Graco ULTRA 500 Operation manual

INSTRUCTlONS/PARTSLIST 307-758
ORACO Rev D
SUPERSEDES C
Thismanual contains IMPORTANT
WARNINGS
end INSTRUCTIONS
READ ANDRETAINFORREFERENCE
120 VAC, 15 Amp
ULTRA@ 500 AIRLESS PAINT SPRAYER
2750 psi (195 bar) MAXIMUM WORKING PRESSURE
Basic, without hose or gun
Model231-032. Series A
Model 231-041
Complete sprayer with hose, gun, RACTM IV
DripLessTMTip Guard and SwitchTipTM.
Model 220-409
Same as231-041. andisCSAcertified. @
Same as Model 231-032, except has low profile cart.
Model231-054, Series A
Same as Model 231-041 except has low profile cart.
Model231-055
PATENTNO. 4,397,610
PATENTED 1983. CANADA
EREVETE
19%
FOREIGNPATENTSPENDING
INDEX
Warnings ................................ 2, 3
Avertissement
........................... 4, 5
Advertencia ............................. 6, 7
Introduction ................................ 8
Operation 10
Setup
9
Shutdown 8 Care ........................ 11
TroubleshootingGuide 13-20
FlushingGuidelines 12
Spin Test;
.................................. 19
Bridge Test
................................ 20
Repair Section Index
.................... 21
Parts List
8 Drawings
Sprayer.
............................ .32-35
How ToOrder Replacement
Parts
............................... 33, 35
Pressure Control
...................... 36
TechnicalDataBack Cover
CircuitBoard
37
.........................................
..................................
......................
.............
...........................
................
Hazard of Using Fluids Containing Halogenated Hydrocarbons
WARNING
Never use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids Containing
such solvents in this equipment. Suchuse could result
in a serious chemical reaction,with thepossibilih/ of explo-
sion, which could cause death, serious bodily injury and/or substantial property damage.
Consult your fluid suppliers to ensure that the fluids being usedare compatible with aluminum and zinc parts.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1444
@COPYRIGHT1986 GRACO INC.

~~ ~ ~~~~~~ ~ ~ ~~~~~~ ~
WARNING
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates veryhighfluidpressure. Sprayfrom
the gun,
leaks or ruptured components can inject fluid
through yourskinand into your body andcause extremely
seriousbodilyinjury, includingtheneedfor amputation. Also,
fluid injected orsplashed intothe eyesor on the skincan
cause serious damage.
NEVER point the spray gun
at anyone or at any part of the
vy to "blow back" paint; this is NOT an air spray system.
body. NEVER put hand or fingers over the spray tip. NEVER
ALWAYS have the tipguard in place
on the spray gun when
spraying.
ALWAYSfollow, the
Pressure Relief Procedure, below,
before cleaning
or removingthespray tip orservicingany
system equipment.
NEVER try
to stop or deflect leaks with your hand or body.
Besure equipmentsafety devicesareoperatingproperly
beforeeach
use.
Medical Alert-Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT ASA
SIMPLE CUT. Tell the doctor exactly whatfluidwas injected.
jury.
It Is
Important to treet the
Injury surgically assoon
Note to
Physician: Injection in the skinisa traumatic in-
ea possible. Do not delaytreatmenttoresearchtoxicity.
Toxicity is e concern
wlh some exotic coatings injacted
direct& into the bloodstream.Consultation
wlh a plastic
surgeon or reconstructivehandsurgeonmaybe advisable.
Spray Gun Safety Devices
each use. Do not remove or modify any part of the gun; this
Besure
all gunsafetydevicesareoperatingproperly before
can cause
a malfunctionand result in serious bodily injury.
Whenever you stop spraying, even for
a moment, always set
Safety Latch
the gun safety latch in the closed or "safe" position, making
thegun inoperative. Failureto
set thesafmlatchcen resultin
accidental triggeringof the gun,
DHuser
The gun diffuserbreaks up spray and reducesthe risk offluid
injectionwhenthe tip
is notinstalled. Check diffuseroperation
regularly. Follow the
Pressure Rellef Procedure, below,
then remove the spray tip. Aim the guninto
a metalpail,
holding the gun firmly to the pail. Using the lowest possible
to an irregular stream, replace the diffuser immediately.
pressure, triggerthegun. Ifthefluidemittedisnotdiffusedin-
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. Thetip guard alerts youto thefluid injectionhazard
and helps reduce,but does not prevent, the risk of accidental-
spray tip.
ly placing your fingers or any part of your body close to the
Trigger Guard
Alwayshavethetrigger guardinplace on thegun when spray-
ing toreduce the risk of accidentally triggeringthe gun if
it is
dropped or bumped.
Spray Tip Safety
Use extremecautionwhen cleaning or changingspray tips. If
thespray tip clogswhilespraying, engagethegun safety latch
immediately. ALWAYS follow the
Pressure Rellef Prp-
cedure and then removethe spray tip toclean it.
PressureReliefProcedure
To reducethe risk of seriousbodilyinjury. includingfluid injection, splashingfluidor solventinthe eyes oron theskin, ar injury
from moving pansor electric shock,
always follow thisprocedurewhenever you shut off thasprayer. when checking or servic-
thegun safety latch.
(2) TurntheON/OFF switch to OFF. 13) Unplugthepower supplycord. 14) Disengagethegunsafety latch.
ingany part of thespray system, when Installing, cleaning or changing spray tips, and whenever you stop spraying. (1) Engage
gun safety latch.
(7) Open the pressure relief valve, having a container readyto catch the drainage. (8) Leave the pressure relief
(5) Hold a metal partof thegun firmlytothe sideof a grounded metal pail, and triggertheguntorelieve pressure. 161 Engagethe
valve open until you are ready to spray again.
I
If you suspectthat the spray tip orhoseis complete& clogged, or thatpressure has nor been ful& relievedafter followingthe
steps above. VERY SLOWLY loosenthetipguard retainingnutor hose endcouplingand relieve pressure gradually, then
loosen
completely. Now clear the tip or hose.
. .... .
ENGAGE SAFETY
LATCH
NEVER wipe off build-uparoundthespray tip until pressureis
fully relieved and the gun safety latch
is engaged.
I
\
I
-
OPENPRESSURE
RELIEF VALVE

EQUIPMENT MISUSE HAZARD
General Safety
Anymisuse of the spray equipment or accessories. such as
overpressurizing, modifying parts, using incompatible
chemicalsandfluids, or using worn or damagedparts,can
causethem toruptureand resultinfluid injection, splashingin
the eyesor on theskin, or other seriousbodilyinjury, fire, ex-
plosion or property damage.
NEVER alter or modify any part of this equipment; doing
so
could cause it to malfunction.
CHECK allsprayequipmentregularlyandrepairorreplace
worn or damaged parts immediately.
Always wear protective eyewear,glovesand clothing as
recommendedby the fluid and solvent manufacturer.
System Pressure
This sprayer candevelop 2750 psi 1195 bar/ MAXIMUM
accessoriesare rated to withstand the maximum working
WORKING PRESSURE. Be surethat all spray equipment and
pressureof this sprayer.
DO NOT exceedthe maximumwork-
ing pressureofanycomponentoraccessoryused in the
system.
Alwaysreed the fluid and.solvent.manufacturer'sliterature
Fluid and Solvent Compatibility
before using them in this sprayer.
HOSE SAFETY
High pressurefluid in the hoses canbe very dangerous.If the
hose develops a leak,split or rupture duetoany kindof wear,
damageor misuse, the high pressure spray emittedfrom
it can
cause a fluid injection injury or other serious bodily injury or
propeny darnage.
ALL FLUID HOSES MUST HAVESPRING GUARDS ON
BOTH ENDSThe spring guards help protectthe hose from
kinks or bends
at or closetothe couplingwhich can result in
hose rupture.
TIGHTEN allfluid connections securely before each use. High
pressure
fluid candislodgea loose coupling or allow high
pressure sprayto be emittedfrom thecoupling.
NEVER use a damaged hose. Beforeeach use, check the en-
tirehosefor cuts, leaks. abrasion,bulging cover. or damageor
movement of the hose couplings.
If any of these conditions
exist, replace the hose immediately.
DO NOTtry torecouple
highpressure hose or mendit withtapeor any other device. A
repaired hose cannot containthe high pressure
fluid.
HANDLE AND ROUTEHOSESCAREFULLY. Do not pull on
hosestomove equipment.
Do notusefluidsorsolventswhich
are not compatiblewiththe innertube and coverof the hose.
(82"Cl or below
-40°F (-40"Cl.
'
DO NOT exposeGracohose to temperaturesabove 180°F
Hose Grounding Continuity
Proper hose groundingcontinuityisessentialtomaintaining a
grounded spray system. Check the electrical resistance of your
fluid hosesat least once a week.
If your hose doesnothave a
tag on
it which specifies the maximumelectricalresistance.
contact the hose supplier or manufacturerfor the maximum
resistancelimits.
Use aresistancemeter in the appropriate
range for your hose to check the resistance. If the resistance
exceeds the recommendedlimits,replace
it immediately. An
ungrounded or poorly grounded hose canmake your system
hazardous.AlsoreadFIRE
OR EXPLOSION HAZARD.
FIRE OR EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the
pump 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 unplugging a power supply cord. Sparks canignitefumes
from solvents and the fluid being sprayed, dust particles and
otherflammable substances, whether you are spraying
in-
doors or outdoors,andcancausea fire or explosion and
serious bodily injuryandpropertydamage.Always plug the
sprayer into an outlet
at least 20 feet 16 m) awav from the
spraver and the sprayarea.
Do not plug in or d in plug any
power supply cords
in thespray area when there is any chance
of igniting fumes still
in the air.
~ ~ ~~~
while usingthisequipment,STOP SPRAYING IMMEDI-
If you experience any static sparking or even a slight shock
ATELY. Checktheentire systemfor proper grounding.
Do not
corrected.
usethesystem againuntiltheproblemhas beenidentifiedand
To reduce the risk of static sparking, ground the sprayer and
Grounding
all other spray equipment used or located in the sprayarea.
CHECK yourlocalelectricalcode for detailedgrounding
in-
structions for your area and type of equipment. BESURE to
ground all of this spray equipment:
1.
2.
3.
4.
5.
6.
7.
Sprayer: plugthe power supplycord, or extension cord,
a properly grounded outlet.
Do notusean adapter.Allex-
eachequippedwithan undamaged three-prong
plug, into
tension cords musthave three wires and be ratedfor
15
amps.
Fluid hoses: useonly groundedhoseswith a maximumof
500 feet (150 mlcombined hoselengthtoensure ground-
ing continuity. Refer to Hose Groundlng Contlnulty.
Spray
gun: obtaingrounding through connection to a
properly groundedfluid how and sprayer.
Objectbeingsprayed: accordingto local code.
Fluid supply container: according to local code.
All solventpails used when flushing, according to local
code. Useonlymetalpails, which are conductive.
Do not
placethe pailona non-conductivesurface, suchas paper
or cardboard, which interruptsthe grounding continuity.
ingpressure, alwaysholda metalpertof the gunfirmly to
To maintaingroundingcontinuify when flushing or reliev-
the side of agroundedmetalpail, then triggerthe gun.
Flushing Safety
Reducethe riskof injection injury, static sparking, or splashing
by following the specific flushing procedure givenon page
12
of thismanual.Follow the Pressure ReliefProcedureon
page
2, and remove the spray tip before flushing. Holda metal
part of the gun firmly to the side of a metalpail anduse the
lowest possiblefluid pressure during flushing.
MOVING PARTS HAZARD
Movingpartscan pinch or amputateyourfingers or other
bodyparts. KEEPCLEAR ofmovingparts when starting or
operating the sprayer. Unplug the sprayer. and follow the
Pressure Relief Procedure on page
2, beforechecking or
servicing any part of the sprayer to prevent
it from starting
accidentally.
IMPORTANT
ticularly the General Standards, Part 1910,
and the Construction Standards, Part 1926"should be consulted.
United States Government safety standards
have beenadopted undertheOccupational Safety and HealthAct. These standards-par-
307-758 3

