Graco ULTRA 600 231-307 Series A Operation manual

02982
INSTRUCTIONS–P ARTS LIST 308–319
Rev A
ELECTRIC, 120 VAC
ULTRA) 600 Airless Paint Sprayer
2750 psi (195 bar) MAXIMUM WORKING PRESSURE
Model 231–307, Series A
Complete sprayer with hoses, gun, RAC IV  DripLess 
T
ip Guard and SwitchT ip
Model 231–325, Series A
Basic sprayer only
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts. A void accidental trig -
gering
of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical
T reatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERST AND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable liq -
uids
in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip -
ment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga -
rettes,
arcs from connecting or disconnecting power cords or turn -
ing
light switches on and off.
Failure to follow this warning can result in death or serious injury .
NOTE: This is an example of the DANGER label on your sprayer . This la -
bel is available in other languages, free of charge. See page 39 to order .

 
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 21. . . . . . . . . . . . . . . . . . . . .
Motor Test 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Board 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 30. . . . . .
Pressure Transducer 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure T ransducer Seal 33. . . . . . . . . . . . . . . . . . . . . .
Suction Hose 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain V alve 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts 36. . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts 38. . . . . . . . . . . . . . . . . . . . . .
Dimensions 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Ultra
)Warranty
and Disclaimers 40. . . . . . . . . .
Phone Numbers 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 
WARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FIRE OR EXPLOSION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray
from the gun, leaks or ruptured components can inject fluid
through your skin and into your body and cause extremely
serious bodily injury , including the need for amputation. Also,
fluid injected or splashed into the eyes or on the skin can
cause serious damage.
NEVER point the spray gun at anyone or at any part of the
body . NEVER put hand or fingers over the spray tip. NEVER
try to “blow back” paint; this is NOT an air spray system.
ALWA
YS have the tip guard in place on the spray gun when
spraying.
ALWA
YS follow the Pressure Relief Procedure , below , be -
fore cleaning or removing the spray tip or servicing any sys -
tem equipment.
NEVER try to stop or deflect leaks with your hand or body .
Be sure equipment safety devices are operating properly
before each use.
Medical Alert––Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
CUT
. T ell the doctor exactly what fluid was injected.
Note to Physician : Injection in the skin is a traumatic in -
jury
. It is important to treat the injury surgically as soon as
possible. Do not delay treatment to research toxicity .
T
oxicity is a concern with some exotic coatings injected
directly into the blood 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
each use. Do not remove or modify any part of the gun; this
can cause a malfunction and result in serious bodily injury .
Safety Latch
Whenever you stop spraying, even for a moment, always set
the gun safety latch in the closed or “safe” position, making
the gun inoperative. Failure to set the safety latch can result
in accidental triggering of the gun.
Diffuser
The gun dif fuser breaks up spray and reduces the risk of fluid
injection when the tip is not installed. Check dif fuser operation
regularly. Follow the Pressure Relief Procedure , below ,
then remove the spray tip. Aim the gun into a metal pail, hold -
ing the gun firmly to the pail. Using the lowest possible pres -
sure, trigger the gun. If the fluid emitted is not dif fused into an
irregular stream, replace the dif fuser 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
and helps reduce, but does not prevent, the risk of acciden -
tally placing your fingers or any part of your body close to the
spray tip.
Trigger Guard
Always have the trigger guard in place on the gun when
spraying to reduce the risk of accidentally triggering the gun if
it is dropped or bumped.
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If
the spray tip clogs while spraying, engage the gun safety
latch immediately . AL WA YS follow the Pressure Relief Pro -
cedure
and then remove the spray tip to clean it.
NEVER wipe of f build–up around the spray tip until pressure
is fully relieved and the gun safety latch is engaged.
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 of f the sprayer ,
when checking or servicing any part of the spray system,
when installing, cleaning or changing spray tips, and when -
ever you stop spraying.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3.
Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and trig -
ger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container ready
to catch the drainage. Leave the valve open until you
are ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved after
following the steps above, VERY SLOWL Y loosen the tip
guard retaining nut or hose end coupling to relieve pres -
sure gradually , then loosen completely . Now clear the tip or
hose.
