotorbrushleadsandtermi-

9. Check for worn motor brushes which should

be

10

mm minimum.

See

page

33.

6.

Tighten terminal screws. Replace brushes

if

9. Replace brushes. See page

33.

I

brushsprings. Rolled portionofspring must rest brush.

See

page

33.

10.

Check for broken and misaligned motor 10. Replacespring ifbroken. Realignspringwith

squarely

on

top of brush.

I

holders.

See

page

33.

11.

Check motor brushes for binding in brush

with small cleaning brush. Align brush lead with

11.Clean brush holders, remove carbon dust

slot

in

brush holder

to

assure free vertical brush

movement.

12. Check circuit board (25) by substituting with

armature tester (growler) or perform spin test.

See

page

19.

~~

12. Replace circuit board.

See

page

26.

~~

I

13.

Replace motor.

See

page

36.

14.

Check bridge

(308)

by substituting with a

goodbridgeorbyperformingthebridgetest.See

page

20

or 23.

tureisdeterminedtobegood.Abadarmaturewill

CAUTION:

Donotperformthischeckuntilarma-

immediately burn

out

a good bridge.

~ ~~

14.

Repiace bridge.

See

page

23.

No

Output

rype

of

Problem What to Check

Aotor runs and pump strokes

1.

Check paint supply.

If

check is

OK,

go

to

the next check

hotor runs but pump does

lot stroke

12.

Check for clogged intake strainer.

1

3.

Check for loose suction tube or fittings.

are seating properly. See page

30.

4.

Checktoseeifintakevalveballandpistonball

'I

2.

Checkconnectingrodassemblyfordamage.

See paQe

34.

3.

Besurecrankindnvehousingrotates:plugin

sprayer and turn

on

momentarily to check. Turn

off

and unplug sprayer. See page

34.

No

Output

vpe

of

Problem

;pray pattern variations

1

What to

Do

If

check is

not

OK.

refer

to

this column

1.

Refill and reprime pump.

2.

Remove and clean, then reinstall.

3.

Tighten;usethreadsealantorsealingtapeon

threads, if necessary.

4.

Remove intake valve and clean. Check balls

and seats for nicks; replace if necessary. See

page

30.

5.

Replace packings.

See

page

30.

Also check

piston valve sat for hardened paint or nicks and

replace, if necessary.

1.

Replace pin if missing.

Be

sure retaining

springisfullyingrooveallaroundconnectingrod.

2.

Replaceconnectingrodassembly.Seepage

34.

3.

Check drive housing assembly for damage

and replace if necessary.

See

page 34.

What to Check

If check is

OK,

go

to

the

nexI

check

What to

Do

If check is not OK, refer

to

this column

1.

Be

sure both

G1

and

G2

leads

tom

bridge

1.

Reconnect securely. See page

26.

(308)

to

circuit board

(25)

are firmly connected.

See

page

26.

I

2.

Checkstall pressure. Refer

to

PrewreCon-

2.

Adjust pressure control.

See

page page

28

trol Adjustment procedure

on

page

28.

I

3.

Checkbourdontubefiag(A)anddetector(B)

(300).

Adjust the pressure control after reas.

circuit board

(25).

repiace the bare pressure control assembly

should

no

drag or bind

In

optical detector slot

of

tor

slot

to see

if

that correctsthe problem.

If

not

position. Turn pressure setting

to

maximum; flag

3.

Carefullybendflagintoalignmentwithdetec-

sembly.

See

pages

27

and

26.

4.

Check circuit board

(25)

by substituting with

a good board.

See

page

26.

4.

Replace circuit board. See page 26.

5.

Check

Low

Output section

on

page

16.

Motor is Hot and Runs Intermittently

Type

of

Problem What

to

Do

What to Check

If check is

OK,

go to the next check If check is not

OK,

refer to this column

Hot motor

1.

Decrease pressure Setting or increase tip

1.

Checkto see

if

sprayer has been operating at

high pressure with small tips, which causes low

motorRPMandresultsinexcessiveheatbuildup.

size.

12.

Check to see

if

ambient temoerature where

12.

Move sorayer to shaded, cooler area

I

Corifsprayer If possible.

I'

..

3. Check to see

if

sprayer has been left in a 3. Turn

off

sprayerwhenever you stop spraying

stalledcondition(sprayerturnedon,pressurized.

for a while and relieve fluid pressure.

but not operating) for long periods of time.