AVERTISSEMENT.
La pulv6risation haute presslon peut causer des blessures trds graves.
R6SeN6 exclusivement A I'usage professionnel. Observer toutes les consignes de s4curit6.
Blen lire et bien cornprendre tous ies menueis d'instructions avant d'utiliser le met6riei.
RlSQUES D'INJECTION
Conslgnes g4n6raies de s4curlt6
Cet appareil produit un fluide B trbhaute pression. Le fluide
fuiies @u deruptures peut penetrer sous la peauou B I'int6rieur
pulv4risB par
le pistolet ou le fluidesous pression provenantde
du corps
et antratner des blessures trbs graves, voir mhe une
amputation. Mdme
sans &re sous presslon, le fluide Bclabous-
sant ou entrant dans
Ies yeuxpeutaussientralnerdes
blessures graves.
tie quelconque du corps. NE JAMAIS menre
la main ou Ies
NE JAMAISpointer le pistoletvers quelqu'unou vera unepar-
doigts sur I'ajutage du pulv4risateur. NE JAMAIS
assayer de
pneumatiqua.
"refouler" la peinture.
Cet appareil West PAS un compresseur
TOUJOURS garder
la protectionde I'ajutage en place sur le
pistoletpendant la pulvbrisation.
TOUJOURSObserver
la March B Sulvre pour DBtendre la
I'aiutage du pulv4risateur, ou d'effeuer un travail quelcon-
Presslon donneeplusloin, avant de
nenoyer ou d'anlever
que sur une partiede I'appareil.
main ou la corps.
NE JAMAIS esqyer d'arr6ter ou dedBvier
Ies fuites avec la
Avant chaque utilisation, bien s'assurer que Ies dispositifs de
s4curitd fonnionnentcorrectement.
Solns m4dlcaux
En casde pBn6tration de fluide sou8 la peau: DEMANDER
IMMEDIATEMENTDESSOINSMEDICAUX
COMME UNE SIMPLE COUPURE.
DURGENCE.NEPAS SOIGNER CElTE BLESSURE
Avls au medecln: La pdndtration des fluides sous la peeu
est untraumetisme. II est Importantdetraiter
chlrurglcalementcenablessurelmm6dlatement.
Ne
pes retarderle traitement pour effectuer des recherches sur
la toxicitd, Certeins revdtements exotiques sont dangereuse-
ment toxiques quand
ils sont inject& directernant dens le
sang. II est souheitable de consuher un chirurgien esthdtique
ou un chirurgien sp&ialisd dans le reconstruction des meins.
Avant chaque utilisation, bien s'assure quetous Ies dispositifs
de Securit4 du pistolet fonnionnent correctement.Nepas
Dlsposltifs
de s4curlt6 du plstolet
enlever ni modifier une partie quelconque du pistolet; ceci ris-
quaraitd'antraherunmauvais fonctionnement
et des
blessures graves.
Varrou de sdcuritd
A chaque fois que I'on s'arrete de pulv4riser. m6ma s'il s'agit
d'un court instant, toujours mettre
le verrou de skurite du
pistolet
sur la position"fermW ou "s4curiW (''safe'') pour
empdcher la pistolet de fonnionner. Si
le varrou de skurite
n'est pas mis, le pistolet peut se declencher accidentellement.
Voir
la fig. 3.
DHusar
La diffuseurdu pistolet sert B diviser le jet et B reduire le8 ris-
quesd'injectionaccidentellequandI'a'utagen'estpas en
place. VBrifier le fonctionnementdu diduuseur r6gulibrement.
Pour cette v4rification.detendre
la pression en observant la
Marche B Sulvre pour DBtendre la Presslon donnbplus
loin puis enlevar I'ajutage du pulv4risateur. Pointer
le pistolet
dans
un seau en m6tal. en le maintenant fermementcontre le
Seau.Puis, en utilisant la pression la plus feible possible, ap-
puyer sur
la gachane du pistolet. Si le fluide projete n'est pas
diffusesous forme de jet irrQulier, remplacer immediatement
le diffuseur.
Protection de I'ajuta e
TOUJOURS maintenir B a protectionde I'ajutage en place sur le
pistoletdupulv6risateur.pendant la pulv6risation. La protec-
tion de I'ajutage attire I'attention sur
Ies risques d'injaction et
contribue B reduira, mais n'dvite pas le risque. que Ies doigts
ouunepartiequelconqueducorps
ne passent accidentelle
ment
B proximiteimmediate de I'aiutage du pulv8risateur.
Consi nes des4curit4concernantI'ajutage
du
pulv4r B sateur
Faire extrdmementattention
B l'occasion du nettoyage ou du
remplacementdesajutages du pulv4risateur.SiI'ajutage
se
bouchependant la pulv6risation.menreimmediatement le
verrou desBcurit6 dupistolet.TOUJOURSbienobserver la
Marche B Suivre pour DBtendre la Presslon puisenlever
l'ajutaga du pulverisateur pour
le nenoyer.
dupulverisatauravant que
la pression ne soit compl6tement
NE JAMAISessuyer cequi
s'est accumuldautourde I'ajutage
tombb
et que le verrou deskuritedupistoletne
toit engage.
~
Marche B Suivre pour D4tendre la Presslon
Pourreduire
les risquesdeblessuresgraves. y compris Ies blessurespar iniection de fluiieou celles caush pardes
B Suivre B chaque fois que Yon arretele p.ulv4risateur. B l'occasion de la verification ou de la reparation d'une piece de I'appareil
Bcleboussures dans
les yeux ousur la peau, despikesan mouvementoupar Blectrocution,toujoursbien observercettemarche
de pulvdrisation,
B I'occasion de I'installgtion, du nettoyage ou du remplacementdes ajutages et d'une manibre gBn6rale B cha-
que arret.
1) Engager le varrou de skuritBdu pistolet. 2) MenreI'interrupteur Marche-ArrBt surARRET ("OFF"). 3) DBbrancher
le cordon d'alimentation. 4) DBsengager le verrou de &curite du pistolet. 5)En maintanant, une partia metallique du pistolet
fermementappuybcontre
le cat6d'un seau en metal, appuyer sur la gachetta du pistolet pour liberer la pression. 6) Engager le-
8) Laisser la soupape ouverte iusqu'a ce que
{e pulverisateur soit de nouveau pret
B &re utilis4.
varrou de s4curit6 dupistolet.
7) Ouvrir la soupape de &curite en prenant soin d'avoir un recipient prdt B r6cupBrer le liquide.
Sil'on soupconne que I'ejutege du pulv.4riseteur ou le tuwuest compldtement bouchd. ou que le pression n'e pas dtd cornpldte-
mentIib4r6eepr& evoirpmcMd eux op4rations ci-dessus,
desserrer TRES LENTEMENT 1'6crou de retenue de la protectionde
I'ajutage ou
le raccord duboutdu tuyau et liberer progressivement la pression, puis terminer le desserrage. On peut maintenant
1 2 3
4 307-758