1,5 234
6
02983

4 308-319
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other
body parts. KEEP CLEAR of moving parts when starting or
operating the sprayer . Follow the Pressure Relief Proce -
dure on page 3 before checking or servicing any part of the
sprayer , to prevent it from starting accidentally .
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemi -
cals and fluids, or using worn or damaged parts, can cause
them to rupture and result in fluid injection, splashing in the
eyes or on the skin, or other serious bodily injury , or fire, ex -
plosion or property damage.
NEVER alter or modify any part of this equipment; doing so
could cause it to malfunction.
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately .
Always wear protective eyewear
, gloves, clothing and respi -
rator as recommended by the fluid and solvent manufacturer .
System Pressure
This sprayer can develop 195 bar (2750 psi) maximum
working pressure . Be sure that all spray equipment and ac -
cessories used are rated to withstand this pressure. DO NOT
exceed the maximum working pressure of any component or
accessory used in the system.
Fluid and Solvent Compatibility
BE SURE that all fluids and solvents used are chemically
compatible with the wetted parts shown in the TECHNICAL
DATA
on page 39. Always read the fluid and solvent manu -
facturer’
s literature before using them in this sprayer .
Do
not use 1,1,1-trichloroethane, methylene chloride, other
halogenated hydrocarbon solvents or fluids containing such
solvents in this equipment, which contains aluminum and/or
zinc parts. Such use could result in a serious chemical reac -
tion, with the possibility of explosion, which could cause death,
serious bodily injury and/or substantial property damage.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear ,
damage or misuse, the high pressure spray emitted from it
can cause a fluid injection injury or other serious bodily injury
or property damage.
All fluid hoses must have spring guards on both ends!
Spring guards help protect the hose from kinks or bends at or
close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use.
High pressure fluid can dislodge a loose coupling or allow
high pressure spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the
entire hose for cuts, leaks, abrasion, bulging cover , or damage
or movement of the hose couplings. If any of these conditions
exist, replace the hose immediately . DO NOT try to recouple
high pressure hose or mend it with tape or any other device. A
repaired hose cannot contain the high pressure fluid.
Handle and route hoses carefully . Do not pull on hoses to
move equipment. Keep hoses clear of moving parts and hot
surfaces of the pump and gas engine. Do not use fluids or
solvents which are not compatible with the inner tube and
cover of the hose. DO NOT expose Graco hose to tempera -
tures above 180  F (82  C) or below –40  F (–40 C).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
grounded spray system. Check the electrical resistance of
your fluid hoses at least once a week. If your hose does not
have a tag on it which specifies the maximum electrical resis -
tance,
contact the hose supplier or manufacturer for the maxi -
mum
resistance limits. Use a resistance meter in the appro -
priate range for your hose to check the resistance. If the
resistance exceeds the recommended limits, replace it imme -
diately
. An ungrounded or poorly grounded hose can make
your system hazardous. Also read FIRE 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 can ignite
fumes from solvents and the fluid being sprayed, dust parti -
cles and other flammable substances, whether you are
spraying indoors or outdoors, and can cause a fire or explo -
sion and serious bodily injury and property damage. Plug the
sprayer into a grounded outlet at least 20 ft. (6 m) from the
sprayer.
If
you experience any static sparking or even a slight shock
while using this equipment, stop spraying immediately .
Check the entire system for proper grounding. Do not use the
system again until the problem has been identified and cor -
rected.
Grounding
To reduce the risk of static sparking, ground the sprayer and
all other spray equipment used or located in the spray area.
CHECK your local electrical code for detailed grounding in -
structions for your area and type of equipment. BE SURE to
ground all of this spray equipment:
1. Sprayer: plug into a properly grounded outlet. Do not use
an adapter . Extension cords must have three wires and
be rated for at least 15 amps.
2. Fluid hoses: use only grounded hoses with a maximum of
500 ft (150 m) combined hose length to ensure grounding
continuity . See Hose Grounding Continuity.
3. Spray gun: obtain grounding through connection to a
properly grounded fluid hose and sprayer .
4.
Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to local
code. Use only metal pails, which are conductive. Do not
place the pail on a non–conductive surface, such as pa -
per or cardboard, which interrupts the grounding continu -
ity.
7.
T o maintain grounding continuity when flushing or reliev -
ing pressure , always hold a metal part of the gun firmly to
the side of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce the risk of fluid injection injury , static sparking, or
splashing by following the flushing procedure given on page
15 of this manual. Follow the Pressure Relief Procedure on
page 3, and remove the spray tip before flushing. Hold a
metal part of the gun firmly to the side of a grounded metal pail
and use the lowest possible fluid pressure during flushing.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards
– particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

308-319 5
Avertissement
La pulvérisation à haute pression peut causer des blessures très graves.
Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité.
Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel.
RISQUES D’INJECTION
Consignes generales de sécurité
Cet appareil produit un fluide à très haute pression. Le fluide
pulvérisé
par le pistolet ou le fluide sous pression provenant de
fuites ou de ruptures peut pénétrer sous la peau ou à l’interieur
du corps et entrainer des blessures très graves, voir même une
amputation. Même sans être sous pression, le fluide éclabous -
sant ou entrant dans les yeux peut aussi entrainer des bles-
sures graves.
NE
JAMAIS pointer le pistolet vers quelqu’un ou vers une partie
quelconque du corps. NE JAMAIS mettre la main ou les doigts
sur l’ajutage du pulvérisateur . NE JAMAIS essayer de “refouler”
la peinture. Cet appareil N’est P AS un compresseur
pneumatique.
TOUJOURS
garder la protection de l’ajutage en place sur le pis -
tolet
pendant la pulvérisation.
TOUJOURS observer la March à Suivre pour Détendre la
Pression donnée plus loin, avant de nettoyer ou d’enlever
l’ajutage
du pulvérisateur , ou d’ef fectuer un travail quelconque
sur une partie de l’appareil.
NE JAMAIS essayer d’arrêter ou de dévier les fuites avec la
main
ou le corps.
Avant chaque utilisation, bien s’assurer que les dispositifs de
sécurité
fonctionnent correctement.
Soins medicaux
En cas de pénétration de fluide sous la peau: DEMANDER IM -
MEDIATEMENT DES SOINS MEDICAUX D’URGENCE. Ne
pas
soigner cette blessure comme une simple coupure.
A vis au medecin: La pénétration des fluides sous la peau est
un traumatisme. Il est important de traiter chirurgicale -
ment cette blessure immédiatement. Ne pas retarder le
traitement pour effectuer des recherches sur la toxicité.
Certains revêtements exotiques sont dangereusement
toxiques quand ils sont injectés directement dans le sang.
Il est souhaitable de consulter un chirurgien esthétique ou
un chirurgien spécialisé dans la reconstruction des mains.
Dispositifs de sécurité du pistolet
Avant chaque utilisation, bien s’assure que tous les dispositifs
de sécurité du pistolet fonctionnent correctement. Ne pas en-
lever ni modifier une partie quelconque du pistolet; ceci
risquerait d’entraîner un mauvais fonctionnement et des bles-
sures graves.
V errou de sécurité
A chaque fois que l’on s’arrête de pulvérisér , même s’il s’agit
d’un
court instant, toujours mettre le verrou de sécurité du pis -
tolet sur la position “fermée” ou “sécurité” (“safe”) pour
empêcher le pistolet de fonctionner . Si le verrou de sécurité
n’est
pas mis, le pistolet peut se déclencher accidentellement.
Diffuser
Le dif fuseur du pistolet sert à diviser le jet et à réduire les risques
d’injection accidentelle quand l’ajutage n’est pas en place.
Vérifier le fonctionnement du dif fuseur régulièrement. Pour
cette
vérification, détendre la pression en observant la Marche
à
Suivre pour Détendre la Pression donnée plus loin puis en -
lever
l’ajutage du pulvérisateur . Pointer le pistolet dans un seau
en métal, en le maintenant fermement contre le seau. Puis, en
utilisant la pression la plus faible possible, appuyer sur la
gachette du pistolet. Si le fluide projete
n’est pas diffusé sous
forme
de jet irrégulier , remplacer immédiatement le dif fuseur.