I I

Electrical

Short

Type

of

Problem What

to

Check

If

check is

OK,

go to the next check

~~~ ~ ~ ~

I

What

to

Do

If

check is not

OK,

refer to this column

as

soon

as sprayer switch is

page ".

CAUTION

Any short in any

motor which are encased in conduit

(22).

See

suretocheckwiresbetweenpressurecontroland

turned

on.

1.

Check all electrical wiring for damaged insu- Building circuit breaker opens

lation,andallteninalsforloosefitordamage.Be

part

Of

the

motor

power

cir-

2.

Check for missing inspection plate gasket

which

is co~-~ected to (see page33), bent terminal forks or other metal

the output side ofthe bridge,

tometalcontactpointswhichcouldcauseashort.

will cause the bridge to burn

out immediately. Correctly di- 3. Checkmotorarmatureforshorts byusingan

agnose and repair all shorts armature tester (growler) or perform spin test.

before checking and

replac.

See page

19.

Inspect windings for burns.

ing bridge.

4.

Check bridge

(308)

by substituting with a

good bridge or by performing bridge test. See

page

20

or 23.

tureisdeterminedtobegood.Abadarmaturew1li

CAUTION

Do not perform this check until arma-

immediately burn out a good bridge.

Building circuit breakeropens

13.

as

soon

as

soraver

is

1. Check 'Basic Electrical Problems'

on

page

plugged intoouilet and

sprayer

is

turned on, sure thesoraverisunoluaaed! Disconnectwires

2.

CheckON/OFFswitch(302).Seepage22.Be

.

I-

from switch and check switch with ohm meter.

The ohm meter should read infinity with the ON/

OFF switch OFF, and zero with the switch ON.

CAUTION:

A short in the motor circuit will burn

the bridge out immediately, which in turn usually

causes the ON/OFF switch to fail in the closed

mode.

1.

Repair orreplaceany damaged wiring ortei

minals. Securely reconnect all wires.

''

2.

Correct faulty conditions.

3. Replace motor. See page 36.

4.

Replace bridge. See page

23.

2.

Replace ON/OFF switch. See page

22.

Spin

Test

To

reduce the risk of serious bodily injury, including

Pressure Relief Procedure

fluid injection, splashing fluid or solvent in the eyes or

on the skin, or injury 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 sprayer.

4. Disengage the gun safety latch. Hold

a

metal par

of the gun firmly to the side of a grounded meta

pail, and trigger the gun to relieve pressure.

5. Engage the gun safety latch.

6.

Open the pressure drain valve. Leave the valve

open until you are ready to spray again.

If

you

suspect that the spray tip or hose is com-

plete/y clogged, or that pressure has

not

been fully

relieved after following the steps above, wrap a rag

around the tip guard retaining nut or hose end cou-

pling and

VERY

SLOWLY

loosen the part to relieve

pressure gradually, then loosen completely. Now

clear the tip or hose.

For checking armature, motor winding and brush

electrical continuity.

Setup

Remove the drive housing from the sprayer

as

de-

scribed in

Drive

Housing Replacement, Steps

l

to

6,

page

35.

Remove the pressure control cover and screws, the

motor cover, the fan cover

(F),

and the inspection cov-

ers

(J).

See Fig.

12.

Disconnect the

two

leads from the motor

to

the bridge

(308). See Fig.

13.

j

Armature

Short

Circuit Test

Quickly turn the motor fan by hand.

If

there are no

shorts, the motor will coast

two

or three revolutions

before coming to a complete stop.

If

the motor does not spin freely and resists rotation,

the armature

is

shorted and the motor must be re-

placed. See page

36.

Armature, Brushes, and Motor Wiring

Open Circuit Test (Continuity)

Connect the

two

black motor leads together with a

test

lead.

Turn the motor fan by hand at about

two

revolutions

per second.

If

there

is

uneven or no turning resistance, check for

the following and repair parts as needed. See page

33.

Broken brush springs, broken brush lead, loose

brush terminal screws, worn brushes, broken motor

leads, loosemotor lead termin,als.

If

there is

stili

uneven or no turning resistance, replace

the motor.

See

page

36.

)

Fig.

12

308

Fig.

13

m362

Bridge

Test

Remove the bridge

(308)

from

the

pressure control

functional.

See

Bridge Rectifier Replacement, page

box and perform this test to determine

if

the

bridge

is

23.

Use

a continuity tester, such

as

multi-meter set

on the

X1

ohms scale.

All tests must be performed.

If

the

bridge fails even

one test, it must be replaced.

Using the chart at the right, connect

the

meter wires

Fig.

14

shows the position

of

the wires on the bridge.

as

indicated and then check the continuity.

000

T

0

-

Check For

1.

Line

short

Ohmmeter

Reading

Connect meter

+

to bridge AC1

Connect meter

-

to bridge AC2

No

continuity

2.

Diode

1

Connect meter

+

to bridge

-

Connect meter

-

to bridge AC1

Connect meter

+

to bridge ACI

Continuity

No

continuity Connect meter

-

to bridge

-

"_"""".""""__._________

3.

Diode2

Connect meter

+

to bridge

-

Connect meter

-

to bridge AC2

Connect meter

+

to bridge AC2

Continuity

No continuity

Connect meter

-

to bridge

-

"""""""""""."""."

1.

Gate 1

Connect meter

+

to bridge

+

Connect meter

-

to bridge ACl

No

continuity

5.

Gate2

Connect meter

+

to bridge

+

Connect meter

-

to bridge AC2

No

continuity

j.

Diode 3

Connect meter

-

to bridge

+

Connect meter

+

to bridge

+

No

continuity Connect meter

-

to

bridge

-

Connect meter

+

to bridge

-

Continuity

Fig.

14

Graco Ultra 1000 Operation manual

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