RISQUES'EN CAS DE MAUVAISE UTlLlSATlON DU MATERIEL
Consignes gBn4ralesde s6curit4 Pression
TouteutilisationanormaledeI'appareildepulv4risation oudesCepulverisateur peutproduire un PRESSION MAXIMUMDE
accesmirescomme.parexemple,lamisesousunepression TRAVAIL 195 bar 12750 Ib/po. s 1. S'assurerque tous Ies
excessive, Ies modifications de pieces, llutilisation de produits
chimiques et dematieresincompatibles et llutilisation de elementsdu pulverisateur et
ses accessoiressont concuspour
pieces usbesouabidespeutcauser des d6gBts
B I'appareilou resister
B la pression maximum de travail de ce pulvbrisateur.
des ruptures depieces et entrainer uneinjection de liquideou NE PAS depasser la pression maximum de travail d'aucun des
d'autresblessuress6rieuses. un incendie,uneexplosion ou
~~~~~~ibili~4 des corps
elementsou accessoires utilis48 avec-cet appareil.
d'autres d6g8ts. Toujoursliresoigneusement
les documents et brochures du
NEJAMAIS altereroumodifierunepiecedecotappareil;ceci
' fabricant des fluides et solvantsutilisbsavantde s'en servir
risqueraitd'entrainerson mauvais fonctionnement. danscepulv6risateur.
VERIFIER regulierementtout I'appareil de pulv4risation et
ses
Bquipements et reparer ou remplacer immediatement 18s
MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXISLES
pieces usees ou abim6es.
~~~~~ ~
Le fluide A haute pression circulant dans Ies tuyaux peut atre
tresdangereux. Encasde fuite sur
le tuyau, defissure.
dechirureou rupture
B la suite de I'usure, de deg8ts ou dune
mauvaiseutilisation,
les projections de fluidehautepression
qui en proviennent peuvent entrainer des blessures graves par
penetration sous la peau ou par contact, ainsi que desdWts
materiels.
TOUS LES TUYAUX FLEXIBLES DOIVENT AVOlR DES
RESSORTS SPIRALE DEPROTECTION AUX
2 BOUTS1
pliures, de bouclesou de nmudssur
Ies tuyaux quipourraient
Les spirales deprotectioncontribuent
B &iter la formation de
entrainer la rupture du tuyau
B I'endroit du raccord ou B son
voisinag4.
tion. Le fluidesouspressionpeutfairesauter un raccord
SERRER FERMEMENTtous
Ies raccords avant chaque utilisa-
desserreou produireunjet
B haute pression s'hchappant par le
raccord.
NE JAMAIS utiliser un tuyauendommag&Avantchaque
utilisation, verifier entierement chaque tuyau pour deceler
Ies
coupures, fuites, abrasions, boursouflures de i'enveloppe ou
toute autre deterioration oujeu des raccords.SiI'on constate
rune de ces d6tbriorations.
il faut remplacer le tuyau im-
mediatement.NE PAS essayer de refaire
le raccordd'un tuyau
haute pressionnide reparer
le tuyauavec durubanadh48if ou
par tout autre moyen. Un tuyaurbparb ne peutpas resister au
fluide sous pression.
RISQUES D'INCENDIE OU D'EXPLOSION
De 1'6lectricit6 statique est produite par le passagedu fluide B
grande vitesse dans la pompe et dans le8 tuyaux. Sitoutes Ies
pieces de I'appareil de pulvbrisation nesont pas convenable-
ment relihs
B la masseou B la terre, des Btincelles peuvent se
produire et I'appareilrisqued'atredangereux. Des Btincelles
peuvent Bgalement
se produire B I'occasion du branchement
oududebranchementducordon d'alimentation. Les Btincelles
sontsuffisantespourallumer
Ies vapeurs desolvants et le
fluidepulv6ris6, Ies finesparticules depoussibreainsique
d'autres substances inflammables, quand on pulverise
B I'in-
terieur ou B I'exterieur, et elles peuventcauser un incendieou
une explosion. ainsi que des blessures graves
et desdeg8ts
trouvant
B au moins 6 m (20 pieds) de I'appareiletde I'endroit
materiels. Toujours brancher
le pulvbrisateur dans une prise se
oh se fait la pulv6risation. Ne pas brancherou debrancher un
cordon d'alimentation que1qu'il soit dans
la zone oh se fait la
encore presentes dans I'air prennent feu.
pulverisation quand
il y a le moindre risque que des vapeurs
S'il
se produit des Btincelles d'blectricit6 statique, ou si vous
ressentez la moindredecherge, ARRETE2 IMMEDIATEMENT
mi8
B le terre. Nevous SEN~Z pasdusystemavant que le pro-
LA PULVERISATION. VBrifiez que ie systbme entier est bien
blhesoit identifib et corrige~
Mise A la terre ou B la masse
Pour r&uire 185 risques de production d'Btincelles d'Blectricit6
statique,
le pulverisateur et tous 18s bquipements utilisbsou se
terreou B la masse. Pourconnaitre le detaildesinstructions de
trouvant dans la zone de pulvbrisation doivent atre relies
B la
mise
B la terredanslaregionet le typeparticulierd'Bquipe-
ment, CONSULTER
le codeou 18s reglementations Blectriques
tion suivants sont bien relies
B la terre:
locaies. S'ASSURER que tous
les Bquipements de pulv6risa-
1. Puldrisateur: Brancher le cordond'alimentation ou la
&at,dans uneprise de courantconvenablementmise
B la
rallongequidoiventatreBquipbs d'une prise
B 3fiches enbon
MANIPULERLES TUYAUX AVECPRECAUTIONET
CHOlSlR SOIGNEUSEMENT LEUR CHEMIN. Nepasdeplacer
le fluide en tirant sur le tuyau. Ne pasutiliser de fluides ou de
solvantsquinesont pas compatibles avecI'enveloppe
in-
terieureouexterieure du tuyau. NE PASexposer le tuyau B
des temperatures supbrieures B 82OC (180OF) ou inferieures B
4OC (4°F).
Continuit6 de le mise B la terre des tuyaux
essentieile pour maintenir la mise
B la terre de I'ensemble de
Unebonnecontinuit6 de lamise
B la term des tuyaux est
vaporisation. V6rifiez.la resistance Blectrique de vos tuyaux B
fiuideset B air, au moins une fois par semaine. Si votretuyau
ne comporte pas d'Btiquette qui precise la resistance Blectri-
que maximum, prenez contact avec
le fournisseur de tuyaux
ou la fabricant pour avoir
Ies limitesde resistance maximum.
votretuyau
et verifier larbsistance. Si ceIIe-cidepasseies
Utilisez un metrede resistance de la gamme appropriee pour
limites recommandees,remplacez le tuyauimmediatement.
rectepeutentrainerdesrisquespourvotre system. Lisez
Untuyausans mise
B laterreouavec une mise B la terre incor-
aussiLES RISQUES O'INCENDIE OUDEXPLOSION ci-
dessus.
terre. Ne pasutiliser d'adaptateur. Toutes
Ies rallonges doivent
avoir 3 fils et atre prevues pour 15 ampbres.
2. Tuyaux flexibles: Afin d'assurer la continuitdde la mise B la
terre, n'utiliser quedestuyaux comportant une mise
B la terre
etayantunelongueurmaximumcombineede
150 m
(1500 pieds). Se reporter Bgalement auparagraphe "Con-
tinuit6
du circuit de mise B la terre des tuyaux".
3. pistolet: RBaliserlamise B Ia'terreen le raccordant B un
tuyau flexibleet
B un pulvbrisateur deja convenablementrelib
B la terre.
4. Recipient d'alimentation: ObSeNer le code ou 185 reelemen-
tations locales.
5. Objets,mat4riel ou surfacesrecevant la pulverisation:
observer le code ou les reglementations locales.
6. Tous Ies seaux de solvants utilisbpour le rincage: observer
dtalliques conducteursde 1'8lectricite. Nepas mettre le seau
le cod0ou 18s r6glementationslocales. Nutiliserque des seaux
sur une surfacenon conductrice comme surdu papier ou du
carton car cela interromprait la continuit6 le la mise B la terre.
rince le matdriel ou quand on libdm la pression, toujours
7.
Pour consarver la continuit6 da la mise la terre quand on
maintenir une partie metalliquedupistolet fermement appuyee
contre
le cat6 d'un seau en mdtal puis appuyer sur la detente
du pistolet.
Mesures de S4curlt4 concernant le Rincage
Pour reduire
Ies risquesdeblessuresparpenetrationdela
aux Bclaboussures. ObSeNer
la marche B suivrepour le rincage
peau et
Ies risques dils aux Btincellesd'6lenricitb statique ou
donnee
B la page 12 de cemanuel.ObseNerla "Marche B
enlevar I'ajutage du pulverisateur avant le rincage. Maintenir
Suivre pour DBtendre
la Pression" donnb B la page 4 en
une pertie metalliquedu pistolet fermementeppuybcontre
le
cat6 d'unseau enmetal et utiliser la pression la plusfaible
possible pendant
le rincage. 307-768
6
~ ~~