Protection de l’ajutage
TOUJOURS maintenir la protection de l’ajutage en place sur le
pistolet du pulvérisateur pendant la pulvérisation. La protection
de l’ajutage attire l’attention sur les risques d’injection et contri -
bue
à réduire, mais n’évite pas le risque, que les doigts ou une
partie quelconque du corps ne passent accidentellement à pro -
ximité
immédiate de l’ajutage du pulvérisateur .
Consignes de sécurité concernant l’ajutage du
pulvérisateur
Faire extremement attention à l’occasion du nettoyage ou du
remplacement des ajutages du pulvérisateur . Si l’ajutage se
bouche
pendant la pulvérisation, mettre immédiatement le ver -
rou de sécurité du pistolet. T OUJOURS bien observer la
Marche à Suivre pour Détendre la Pression puis enlever
l’ajutage
du pulvérisateur pour le nettoyer .
NE
JAMAIS essuyer ce qui s’est accumulé autour de l’ajutage
du pulvérisateur avant que la pression ne soit completement
tombée
et que le verrou de sécurité du pistolet ne soit engagé.
Marche à Suivre pour Détendre la Pression
Pour réduire les risques de blessures graves, y compris les
blessures par projection de fluide ou celles causées par de
éclaboussures
dans les yeux ou sur la peau, par des pièces
en mouvement, toujours bien observe cette marche à suivre
chaque fois que l’on arrête le pulvérisateur , à l’occasion de la
vérification, du égale ou du nettoyage du système ou lors du
changement des ajutages.
1. Engager le verrou de sécurité du pistolet.
2. Mettre le levier d’arrêt du moteur sur ARRET (OFF).
3. Débrancher le cord d’alimentation.
4. Désengager le verrou de sécurité du pistolet. T out en
maintenant une partie métallique du pistolet fermement
appuyé contre le côte d’un seau en métal, actionner le
pistolet pour libérer la pression.
5. Engager le verrou de sécurité du pistolet.
6. Ouvrir la soupape de sécurité et la laisser ouverte jus -
qu’à ce que l’on soit prêt à se servir de nouveau du pul -
vérisateur.
Si l’on soupconne que le tuyau ou l’ajutage est complètement
bouché ou que la pression n’a pas été complètement libérée
après avoir procédé aux opérations ci–dessus, desserrer
TRES LENTEMENT un raccord de bout de tuyau ou l’écrou
de
retenue de la protection de l’ajutage et libérer progressive -
ment
la pression.
1,5 234602983

6 308-319
RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL
Consignes générales de sécurité
Toute utilisation anormale de l’appareil de pulvérisation ou des
accessoires comme, par exemple, la mise sous une pression
excessive, les modifications de pièces, l’utilisation de produits
chimiques
e t d e m atière s i ncompatible s e t l ’utilisatio n d e p ièces
usées ou abîmées peut causer des dégâts à l’appareil ou des
ruptures de pièces et entraîner une injection de liquide ou
d’autrès blessures sérieuses, un incendie, une explosión ou
d’autrès
d égâts.
Ne Jamais alterer ou modifier une piece de cet appareil; ceci
risquerait d’entraîner son mauvais fonctionnement.
Vérifier régulièrement tout l’appareil de pulvérisation et ses
equipements et réparer ou remplacer immédiatement les
pièces
usées ou abîmées.
Pression
Ce
pulvérisateur peut produire une PRESSION MAXIMUM DE
TRAVAIL 195 bar (2750 lb/po2). S’assurer que tous les
éléments
du pulvérisateur et ses accessoires sont conçus pour
résister à la pression maximum de travail de ce pulvérisateur.
NE
P AS depasser la pression maximum de travail d’aucun des
éléments ou accessoires utilisés avec cet appareil.
Compatibilité chimique des corps
Bien s’assurer que tous les corps des solvants utilisés sont
chimiquement compatibles avec les parties mouillées indi-
quées
dans les Technical Data , à page 39. T oujours lire soig -
neusement
les documents et brochures du fabricant des fluides
et solvants utilisés avant de s’en servir dans ce pulvérisateur .