ADVERTENCIA
EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES.
SOLO PARA US0 PROFESIONAL. RESPETELOS AVISOS DE ADVERTENCIA.
Lea y entienda todo el manual de instrucciones antas de manejar el equipo.
PELIGRO DE INYECClON DE FLUID0
Segurldad general Apsratos de seguridad de la pistola pulverizadora
Este equipogenera un fluido aunapresi6n muy aka.El
rociadode lapistola,
10s escapes de fluido o roturasde 10s
Asegurarqua todos 10s aparatospmtectoresdelapistola
estbn funcionandobienantesdecadauso. No sacar ni
componentes pueden inyectar fluido en la piel y e1 cuerpo y
causar lesionesearemadamente raves, incluyendo aveces la modificarninguna pieza de la pistola pues podrla causar
e1
necesidaddeamputaci6n.Tam 'b i6n, e1 fluido inyectado o
malfuncionamiento de la misma con 18s consiguientes lesiones
salpicado
en 10s ojos puedecausar graves daflos. personalas.
Pestilo de seguridad
NUNCAapuntar
la pistola haciaalguien o algunapartedel
cuerpo.NUNCAcolocarlamano
o 10s dedosencimadelabo-momento,siemprecolocar el pestillo deseguridaden la
Cada vez que se deje de pulverizar, aunque saa porunbreve
quilla.NUNCAtratarde"hacerretornarlapintura";este NO posici6n "cerrada",
lo que dejala pistolainoperante.' El no
as un sistemaderociadodeaire.hacerlopuedellevsr al disparoimprevistodelapistola.
SIEMPRE tenercolocado
e1 protector de laboquiila enla
pistola mientras
se est& pulverizando.
Difusor
SIEMPRE seguir el procedlmlento dedescargade presl6n.
e1 riesgodeinyecci6ncuando no estb instaladalaboquilla.
El difusor de la pistoladispersa e1 chorro pulverizado y reduce
dado
m6s abjo, antes de limpiar o sacarla boquilla o de dar Revisarcon regularidad
el funcionamiento del difusor. Seguir
selvicio
a cualiquierequipodel sistema. e1 procedlmlentode descargadepresi6n. dadomdsabajo,
y despuk sacarla boquilla.Apuntar la pistola a un balde
NUNCA tratar de parar
o desviar 10s escapescon la mano o el
cuerpo. metdlico,sosteniendolabienfirmecontra
61. Utilizando la
Asegurerque todos
10s aparatosdeseguridaddelequipo presi6n
mhs bajoposible,dispararlapistola.Si el fluido
estBn funcionando bien antes decada uso. emitidonosale disperso enun chorro irregular, reemplazar de
inmediato
e1 difusor.
Tratamlento
mBdlco
Si pareciera queun poco de fluido penetr6 la piel, conseguir
TRATAMIENTOMEDICO DEURGENCIADE
IN-
MEDIATO. NOTRATAR LA HERIDA COMOUNSIMPLE
CORTE. Decir al medico exactamente cua fluido fue.
Avlso ai medico: Si se llega a inyectar estefluidoen la piel
se causa una lesidntraumdtice. Es lmportantetratar
demorar
el tratamiento para investigarla toxicidad. La tox-
qulrOrglcamentelalesl6n
a la brevedad poalble. No
icidad as elgode soma importanciaenelgunas pinturas
exdticascuendo se inyectendirectamante
al torrente
ssngulneo. Sird conveniente consultar
a on especielista en
cinigia pldstica o reconstructive de las manos.
Rotector de la boquilla
SIEMPREtener el protector dela boquillacolocadoen la
pistola mientras se esta pulverizando. Este protector llama la
atenci6n contra
e1 peligro de inyecci6n y ayuda a reducir, pero
no evita. la colocaci6n accidental de 10s dedos o cualquierotra
parte del cuerpocirca de la boquilla.
Segurldad de la boqullla pulverizadora
Tenermuchocuidado e1 limpiar o cambiar 18s boquillas. Si
llegara
a obstruirse mientrasest6 pulverizando, enganchar e1
pestillo de lapistola de inmediato. SIEMPREseguir e1 pro-
quilla para limpierla.
cedlmlento dedescarga de presldn
y despuksacar la bo-
NUNCA limpiar la acumulaci6n de pintura alrededor de labo-
quills antesdeque se hayadescargadoporcompletola
Dr-"n y
e1 pestillo est6 enganchado.
\
Marche B Suivre pour DBtendre la Pression
Pour reduire 188 risquasdeblessuresgraves, y compris 18s blessurespar injection de fluide ou celles causks pardes
klaboussuresdans
Ias yeux ousur la peau, des piecesen mouvementoupar Blectrocution, toujours bien observer cette marche
B suivre chaqua fois que I'm arrete le pulv6risateur. B VOccasion de la vbrification ou deia reparation d'une piece de I'appareil
de pulv6risation,
B I'occasion de I'installgtion, du nenoyageou duremplacement des ajutageset d'une manibre gbnbrale B cha-
que arret. 1) Engager le verrou de s6curitbdupistolet. 2) Mettrellinterrupteur Marche-Arr& surARRET ("OFF). 3) Dbbrancher
fermementappuykcontre
le cat4 dun seau en mbtal, appuyer sur la gachette du pistolet pour libbrer la pression. 6) Engager le
la cordon d'alimentation. 4) Dbsengager le verrou de sbcuritb du pistolet. 5) En maintenant une partie mbtalliquedu pistolet
verrou
de sbcuritbdu pistolet. 7) Ouvrir la soupape de sbcurite en prenant soin d'avoirun recipientpr& B rbcupbrer la liquide.
8) hisser la soupape ouvertejusqu'a ce que !e pulvbrisateur soit de nouveau pret B &re utilisb.
ment lib&& aprdsavoirpmcddd aux opBrations ci-dessus, desserrer TRES LENTEMENT 1'6crou deretenuede la protection de
Si I'on soupconne queI'ajutage du puk4risateur ou le tuvauestcompl&tementbouchd, ou que la pression n'a pas Bt.4compl&te
I'aiutage ou la raccorddu bout dutuyauet libbrer progressivement la pression, puis terminer
le desserrage. On peut maidtenant
dbboucher I'ajutageou
le tuyau.
1 2 3 7

PELIGRO POR MAL US0 DEL EQUIP0 PELIGRO DE INCENDIO 0 EXPLOSION
Sa urldad general
Culquier mal us0 del equipo pulverizador
o 10s accesorios, tal
El flujo aakavelocidaddel fluido alpasar por la bomba y
comosobrepresurizaci6n,modificaci6ndepiezhs,us0de mangueracreaelectricidadesthtica. Si todas Ias partesdel
equipopulverizador no tienenbuenatierra,puedenocurrir
materiales
y productosquimicosincompatibles, o utilizacibn chispas, convirtiendo a1 sistemaenalgo peligroso. Tambibn,
piezas dafiadas desgaadas, pu& hacen que se rompan
pueden producirse chispas al enchufar o desenchufar al cor-
y causenla inyecci6n de fluido u otraslesionescorporales d6n elbctrico. Estaschispaspuedeninflamar
10s VaPores de
graves, incendio, explosi6n
o daflon a la propiedad.
10s solventes y el chorro de fluido pulverizado, particulas de
NUNCAalterar
0 modificarninguna Piezade est0equiP0; el techo, lo que podrracausaruna explosi6n 0 incandioy graves
polvo
y otrassusianciasinflamables, 888 a1 sire libre o bajo
hacerlopodrlacausarunaaverla.lesiones cormrales
v daAosa laDrockdad.Enchufarsiempre
REVISAR con regularidad
e1 equipo pulverizador y reparar o
reemplazar de inmediato18s piezas dafladas o desgastadas.
Presi6n del alatema
Esta pulverizadorapuededesarrollar195barlas 12750 psi) de
PRESION DE TRAEAJO MAXIMA. Asegurarque todo el
equipo pulverizador y sus accesoriostienen la capacidad para
aguantar la presi6n mhxima de trabajo de esta pulverizadora.
NOexcederla presidnmeximadetrabajode ningdn com-
ponente
o accesorio de este sistema.
Compatlbilidad
de fluldo
solvente antesde usarlosen esta pulverizadora.
Siempre leer 18s instrucciones del fabricantedelfluido
y
SEGURIDAD EN EL US0 DE LAS MANGUERAS
ser muypeligroso. Sien la manguera se dasarrolla unescape,
El fluido que escapa a aka presi6n por Ias mangueras puede
daflo
o maltrato. el chorro aalia presibn emitido porall1puede
una rotura
o rajaduradebidoacualquier tip0 de desgaste,
graves
o daflos ala propiedad.
Causaruna lesi6nporinyecci6nuotraslesionescorporales
1TODAS
LAS MANGUERASPARA FLUIDOS TIENEN
QUE TENER GUARDAS DERESORTE EN AMBOS
EX-
TREMOSl Estas protegenlasmanguerascontradobleces o
retorcedurasen 10s acoplamientos o cercade ellos, 10s que
podrian traducirseen roturas de la manguera.
Antes deusarlas, APRETARbien firmes todas18s conexiones.
Elfluido aalia
prdn puededesalojar un acoplamiento suelto.
o dejar que por 41 escape unchorro a alta presi6n.
NUNCAusarunamangueraque
esth daflada.Siempre,
revisarla en busca de cortaduras. escapes, abrasi6n. cubierta
abultada,
o acoplamientos sueitos o daflados. Si llegara a en-
contrarse cualquiera deenas condiciones,reemplazar de
in-
mediato la manguera. NO intentar reacoplar una manguera de
alta presi6n
o enmendarla con cinta adhesiva u otro material
similar. Una manguera que ha sido remendada no aguante
e1
fluido a alta presidn.
MANEJAR
Y PASARCUIDADOSAMENTELAS
equipo.Nousar fluidos
o solventesque Sean incompatibles
MANGUERAS.Notirarde Iasmangueraspara mover
el
con e1 tub0 interno y la cubiertadela manguera. NO exponer
Ias manguarasatemperaturassobre82°C l1Bo"F) o bajo
4'C 14°F).
Continuidad del circuito de puaste a tlerra de la
manguera
La continuidaddelcircuito depuestaatierraapropiado es
esencialparamantener conectado a tierra el sistema
pulverizador.
Es indispensablerevisarlaresistencia elktrica
maximade 18s mangueras de aire
y defluido por Io menos una
vezalasemana. Si
la manguera no tiene una etiqueta en la
cual
se espacifica la resistenciaalktricamaxima, ponerse en
contact0con
el proveedor o fabricantede la manguera para la
informaci6n sobre
10s limitesde resistencia. Usar un metro de
resistencia en la gama apropiada para comprobarla resisten-
cia;siexcede
10s Ifmitesrecomendados.reemplazarladein-
mediato. Es muy arriesgado tenar una manguera sinpumaa
tierra
o con la puesta a tierra enmalascondiciones. Leer tam-
bibnla informaci6n sobre RIESGO DEINCENDIO
0 EXPLO-
SION.
mas arriba.
la pulverizadora
a untomacorriente que se encuentre apoi lo
menos 6 m IB pies)delamhquina y del Brea que se vaa
rociar. No enchufar
o desenchufar ningdncord6nelbctricoen
el lugardonde se esth rociandocuandotodaviaexistala
posibilidad de que queden vapores inflamables
en d aire.
choqueelbctricomientras
se usa el equipo,DEJAR DE
Si ocurre una chispa de electricidad esthtica o inclusounligero
buscade
una tierraapropiada.Nousardenuevo e1 sistema
PULVERIZAR
DE INMEDIATO.Revisar todo e1 sistemaen
hasta haber identificado
y solucionado el problema.
Puesta
a tlerre
Para reducir el riesgode chispas estbticas, conectar a tieria la
pulverizadoray todo
e1 otro equipode pulverizar que se use o
se encuentre en el lugar que se va a rociar. CONSULTAR el
c6digo elbctrico dela localidadpara Iasinstrucciones sobre Ias
conexionesatierraexigidasparalazona
y tip0 deequipo.
ASEGURARdeconectaratierra todo esteequipo
pulverizador:
sor, cada uno con un enchuf de tres patas enbuen estado, a
1. Fulverizadora: enchufar
el cord6nelbctrico,
o cable exten-
un tomacorrientecon pumaa tierraapropiado.No usar
un
adaptador. Totos 10s cables extensores tienen que tener tres
hilos
y una capecided de 15 amperios.
2. Mangueras para fhidos: usarsolamentemangueras con
puestaatierradeuna longitud combinada de150
m
I500 pies), para asegurar buenacontinuidad a tierra. Referirse
tambibnalpbrrafosobre continuidad
e tlerrade la
3. pistola: hacer lapuesta a tierraconecthndolaauna
manguera.
manguera defluido
y pulverizadora bien conectadas a tierra.
4. Suministrar un recipiente:deacuerdoalc6digodela
localidad.
5. Objeto quese estd rociando: de conformidad con el c6digo
local.
6. Todos /os baldes de solvente usados durante e1 lavado, de
metal, que Sean conductivos.Nocolocar
e1 balde enuna
conformidadcon
el c6digolocal.Usar solamenta baldesde
superficienoconductiva,comopapel
o cartdn,queinter-
rumpela continuidad a tierra.
7. Para mantenerla continuidad a tierra durante al lavado o
descarga de presidn, siempre apoyar una parte metBlica de la
despuk apretar
el gatillo.
pistolabienfirmecontra
el costadodelbaide de metal,
Seguridad durante el lavedo
piel,
o que ocurra una descarga de electricidad esthtica, siam-
Para reducir
el riesgo de que se inyecte o salpiquefluido en la
preseguir Ias INSTRUCCIONES PARA EL LAVADO, dadasen
laphgina12. Segyir
e1 procedlmiantode descarga de
preslbnen la pdgna 6,
y quitar la boquilla rociadora antes de
lavar. Apoyar
una parte methlica de la pistola bien firmecontra
el costado de un balde de metal y usar le presi6n mhs baja
posible defluido durante
e1 lavado.
PELIGRO DE LAS PIEZAS MOVILES
Las piezasan movimianto pueden pinchar o amputar dedos u
otraspartesdelcuerpo.MANTENERSEALEJADOdelas
de la pulverizadora. Desenchufar la pulverizadora
v descargar
piezasen movimiento durante
e1 arranque o funcionamiento
la presi6n antes de revisar o dar servicio. a cualquierpartede
puiverizadora, para impedir qua arranque inesperadamente.
IMPORTANT
Se han adoptadoIas normasde seguridad del gobierno de 10s
E~tadosUnidos de Norteam4rica bajo el Acta de Seguridad V
SaludOcupacional.Deberhnconsultarseestasnormas, en
especial Ias Generales, Parte 1910,
y Ias Normas de Construc-
ci6n.Parte1926.

ULTRA" 500 BASIC COMPONENTS
Model
231-041 shown
n
PRESSURE CONTROL KNOB
ELECTRIC MOTOR
FLUID FILTER
DRIVE ASSEMBLY
FLUID ounm
PAILHANGER
DISPLACEMENTPU
CIRCUIT BREAKER
RESET BUlTON
ONlOFFSWITCH
PRESSURE RELIEFVALVE
MAINFLUID HOSE
Your newUltra" 500 Sprayer functions andoperates
will help you becomefamiliar with thesprayerbefore
differently than otherairless paint sprayers. This section
operating
it.
Preasure Control
'fhe pressurecontrolincludes an ON/OFF switchfor the
sprayer, the pressureadjustingcontrolknob,
a pressure
with a manual resetbutton. Ita functionistocontrolthe
sensingdevice,and
a currentoverload circuit breaker
fluid pressure
at the pump outlet.
motor speed
so that the sprayermaintains constant
Motor
The DC motor hassealedbearingsandreplaceable
motorbrushes.
Its function istodrive the displacement
pump
at the rate needed to supply sufficient paint
volume
at the selected pressure.
Workingtogether,thepressure control and motor
cause the pump to cyclewheneverthereis fluid or
pressure demand. Whenthe pumpiscycling, the motor
sounds like
an automobile startercranking. When the
pump is not cycling, the motor hums,hums intermit-
will atill
be power to the sprayerand
it will stay
tently, or appearstohaveshut itself
off. However, there
pressurized and readyto
use unless you manuallyshut it
off and relieve pressure:
voltage or voltagefluctuationsthanan AC motor, and a
Because the motor is
DC, it is less sensitive tolow
heavy gauge extension cord
of up to 150 feet (45 m)
can be used.
The
sealed drive assembly transfers powerfrom the DC
Drive Assembly
motortothe displacement pump.
Displacement Pump
The positivedisplacement, volume-balanced pumppro-
videsequal fluid deliveryon both the upand down
filled with Graco Throat
Seal Liquid,helpsprevent
pump strokes. The pump has
a wet-cup which, when
damage tothe throat packings endpistonrod.
Fluid Filter
The fluid filter provides thefinal paint strainingto help
avoid clogsinthe hose and spraytip. The filter includes
a reusable element and a pressure relief valvefor reliev-
ingfluid pressure whenshutting
off the sprayer.
The grounded,nylonspray hoses havespringguardson
Hoses
both ends. The 50 foot (15.2 m)hose has a 114 in. ID.
The 3 foot (0.9 m), 3/16 in. ID whip hoseallows flexi-
ble gun movement. The nylon hose material
acts as a
pulsation dampenertoabsorb pressurefluctuations.
Spray Gun
b RAC IV DripLessTMTip Guard
whichprevents accidental triggering when
it is engaged
Graco high pressurespraygunshave atriggersafety
(seeFig
1). TheReverse-A-Clean IV SwitchTipTMuses
high pressure fluid to remove clogs from the spray tip
without removing
it fromthe gun. It includes a safetytip
guard which helps reduce the risk of fluid injection in-
iuw.
Fig 1

SETUP
1. ConnectHoseandGun (Refer to Fig 2.)
a. Remove the plasticcap plug from the filter
fluid hose onto the nipple.
outlet nipple and screw the
50 ft (15.2m) main
b. Connect the whip hose between the fluid hose
f
and the gun inlet connection.
c.Don'tusethreadsealant,anddon't installthe
spray tip yet1
If you are supplyingyour own hosesandspray
WARNING
gun,besure they are electricallygroundedand
rated for at least
2750 psi (195 bar)Working
to reduce the risk of serious bodily injurycaused
Pressure, and that thegun has a tipguard. Thisis
by staticsparkingand fluid injection orover-
pressurizina and ruDturina the eouioment.
To avoid damaging the pressure control, which
CAUTION
may result in poorequipmentperformanceand
component damage, follow these precautions:
1. Always use nylonsprayhose at least 50 ft
(15.2 mllong.
2. Never use
a wire braid hose as it is too rigid
to act as
a pulsation dampener.
3. Never install any shutoff devicebetween
the filter and the main hose. See Fig 3.
4. Always use themain filter outlet for one-
gun operation. Never plug this outlet.
2. FillPackingNut/Wet-CuD (SeeFia 3.)
Fill thepacking nut/wet-iup1/3 full with Graco
Throat Seal Liquid
(TSL), supplied.
- ~.
3. CheckElectricalService
a.
Bu sure the electricalservice is 120 V,
80 HzAC, 15 Amp(minimum) and that the
Outlet you use is properly grounded.
b.
bse an extensioncord which has 3 wires of a
minimum 12 gaugesize,and a maximum of
150 ft (45 mllong. Longer lengthsmay affect
sprayer performance.
4. Plug in the Sprayer
a. Besure theON/OFF switch is OFF.Refer to
Fig
4.
b.Plugthepowersupplycord into agrounded
electrical outletthat is at least 20 ft (6 m)away
from the spray area to reduce the chance
of a
spark igniting the spray vapors.
c.
Do not remove the third prong of the power
supplycordplug, which
is the grounding
prong, and do not use an adapter.
5. Flush thepumpto remove the lightweight oil
which wss left in to protect pump parts afterfac-
tory testing.
a.
Before using wafer-basepaint, flush with
mineralspirits followed by soapywater,and
then a clean water flush.
b. Before using oil-base paint, flush with mineral
spirits only.
c.
See FLUSHINGGUIDELINESon page 12 for
6.. Preparethe paintaccordingtothe manufacturer's
flushing procedure.
a.Removeany skin that mayhave formed.
recommendations.
b. Stir thepaint to dissolvepigments.
c. Strain the paintthroughafine nylonmesh bag
(availableat most paintdealers) to remove par-
ticlesthat couldclogthefilter or spraytip.
This
is probably themosf important step toward
trouble-free spray painting.
307-758 9