MESURES DE SECURITE CONCERNANT LES TUY AUX FLEXIBLES
Le fluide à haute pression circulant dans les tuyaux peut être
très
dangereux. En cas de fuite sur le tuyau, de fissure, déchi -
rure ou rupture à la suite de l’usure, de dégâts ou d’une
mauvaise
utilisation, les projections de fluide haute pression qui
en proviennent peuvent entraîner des blessures graves par
pénétration
sous la peau ou par contact, ainsi que des dégâts
matériels.
Tous
les tuyaux flexibles doivent avoir des ressorts spirale
de protection aux bouts! Les spirales de protection contribu -
ent
à eviter la formation de pliures, de boucles ou de nœuds sur
les tuyaux qui pourraient entraîner la rupture du tuyau à l’endroit
du raccord ou à son voisinagé.
Serrer fermement tous les raccords avant chaque utilisation. Le
fluide sous pression peut faire sauter un raccord desserre ou
produire
un jet à haute pression s’échappant par le raccord.
Ne Jamais utiliser un tuyau endommagé. Ne Pas essayer de
refaire le raccord d’un tuyau haute pression ni de réparer le
tuyau
avec du ruban adhesif ou par tout autre moyen. Un tuyau
réparé ne peut pas résister au fluide sous pression.
Manipuler les tuyaux avec precaution et choisir soigneusement
leur chemin. Ne pas déplacer le fluide en tirant sur le tuyau. Ne
pas utiliser de fluides ou de solvants qui ne sont pas com-
patibles
avec l’enveloppe intérieure ou extérieure du tuyau. NE
PAS exposer le tuyau à des températures supérieures à 82 C
(180F)
ou inférieures à –40  C (–40 F).
Continuité de la mise à la terre des tuyaux
Une bonne continuité de la mise à la terre des tuyaux est essen -
tielle
pour maintenir la mise à la terre de l’ensemble de vaporisa -
tion.
Vérifiez la résistance électrique de vos tuyaux à fluides et
à air , au moins une fois par semaine. Si votre tuyau ne comporte
pas d’étiquette qui précise la résistance électrique maximum,
prenez contact avec le fournisseur de tuyaux ou la fabricant
pour
avoir les límites de résistance maximum. Utilisez un mètre
de résistance de la gamme appropriée pour votre tuyau et véri -
fiez la résistance. Si celle–ci dépasse les límites recom-
mandées, remplacez le tuyau immédiatement. Un tuyau sans
mise
à la terre ou avec une mise à la terre incorrecte peut en -
traîner des risques pour votre systeme. Lisez aussi LES
RISQUES D’INCENDIE OU D’EXPLOSIÓN ci–dessus.
RISQUES D’INCENDIE OU D’EXPLOSION
De l’électricité statique est produite par le passage du fluide à
grande vitesse dans la pompe et dans les tuyaux. Si toutes les
pièces de l’appareil de pulvérisation ne sont pas convenable-
ment
reliés à la masse ou à la terre, des étincelles peuvent se
produire et l’appareil risque d’être dangereux. Des étincelles
peuvent également se produire à l’occasion du branchement
ou
du débranchement du cordón d’alimentation. Les étincelles
sont suf fisantes pour allumer les vapeurs de solvants et le fluide
pulvérisé, les fines particules de poussieère ainsi que d’autrès
substances inflammables, et elles peuvent causer un incendie
ou une explosión, ainsi que des blessures graves et des dégâts
matériels. T oujours brancher le pulvérisateur dans une prise se
trouvant à au moins 6 m (20 pieds) de l’appareil et de l’endroit
où se fait la pulvérisation.
S’il se produit des étincelles d’électricité statique, ou si vous res -
sentez la moindre décharge, arrêtez immédiatement la pulvé -
risation
. Vérifiez que le système entier est bien mis à laterre. Ne
vous servez pas du système avant que le problème soit identifié
et corrigé.
Mise à la terre ou à la masse
Pour réduire les risques de production d’étincelles d’électricité
statique, le pulvérisateur et tous les équipements utilisés ou se
trouvant dans la zone de pulvérisation doivent être reliés à la
terre
ou à la masse. Pour connaître le detail des instructions de
mise à la terre dans la region et le type particulier d’équipement,
CONSULTER le code ou les réglementations électriques lo-
cales.