OPERATION
WARNING
To reduce the risk of serious bodilyinjury, in-
Preaaure
Rellef Procedure
cludingfluid injectionorsplashinginthe
eyes or on
the skin,or injury from movingparts or electric
shock, alwaysfollow this procedure wheneveryou
shut
off the sprayer, when .checking or servicing
any part of the spray
system, wheninstalling,
stop spraying.
cleaning or changing spray tips, and whenever
you
2. Turn the ON/OFF switch to OFF.
1.Engage the gun safety latch.
3. Unplugthe power supply cord.
4. Disengage the gun safety latch.
6. Hold
a metalpartof thegunfirmlytothesideof
a metalpail,andtrigger the gun to relieve
preasure.
tainer ready to catch thedrainage.
are ready to operate the sprayer again.
6. Engage the gun safety latch.
7. Open the pressurereliefvalve,having a con-
8. Leave the pressurereliefvalveopen until you
If you suspect that the spray tip or hose is com-
pletely clogged,or that pressure has not been fully
relieved
after followingthe steps above, VERY
SLOWLYloosen the tip guardretaining nut or
hose endcouplingand relieve pressure gradually.
Then loosenthe nut completely. Nowclear the tip
or hose obstruction.
Prime the Sprayer with Paint.
J
e. Close the filter'spressure relief valve. See Fig 2.
b.Don't installthe spray tip yet1
c. Put the suction tube into thepaint container.
d. Turn the pressure adjusting knob all theway
counterclockwisetolower
the pressuresetting.
e. Disengagethe gun safetylatch.
f. Hold a metal part of the gun firmly againstand
aimed into
a metalwaSte container. See Fig 5.
Squeeze the trigger and hold it open, turn the
ON/OFFswitchtoON, and slowly increase the
pressure setting until the sprayer
starts. This
procedurereduces the risk of staticelectric
dischargeandsplashing.Keep the gun trig-
gered until
all air is forcedoutof thesystem and
the paintflowsfreely from the gun.Releasethe
trigger and engage the safety.
NOTE: If the pumpis hard toprime, place a con-
tainer under
the pressure relief valve and
open
it. Whenfluidcomesfromthevalve,
close
it. Thendisengage the gun safety
latchend proceedas
in Step If, above.
g. Check all fluid connectionsfor leaks. If any are
found, follow the Pleasure Rellef Procedure
Warning, above, then tighten connections.
METALTO METAL
MAINTAIN FIRM
GUNAND CONTAINER
CONTACT BETWEEN
Fig 5
2. Install the SprayTipendTipGuard
a. Be sure the gun safetylatchisengaged.
b.Installthespray tip.
If usingtheRACIV,refer
to manual
307-848, supplied with the gun, for
installation instructions.
3. Adjustingthe Spray Pattern
a. Increase the pressure adjusting knob setting
just until'spray from theguniscompletely
atomized.Toavoidexcessiveoversprayand
fogging, and to decrease tip wear and extend
the
lie of the sprayer, always use the lowest
possiblepressureneeded to getthe desired
results.
b.
If morecoverageisneeded, use e larger tip
rather than increasing the pressure.
c.Test the spray pattern. Toadjust thedirection
of the spraypattern,engage thegunsafety
latchand loosen the retainingnut. Position the
tip guard horizontally. for
a horizontal pattern
the retainingnut.
or vertically, for a vertical pattern. Thentighten
4. Operating Tlps. .The'sesuggestions will helppre-
vent the motor from runningtoo hot or operating
intermittently.
'a. Decrease the pressurewhenusing a small tip.
b. Keep the sprayer in
a shaded areawhenspray-
c. Turn
off the sprayerandrelievepressure
. ...
ingoutdoors.
whenever
you stop spraying.
10 307-758

5. Cleaning a Clogged TIP
To reduce the risk of serious bodily injury from
WARNING
fluid injection orsplashing in the eyes or on the
skin,useextreme cautionwhen cleaningor
spraying, engage the gun safety latch immediate-
changing spray tips. If the spray tip clogs while
ly,then follow theprocedure in Steps
Ea-b,
below.
NEVER wipe
off builduparound the spraytip until
engaged.
pressureisfully relieved and
the gun safetylatchis
a. Clean the front of the tip frequently during the
day'soperation.
First, follow the Pressure
Rellef Procedure Warningon page
10. Then
use
a solvent-soaked brush to keep paintfrom
building up and clogging thetip.
.b.
If the spray tip doesclog,release the gun trig-
ger,engage the gun safety,end rotate the
spray tip handle
1W. See Fig 6.
c.Disengage the gun safety latch and trigger the
gun into
e westecontainer. Engage thegun
safety latch again.
d.Returnthehandle to theoriginalposition,
disengage thegunsafety,andresumespray-
ing.
e. If the tip is still clogged, engage the gun safety
latch,shut
off end unplug the sprayer,and
open the pressurereliefvalve to relieve
pressure. Clean the spray tip.
SHUTDOWN
AND CARE
1. Check thepacklngnutlwet-cup dally. First
follow the Pressure Relief ProcedureWarning
on page
10. Besure the wet-cu is 1/3 full of TSL
et el1 times to help prevent pent P buildup on the
piston rod andprematurewear of packinga.The
packing nut should be tight enough to stop
leakage, but no tighter. Overtightening
may cause
bindingend excessive pecking wear.
Use e screw-
driverand light hammer to adjustthe nut. See
Fig 7.
2. Clean thefluldfilteroften endwhenever the
sprayer is stored.
First follow the Pressure Relief
Procedure Warnlngon page 10. Refer to manual
307-273, supplied, for the cleaning procedure.
3. Flushthe sprayer at theend of eachwork day
and
fill it with mineral spiritsto help preventpump
corrosion and freezing. See"FlushingGuidelines"
,.onpage
12.
CAUTION
night to: (1) preventpumpcorrosion; (2) to pre-
Never leave water or anypaintinthesprayer over-
vent the paintor waterfromfreezinginthe pump
endpressure control which cen
cause loss of
Always
use mineral spirits for the final flush.
pressure, stalling orserioussprayerdamage.
Relieve pressure. This leaves
a protective coating
of mineral spiritsinthe sprayer.
4. Forvery short shutoffperiods, leavethe suction
tube
in the paint, follow the Preasure Rellef Pro-
tip.
cedure Warnlngon page 10, and clean the spray
5. Coil the hose andhang it on the hoserack when
storing
it, even for overnight, to help protect the
hosefrom kinking, abrasion, couplingdamage, etc.
BE SURE QUN
SAFETY LATCH
IS ENGAGED
Fig 6
307-758 11

When to Flush 5.
1.
2.
3.
4.
New Sprayer. Your new Ultra@ 500 Sprayerwas
factory tested inlightweightoilwhichwas
left into
Before using wafer-base paint, flushwith mineral
protect pump parts.
water flush.
spirits, followed by soapy water, and then
a clean
Before using oil-base paint, flush with mineral
spirits only.
such as mineral spirits or water.
ChangingColors. Flush.with
a compatiblesolvent6.
Changing from water-base to oil-base paint.
Flush with soapy water, then mineral spirits.
Changing from oil-base to water-basepaint.
Flushwith mineral spirits, followed bysoapy water,
then
a clean water flush.
" Storage.
Water-basa palnt flush with water, then mineral
spiritsand leavethe pump, hose and'gunfilledwith
mineralspirits.Shut
off andunplugthe sprayer,
open the presaurereliefvalve to relievepressure
and leave open.
Oll-base palnt flush with mineral spirits. Shut off
valve to relieve pressure and leave open.
and unplugthe sprayer,open the pressurerelief.
Startup
after storage.
Before
uslng water-base palnt, flush out mineral
flush.
spirits with soapywaterand then
a clean water
When uslng oll-base palnt, flush out the mineral
spiritswith the paintto be sprayed andthe sprayer
isready to
usa.
How to Flush
1.
2.
Follow the Pressure Relief Procedure Warning
on page
2 or 10.
307-273 supplied. Clean the screenseparatelyand
Remove the filter bowl andscreen;seemanual
installthe bowl without the screen to flush
it. See
Fig 8.
UPRESSURE RELIEF
ne 8
3. Close the filter pressurereliefvalve.
4. Pour one-half gallon (2 liters)of compatible solvent
into
a bare metal pail. Put the suction tube inthe
pail.
IVALVE
6. Remove thespray tip fromthe gun.
6.
12
into a metal waste container andwith a metal part
Disengagethe gunsafety latch. Point the spraygun
of the gun firmly touchingthemetalcontainer,
cedure
helps reduce the rlsk of static sparklng
squeeze the gun trigger. See Fig 9. Thls pr-
and splashlng. With the gun triggered, turn the
adjusting knob clockwise
lust until the sprayer
ONlOFFswitchto
ON and slowlyturn the pressure
starts. Keep the gun triggered until cleansolvent
comes from the nozzle.
Release thetriggerand
engage the gun safety latch.
307-758
METALTO METAL
MAINTAIN FIRM
GUN AND CONTAINER
CONTACT BETWEEN
7.
8.
9.
Check all fluid connections for leaks. If anyleak,
first follow the Pressure
Rellef Procedure Warn-
start the sprayer, and recheck the connectionsfor
ing on page 2 or 10. Nowtightenthe connections,
leaks.
the gun safety and triggerthe guntoforce solvent
Remove the suction tubefrom the pail. Disengage
from the hose.
Do not let the pump run dry for
pump packlngsl Then turn ON/OFFswitchtoOFF
more
than 30 seconds to avold damaging the
and engage the gun safety.
Unplug the power supply cord.Open the pressure
relief valve and leave openuntilyouare readyto
use
the sprayeragain.Unscrewthe filter bowl and
reinstall the clean screen. Reinstall the bowl, hand
tight only.
10. If you have flushedwith mineral spirits andare go-
water followedbya clean water flush. Than repeat
ing to
use a water-basepaint, flush with soapy
Step
1.