S’ASSURER que tous les équipements de pulvérisation
suivants sont bien reliés à la terre:
1. Pulvérisateur: Brancher le cordón d’alimentation ou la ral -
longe qui doivent être équipés d’une prise à 3 fiches en
bon état, dans une prise de courant convenablement mise
à la terre. Ne pas utiliser d’adaptateur . T outes les rallonges
doivent avoir 3 fils et être prevues pour 15 ampères.
2. Tuyaux flexibles: Afin d’assurer la continuité de la mise à la
terre, n’utiliser que des tuyaux comportant une mise à la
terre et ayant une longueur maximum combinée de 150 m
(1500 pieds). Se reporter également au paragraphe
Conti-
nuité du circuit de mise à la terre des tuyaux.
3. Pistolet : Réaliser la mise à la terre en le raccordant à un
tuyau flexible et à un pulvérisateur dèjá convenablement
reliés à la terre.
4. Récipient d’alimentation: observer le code ou les régle -
mentations locales.
5. Objets, matériel ou surfaces reçevant la pulvérisation: ob -
server le code ou les réglementations locales.
6. Tous les seaux de solvants utilisés pour le rinçage: ob -
server le code ou les réglementations locales. N’utiliser
que des saux métalliques conducteurs de l’électricité. Ne
pas mettre le seau sur une surface non conductrice
comme sur du papier ou du carton car cela interromprait la
continuité de la mise à la terre.
7. Pour conserver la continuité de la mise à la terre quand on
rince le matériel ou quand on libére la pression , toujours
maintenir une partie métallique du pistolet fermement ap -
puyée contre le côté d’un seau en métal puis appuyer sur
la détente du pistolet.
Mesures de sécurité concernant le rincage
Pour réduire les risques de blessures par pénétration de la
peau et les risques dûs aux etincelles d’electricite statique ou
aux
éclaboussures, observer la marche à suivre pour le rincage
donnée à la page 15 de ce manuel. Observer la “Marche à
Suivre pour Détendre la Pression” donnée à la 5 en
enlever
l’ajutage
du pulvérisateur avant le rincage . Maintenir une partie
métallique du pistolet fermement appuyée contre le côté d’un
seau
en métal et utiliser la pression la plus faible possible pen -
dant
le rincage.

308-319 7
ADVERTENCIA
El rociado a alta presión puede causar graves lesiones. Solo para uso profesional. Respete los avisos de
advertencia. Lea y entienda todo el manual de instrucciónes antes de manejar el equipo.
PELIGRO DE INYECCION DE FLUIDO
Seguridad general
Este equipo genera un fluido a una presión muy alta. El rociado
de la pistola, los escapes de fluido o roturas de los com-
ponentes
pueden inyectar fluido en la piel y el cuerpo y causar
lesiones extremadamente graves, incluyendo a veces la
necesidad de amputación. También, el fluido inyectado o sal-
picado
en los ojos puede causar graves daños.
NUNCA apuntar la pistola hacia alguien o alguna parte del
cuerpo.
NUNCA colocar la mano o los dedos encima de la bo–
quilla. NUNCA tratar de “hacer retornar la pintura”; este NO es
un sistema de rociado de aire.
SIEMPRE tener colocado el protector de la boquilla en la pis-
tolamientras
se está pulverizando.
SIEMPRE seguir el procedimiento de descarga de presión,
dado
másabjo, antes de limpiar o sacar la boquilla o de dar ser -
vicioa
cualiquier equipo del sistema.
NUNCA tratar de parar o desviar los escapes con la mano o el
cuerpo.
Asegurar
que todos los aparatos de seguridad del equipo están
funciónando bien antes de cada uso.
Tratamiento médico
Si pareciera que un poco de fluido penetró la piel, conseguir
TRATAMIENTO MÉDICO DE URGENCIA DE INMEDIA TO.
NO
TRA T AR LA HERIDA COMO UN SIMPLE CORTE. Decir
al médico exactamente cua fluido fue.