~~ ~~ ~~~ ~ ~~~ ~ ~~~~~~~~~~ ~ ~ ~~~
TROUBLESHOOTING GUIDE
Pressure Relief Procedure WARNING
jury from movingparts or electric shock, always follow this procedure whenever you shut off the sprayer, when
To reduce the risk of serious bodily injury, including fluid injection, splashing fluid in theeyes or on theskin, or in-
you stop spraying.
checking or servicing any part
of the spraysystem, when installing, cleaning or changing spray tips, and whenever
2. TurntheON/OFFswitch to OFF.
1. Engage the gunsafetylatch.
3. Unplug thepowersupplycord.
4. Disengagethegun safety latch.
5. Hold a metal part of the gun firmly to theside ofa grounded metalpail, and trigger the gunto relieve pressure.
6. Engage the gunsafetylatch.
8. Leave the pressure relief valve open until you are ready to spray again.
If you suspect that thespray tip or hose is completely clogged, or thatpressure has not been fully relieved after
followingthe steps above,
VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve
pressure gradually, then
loosen completely. Now clear the tip or hose.
’ 7. Open the pressurerelief valve, having a containerready to catch the drainage.
I.
asic ElectricalProblems
WHAT TO CHECK
If check I8 OK, go to nextcheck
1. Check the pressure control knob setting. Thl
ting lfully counterclockwise).
motor
will not run if it is at the minimum sei
2. Check for a cloggedspray tip. Refer to your
separate gun or tip instructionmanual.
1. Check for frozen or hardened paint inthe
tube. Using
a screwdriver, carefully tly to
pump
(39) andlor pressure control bourdon
rotate
fan at back of motor by hand. See
page19.
2. Checkdisplacement pump connectingrod
pin
(20). It must be completely pushed into
connecting rod
(291 and spring retainer (351
should be firmly in groove of connecting rod
See page 28.
”
3. Check for motor damage. Remove drive
housingassembly (181. See page 28. Try to
rotate fan byhand.
”
~~
‘Thaw the sprayer if water or water-based paint has frozenin
warm area.
Do not try tostartthe sprayer until it has thawed
it, due to exposure tolow temperatures, by placing it in e
completely. If the bourdon tube was not damaged by the
freezing, the pump should operate.If painthardened (dried)in
the sprayer, the pump packingsandlor bare pressure control
must be replaced. See page 26 or manual
307-7(0.
1.Checksprayer circuit breaker (309) button tc
be sure it has not popped up.
2. Check electrical supply with volt meter.
Meter should read
105 to 125 VAC.
3. Check extension cord for visible damage.
Use
a volt meter or test lamp at extension
cord outletto check.
4. Checksprayer power supply cord (3111 for
vi5ible damage such
as broken insulation or
wres.
5. Check motor brush leads, terminals and
brush length. Brush lengthshould be
112”
minimum. See page 22.
’When re1
remove
tb
herdand
bare box.
WHAT TO DO
When check Is not OK refer tothls coturn1
1. Slowly increase the pressure setting to see if
the motorstarm.
2. Relieve pressure, refer to your separate gun
or tip instructionmanual for tip cleaning.
1. Thaw‘.PlugInsprayerand turn on. Slowly
increase pressuresettingto
see if motor
stam. If it doesn’t, replace the displacement
pump packings
(see manual 307-7531 andlor
replace the bare pressure control
box (301)’.
See page 26.
2. Push pin into place and secure with the
springretainer.
2. Replace motor (1) if fan won‘t turn.
v
1
I
-
-
-
:in9 the barepressure control box(itern-3011.
circuitbreaker,
ONIOFF switch,bridge, circuit
sctrical hardware and reinstall these parts in the
1.Depress circuit breaker button to reset.
If
trical Short”, page 18.
circuit breaker continues to open, see “Elec-
2. Reset buildingcircuit breaker;replace
buildingfuse.
Tly another electrical outlet.
3. Replaceextensioncord.
4. Replace power supply cord. See page 23.
5. Tightenterminalscrews;replacebrushes.
See page 22.
Troubleshooting continuedonnextpege.
3OJ-J50 13

YPE OF PROBLEM
IOTOR WON7OPERATE
iagnosing circuit board in-
mdition is red lamp
on,
cator lamps. The normal
ear lamp on when board is
iling pump to run.
DIIOW Pressure Relief Pro-
dure. Remove gun from
OW. Remove pressure con-
01 cover end checkfor fault
mdition of circuitboard
mps.
ondition A bothlamps
on;
ump won't operate and
lmtor is not running
:ondition
B
lothlamps off
WHAT TO CHECK
If check is OK. to to next check
I. Check leads from bridge (308) to motor to be
sure they-aresecurely fastened and properly
mated.
2. CheckG1andG2 connectionsbetween cir-
cuit board (23) and bridge (3081 for damage
or
loose terminals.
3. Check for loose motor brush lead connec-
tions and terminals. See page 22.
0. Check brush lengthwhich should be 112"
minimum.
See page 22.
the same rate on bothsides of the motor.
NOTE also that the brushes do not wear at
5. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top ofbrush. See page
22.
5. Check motor brushes for binding in brush
holders.
See page 22.
7. Check motor armature commutatorfor burn
spots, gouges and extreme roughness.
Remove motor cover and brush inspection
platesto check.
See page 22.
8. Check motor armature for shorts using er-
mature taster (growler)or performspin
test.
See page 19.
good bridge or performingbridge test. See
armature is determinedto be good. A bad
CAUTION:
Do not performthis check until
armature will immediately burn out
a good
bridge.
1. Check circuit breaker (309) buttonto be sure
it has not popped up.
9. Check bridge (308) by substitutingwith a
page m.
2. Check sprayer power supply cord (311).
DisconnectTP6female andTP1femaleand
connect volt meter to these leads. Plug in
spr8yer:Meter should read
105 to 125 VAC.
Unplugsprayer. Reconnect TP1.
3.Check ON/OFF switch
(303). DisconnectTP;
and connect volt meter to TP6 female and
TPZmale.Plug in sprayer and turn
on. Metel
should read 105 to 125 VAC. Turn
off and
unplua sprayer. Reconnect TP2.
4. Check jumper wire (306). DisconnectTP3
and connectvolt meter to TP6 female and
TP3 female. Plug in sprayer and turn
on.
Meter shouldread 105 to 125 VAC. Turn off
and unplugsprayer. Reconnect TP3.
5. Check circuit breaker (3091. Connect volt
meter to TP6 female and TP4. Plug in
sprayer and turn
on. Meter should read105
to
125 VAC. Turn off and unplug sprayer.
WHAT TO DO
When check Is not OK refer to this columr
Replace any loose terminals andcrimp to
straight andfirmly connectedto mating part.
leads. Be sure male terminal blades are
Clean circuit board male terminals. Re~lace
loose or damaged terminals. Securely 'recon-
nect leads.
Tighten terminal screws. Replace brushes if
leads are damaged.
Sea page 22.
Replace brushes. See page 22.
Replace spring if broken. Realign spring with
brush. See page
22.
Clean brushhddars. Remove carbonwith
small cleaning brush. Align brush leadwith
slot in brush holderto assure free vertical
brush mOVem9nt.
face commutator if possible. See page 30.
Remove motor and have motor shop resur-
Replace motor. See page
30.
Replace bridge. See page 24.
Depress circuit breaker buttonto reset.
If cir
trical Short", page 18.
cuit breaker continues to open, sea "Elec-
Replace power supply cord. See page
23.
Replace ON/OFF switch. Sea page 23.
Replace jumper wire. See page 25.
Replace circuit breaker. See page 24.
Troubleshootingcontinuedon nextpage
14 307-758

fPE OF PROBLEM
Indinion B
ontinued)
mdition
C
ad lamp on, clear lamp off
nplug spra yerl
WHAT TO CHECK
Ii check Is OK, go to next check
6. Check motor thermal cutout switch.
Connect volt meter to TP6 female and TF3
female. Plug in and turn on sprayer. Meter
should read
105 to 125 VAC. Turn off end
unplugsprayer.
7. Check microswitch (302). ReconnectTP6
connectors. Connect volt meter to TP15
male end TP4. Meter should read 50-125
VAC.
E. Visuallyinspect microswitch (3021 bunon.
Adjustment stud should not depress the
zero. Manuallycheck by depressing bunon
microswitchbutton when fluid pressureis
with small screwdriver; an audible click in-
dicates microswitchis innormal position.
9. Check microswitch (302) continuity with ohm
meter.
Be sure sprayer isunplugged1 Meter
should read zero ohmswith
no fluid pressure
inthe sprayer.
10.Check
all terminals for damage or loa fit.
Reconnect TP6connectors.
11.Check circuit board
(23) by substitutingwith
a good board. See page 25.
1. Check circuit board 123) bv removinofrom
~~
25 for removal procedure.
box withoutdisconneciing wires; s& page
WARNING: Removing the circuitboard
while
still wired over-rides the opticel detec-
tor which could cause the sprayer to over-
pressurize,
if the microswitchdoes not func-
tion properly. Turn the sprayer on
ONLY
longenoughto check lampcondition, then
shut
off immediately.
WARNING: To reduce the risk of electric
shock, handle board by edges only1
Do not
allow any metal objectsto come incontact
with the boardl
should be
on now - removingthe circuit
Plug in and turn
on sprayer. Clear lamp
board over-ridesthe optical detector. Turn
off and unplug sprayer.
2. Check bourdontube flagand detector posi-
tion. Reinstall circuit board
(see page 25).
Turn pressuresening to maximum; flag
should extendless than half way into optical
detectorslot from the bonom.
VIEW
OF OPTICAL DETECTOR AND FLAG
'Whenreplacingthebarepressurecontrol
box 1301), removethecircuitbreaker.
bridge, circuit board and
electrical hardware end reinstall inthe new bare box.
WHAT TO DO
When check 1s not OK nisr lo thls column
~ Allow motor to
cool. Correctcause of over-
heating.
If switch remains open after motor
~001s. check continuitybetweenTi3female
end TP10 with ohmmeter. If
open, replace
motor.
loose or damaged terminals. Securely recon-
Clean microswitchmale terminals. Replace
nect leads.
Microswitchisfaulty. Returnsprayer for
repair.
Micmswitch
is faulty. Return sprayer for
repalr.
).Replace damaged terminals and reconnect
securely.
I.Replacs circuit board.
See page 25.
, Replace circuit board. See page25.
. Calibrate pressurecontrol to see if that cor-
rects problem.
See page 27.
If not, replace bare pressure control box
(301)'. See page 26.
Troubleshootingcontinuedon nextpage