Aviso al médico: Si se llega a inyectar este fluido en la piel se
causa una lesión traumática. Es importante tratar quirúrgi -
camente la lesión a la brevedad posible. No demorar el
tratamiento
para investigar la toxicidad. La toxicidad es algo
de suma importancia en algunas pinturas exóticas cuando se
inyectan directamente al torrente sanguineo. Sirá con-
veniente consultar a un especialista en cirugia plástica o
reconstructiva
de las manos.
Aparatos de seguridad de la pistola pulverizadora
Asegurar que todos los aparatos protectores de la pistola están
funciónando bien antes de cada uso. No sacar ni modificar
ningúna
pieza de la pistola pues podria causar el malfuncióna -
miento
de la misma con las consiguientes lesiones personales.
Pestillo de seguridad
Cada vez que se deje de pulverizar , aunque sea por un breve
momento, siempre colocar el pestillo de seguridad en la posi-
ción “cerrada” lo que deja la pistola inoperante. El no hacerlo
puede
llevar al disparo imprevisto de la pistola.
Difusor
El difusor de la pistola dispersa el chorro pulverizado y reduce
el riesgo de inyección cuando no está instalada la boquilla.
Revisar
con regularidad el funciónamiento del difusor . Seguir el
procedimiento de descarga de presión, dado más abajo, y
después
sacar la boquilla. Apuntar la pistola a un balde metáli -
co,
sosteniéndola bien firme contra el. Utilizando la presión más
bajo posible, disparar la pistola. Si el fluido emitido no sale dis -
perso
en un chorro irregular , reemplazar de inmediato el difusor .
Protector de la boquilla
SIEMPRE tener el protector de la boquilla colocado en la pistola
mientras se está pulverizando. Este protector llama la atención
contra el peligro de inyección y ayuda a reducir , pero no evita,
la colocación accidental de los dedos o cualquier otra parte del
cuerpo cerca de la boquilla.
Seguridad de la boquilla pulverizadora
Tener mucho cuidado al limpiar o cambiar las boquillas. Si llega -
ra a obstruirse mientras está pulverizando,
enganchar el pes -
tillo de la pistola de inmediato. SIEMPRE seguir el procedi-
miento de descarga de presión y después sacar la boquilla
para
limpiarla.
NUNCA limpiar la acumulación de pintura alrededor de la bo–
quilla antes de que se haya descargado por completo la presión
y el pestillo este enganchado.
Procedimiento de descarga de presión
Para reducir el riesgo de sufrir graves lesiones corporales, in -
cluyendo inyección o lesiones causadas por piezás en
movimiento o choque eléctrico, siempre seguir este
procedimiento
al apagar la máquina pulverizadora, al revisar
o dar servicio a cualquier parte del sistema de pulverización,
al instalar , limpiar o cambiar las boquillas, y cada vez que se
deja de pulverizar .
1.
Enganchar el pestillo de la pistola.
2. Mover el interruptor eléctrico (ON/OFF) a la posición
OFF (apagado).
3. Desenchufar el cordón electrico.
4. Desenganchar el pestillo de la pistola. Sujetar una parte
metálica de la pistola bien firme contra un balde de
metal, y disparar la pistola para descargar la presión.
5. Enganchar el pestillo de la pistola.
6. Abrir la válvula de presión. Dejar la válvula de alivio de
presión abierta hasta que se este nuevamente listo para
pulverizar.
Si se sospecha que la boquilla o la manguera está com-
pletamente obstruida, o que no se ha descargado por com-
pleto
la presión después de haber seguido el procedimiento
anterior, aflojar muy lentamente la tuerca de retención del
protector
de la boquilla o acoplamiento de la punta de la man -
guera y descargar gradualmente la presión, después,
aflojarlo
por completo. Luego, despejar la boquilla o la man -
guera.
1,5 234
6
02983

 
PELIGRO POR MAL USO DEL EQUIPO
Seguridad general
Cualquier mal uso del equipo pulverizador o los accesorios, tal
como sobre presurización, modificación de piezás, uso de
matériales
y productos quimicos incompatibles, o utilización de
piezás dañadas o desgastadas, puede hacen que se rompan
y causen la inyección de fluido u otras lesiones corporales
graves,
incendio, explosión o dañon a la propiedad.