OW OUTPUT
iO0UTPuT
dotor runs andpump stroke
1. Check for worn spray tip.
2. Check to see that pump does not continue
to stroke when gun trigger is released. Plug
in and turn
on sprayer. Prime with paint.
Trigger gun momentarily,then release and
engage safety latch. Relieve pressure, turn
off and unplug sprayer.
3. Check electrical supplywith volt meter.
Metershouldread
105 to 125 VAC.
4. Check extensioncord size and length; must
be at least 12 gauge wire and no longerthar
150
ft (15.2 mi.
5. Check G1 and G2 leads from bridge (308) to
circuit board
123) for damage or loose wires
or connectors. Refer to page 25.
E. Check stall pressure.Refer to Calibration
Procedure
on page 27.
7. Check bridge (308) + and - leadsand ter-
minals to motor. lnsmct wirina insulation
and terminals for signs of ovehating. See
page
20.
8. Check for loose motor brush leads and ter-
minals. See page
22.
be 112" minimum. See page 22.
9. Check for worn motor brusheswhich should
10.Check for broken and misalignedmotor
brush springs.
Rolled pbrtionof spring must
rest squarely on top of brush.
holders. See page 22.
11.Check motor brushes for'binding inbrush
12.Check circuit board
(23) by Substituting with
a good circuit board. See page 25.
13.Check motor armature for shorts by using a1
armature tester (growler) or performspin
test. Seepage 20. :
14.Check bridge 13081 by substituting with a
good bridge or by performingthe bridge
test. See page 20.
CAUTION: Do not performthis check until
armature is determinedto be good. A bad
armature will immediatelybum out
a good
bridge.
' I
I. Check paintsupply.
2. Check for clogged intakestrainer.
3. Check for loosesuctiontube or fittings. See
page 28.
1. Follow Preasure Relief Procedure Wem-
Ingthen replacetip. See your separategun
or tip manual.
2. Servicepump. See manual 307-793.
3. Reset buildingcircuit breaker;replace
buildingfuse. Repair electrical outlet or
try
another outlet.
a. Replacewith a correct, grounded extension
cord.
5. Clean circuitboardmaleterminals. Replace
loose
or defectivelead terminals. Securely
reconnectlead terminalsto board.
5. Calibrate pressure control. Seepage 2?.
1. Be sure male terminal blades are centered
and firmly connectedto female terminals.
ing. Securely reconnect wiresto bridge.
Replace any loose terminal
or damaged wir-
8. lightenterminal screws. Replace brushes if
leads are damaged. See page 22.
3. Replace brushes. See page 22.
10.Replace spring if broken. Realign spring with
brush. See page
2'2,
11.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holder to assure free vef-
tical brushmovement.
12.Replace circuit board. See page
25.
13.Replace motor. See page 30.
14.Replace bridge. See page 24.
1. Refillandreprimepump.
2. Removeandclean, then reinstall.
3. lighten; use thread sealant or sealing tape
on threads if necessary.
Troubleshooting continued on nextpage

TYPE OF PROBLEMTYPE OF PROBLEM
NO OUTPUT
(Continued)
Motor runs
but pump does
not stroke
EXCESSIVE PRESSURE
FLUCTUATIONS
Spray patternvariations.
MOTOR IS HOT e
RUNS IMERMI'ITENTLY
Motor runs
but pump does
not stroke
FLUCTUATIONS
WHAT TO CHECK
If check Is OK, go to next check
. Check to see If Intake valve ball and piston
ball are seating properly.
See manual
307-793.
#. Check for leaking around throat packing nut
which may indicateworn
or damaged pack-
1ngs.See manual
307-793.
. Checkdisplacement pump connecting rod
pin. See page
28.
I. Check connecting rod assembly for damage.
See page 28.
I. Besurecrank in drive housing rotates: plug
insprayer and turn onmomentarilyto check.
Turn
off end unplug sprayer. See page 28.
I. Be sure both G1 and G2 leadsfrom bridge
connected.See page
25.
(308) tocircuit board
(23) are firmly
!. Check stall pressure. Refer to Calibration
I. Check bourdontube flag end detector posi-
tion. Turn pressure setting
to maximum: flag
shouldnot drag or bind
In optical detector
slot of circuit board.
procedureon page
27.
fClRCUlTBOARD
r
VIEW OF OPTICALDETECTORAND FLAG
1. Check circuit board (231 bysubstituting with
i. Check LOW OUTPUT section on page 16.
a good board. Sea page 25.
I, Check to see if sprayer has been operating ai
high pressurewith small tips, which causes
low motor RPM and results
in excessive heal
build up.
I. Check to see if ambient temperature where
sprayer is locatedis more than
WF 132%)
or
if sprayer Is located in direct sun.
3, Check tosee if sprayer has been laft In a
Stalled condition (sprayer turned on,
pressurized. but notoperating) for long
periods of time.
WHAT TO DO
When check Is not OK refer to this columr
.. RemoveIntakevalve and clean. Check balls
and seats for nicks: replace if necessary. Sef
manual
307-793.
I. Replacepackings. See manual 307-793. Also
check pistonvalve seatfor hardened paint 01
nicks and replace if necessary.
. Replace pin if missing.Besureretainer
spring isfully in groove
all around connect-
ing rod. See page
28.
. Replaceconnecting rodassembly.Seepage
. Check drive housingassembly for damage
28.
and replace if necessary. See page 28.
. Reconnect securely. See page 24 end 26.
,. Calibrate pressure control. See page 27
,. Carefully bend flag into alignment with
detector slotto see if thatcorrects problem.
If not, replace bare pressurecontrol
assembly
(301)'. .Calibrate pressurecontrol
after reassembly.
.. Replacecircuitboard. See page 25,
. Decrease pressuresetting or increasetip
size.
!. Move sprayer to shaded, cooler area if
possible.
I. Turn off sprayer whenever you stop sprayins
for
a while and relieve fluid Dressura.
'When rnplecing the
bare pressure control box 13011. remove the circuit board, bridge,
circuit board.
end electrical hardware and reinstall in the new barn box. Troubleshootingcontinuedon nextpage

TYPE OF PROBLEM
ELECTRICAL SHORT
Building circuit breaker opens
as soon as sprayer switch
is
turned on.
CAUTION
Any short in any part of the
motor power circuit, which
is
connected to the output side
of the bridge, will causethe
bridge to burn out immediate-
ly. Correcth,diagnose and
repair
all shotts before check.
ingandreplacingbridge.
as soon as sprayer is plugged
turned on.
into outletand sprayer is NO1
Sprayer circuit breaker opens
after sprayer operates for only
5 to 10 minutes.
WHAT TO CHECK WHAT TO
DO
If check Is OK. aa to next checkl When check
Is not OK refer to this column
1. Check all electrical wiring for damaged in-
1. Repair or replace any damaged wiring or ter-
sulation. and
all terminals for loose fit or
damage. Be sure to check wires between minals. Securely reconnect
a11 wires.
ed in conduit
(221. See page 30.
pressure control and motorwhich are encas-
1. Check for missinginspectionplate gasket
2. Correctfaulty conditions.
metal to metalcontact pointswhich could
(see page
22). bent terminal forks or other
cause
a short.
3. Check motor armaturefor shorts by using an
3. Replace motor. Seepage 30.
armature tester (growler) or performspin
test.Seepage
19. Inspectwindings for
burns.
6. Check bridge (308) by substituting with a
4. Replace bridge. See page 24.
good bridge or by performing bridgetest.
See page 20.
armature is determinedto be good. A bed
CAUTION: Do not performthis check until
armature will immediatelybum out
a good
bridae.
1. Check'BasicElectricalProblems' on page 13.
2. Check ONlOFFswitch I3031 Seepage 23.
2. Replace ONlOFFswitch. Seepage 23.
wires from switchand check switch with
Be
sure the sprayer is
unplugged1Disconnect
ohm meter. The ohm meter should read in-
finity with theON/OFF swltch OFF, and zero
with the switch ON.
burn thebridgeout immediately, which
in turn
CAUTION: A short inthe motor circuit will
usuallycausea the ON/OFFswitchtofail inthe
closedmode.
1. Check electrical supplywith volt meter.
2. Loosenpackingnut.Check for leaking 2. Check tightness of pump packing nut. Over-
1. If voltageistoo high, do not operate sprayer
Meter should read
105 to 125 VAC. until corrected.
tightening nut tightenspackingson rod,
packings.
aroundthroat. Replace pump pecklngs.
if
necessaly. See manual 307-793.
restrictspumpaction, and damages
the top of the fluid filter, arrd installa
5ooo
psi (350 bar1fluid-filledpressure gauge. See
page 27. Pluginand turn on sprayer. Slowly
should
stall at 2550-2750
osi (178-195 bar).
increase pressuresetting to maximum.Pump
3. Check stall pressure. Removethe plug from' 3. 'Calibratepressurecontrol. See page 27
Turn off and unplugspraier.
4. After determiningthat there is no short in pops up), replacethe circuitbreaker.
See
system, resat circuit breaker button.
4. If circuit breaker continuesto open (button
page
24.
Troubleshootingcontinuedon nextpege
18 307-758

... .
..
SPIN TEST
Beforedoingthis procedure, follow the Pressure
Relief Procedure Warningonpage
13 to reduce
the riskof afluid injectioninjury, injuryfrom mov-
ing parts, or electric shock.
For checkingarmature, motor winding and brushalec-
trical continuity.
Setup
cribed
on page 28.
Remove thedrivehousing from'the sprayerasdes-
motor cover, the fan cover(F),and the inspection
Remove the pressure control coverandscrews, the
covers
(J). See Fig10.
Disconnect the
two leads from the motor to the bridge
(3081. See Fig 11.
Armature Short Circuit Test
shorts, the motor will coast two orthreerevolutions
Quickly turn the motor fanby hand.
If thereare no
before comingto a complete stop.
If the motordoes notsvinfreelv and resists rotation.the
armature
is shorted and the motor must bereplaced.
See page 30.
Armature, Brushes, end MotorWiringOpen'
Circuit Test (Continuity)
Connect the
two black motor leads togetherwith a test
lead.
Turn the motor fan by hand
at about two revolutions
per second.
following: a)brokenbrush springs; b) brokenbrush
Ifthereisunevenor
no turning resistance,check the
leads; c) loose brush terminal screws;dlworn brushes;
e) broken motor leads; fl loose motor leadterminals.
Repair parts as needed. Sea page 22.
the motor. Seepage 30.
If there is still uneven or no turning resistance, replace
Fig 10
Fig 11

BRIDGE TEST
performthis test todetermineifthe bridge is functional.
Remove the bridge from the pressure control box and
continuity tester,such
as multi-meter set on the X1
See Brldge Rectifier Replacement, page 24. Use a
ohmsscale ( 0 1.
the bridge fails even one test, it mustbe replaced.
Eight individualchecks, or tests, mustbe performed.If
Fig 12 showstheposition of the wires onthe bridge. Us-
ingthe chartatthe right, connectthe meter wires as in-
dicated by the blackdotsfor each test, then check the
Continuity.
InTests
1, 2 and 3, there should be NO continuity.
In Tests 4,5 and 6, connect the + and - meter wires as
indicated, check continuity, thenswitchthe meter wire
connectionsandcheck continuity again.
You should
get
NO continuity oneway,and YES continuity the
other way.
In Tests
7 end 8, connect themeter wires as indicated
by the black dots. Touch the indicated “G wire toone
meter wire, and then to the other.
You should get NO
continuityone way, end YES continuitythe other way.
Fig 12
..