NUNCA alterar o modificar ningúna pieza de este equipo; el
hacerlo
podria causar una avería.
REVISAR con regularidad el equipo pulverizador y reparar o
reemplazar
de inmediato las piezás dañadas o desgastadas.
Presión del sistema
está pulverizadora puede desarrollar 195 barías (2750 psi) de
presión DE TRABAJO MÁXIMA. Asegurar que todo el equipo
pulverizador y sus accesorios tienen la capacidad para aguan -
tar la presión máxima de trabajo de está pulverizadora. NO ex -
ceder la presión máxima de trabajo de ningún componente o
accesorio
de este sistema.
Compatibilidad de fluido
Siempre leer las instrucciónes del fabricante del fluido y sol-
vente
antes de usarlos en está pulverizadora, dadas en la pági -
na
39.
Siempre usar gafas, guantes, vestimetas protectora y un
respiradero,
tal como recomiendan los fabricantes del fluido y
del solvente.
SEGURIDAD EN EL USO DE LAS MANGUERAS
El fluido que escapa a alta presión por las mangueras puede
ser
muy peligroso. Si en la manguera se desarrolla un escape,
una rotura o rajadura debido a cualquier tipo de desgaste, daño
o maltrato, el chorro a alta presión emitido por alli puede causar
una lesion por inyección u otras lesiones corporales graves o
daños
a la propiedad.
!Todas las mangueras para fluidos tienen que tener
guardas
de resorte en ambos extremos! Estas protegen las
mangueras contra dobleces o retorceduras en los acoplamien -
tos
o cerca de ellos, los que podrian traducirse en roturas de la
manguera.
Antes de usarlas, APRET AR bien firmes todas las conexiones.
El fluido a alta presión puede desalojar un acoplamiento suelto
o dejar que por el escape un chorro a alta presión.
NUNCA usar una manguera que está dañada. Siempre,
revisarla
en busca de cortaduras, escapes, abrasion, cubierta
abultada, o acoplamientos sueltos o dañados. Si llegara a en -
contrarse cualquiera de estás condiciónes, reemplazar de in-
mediato la manguera. NO intentar racoplar una manguera de
alta presión o enmendarla con cinta adhesiva u otro matérial
similar. Una manguera que ha sido remendada no aguante el
fluido
a alta presión.
MANEJAR Y PASAR CUIDADOSAMENTE LAS MAN-
GUERAS.
No tirar de las mangueras para mover el equipo. No
usar fluidos o solventes que sean incompatibles con el tubo in -
terno
y la cubierta dela manguera. NO exponer las mangueras
a temperaturas sobre 82  C (180 F) o bajo –40 C (–40
F).
Continuidad del circuito de puestá a tierra de la
manguera
La continuidad del circuito de puestá a tierra apropiado es
esencial para mantener conectado a tierra el sistema pul-
verizador. Es indispensable revisar la resistencia eléctrica
máxima
de las mangueras de aire y de fluido por lo menos una
vez a la semana. Si la manguera no tiene una etiqueta en la cual
se especifica la resistencia eléctrica, ponerse en contacto con
el proveedor o fabricante de la manguera para la información
sobre
los límites de resistencia. Usar un metro de resistencia en
la gama apropiade para comprobar la resistencia; si excede los
límites recomendados, reemplazarla de inmediato. Es muy ar -
riesgado
tener una manguera sin puestá a tierra o con la puestá
a tierra en malas condiciónes. Leer también la información
sobre
RIESGO DE INCENDIO O EXPLOSION , más arriba.
PELIGRO DE INCENDIO O EXPLOSION
El flujo a alta velocidad del fluido al pasar por la bomba y man -
guera
crea electricidad estática. Si todas las partes del equipo
pulverizador no tienen buena tierra, pueden ocurrir chispas,
convirtiendo al sistema en algo peligroso. T ambién, pueden
producirse
chispas a enchufar o desenchufar el cordón electri -
co.
Estás chispas pueden inflamar los vapores de los solventes
y el chorro de fluido pulverizado, particulas de polvo y otras sus -
tancias
in flamables, sea al aire libre o bajo techo, lo que podria
causar una explosión o incendio y graves lesiones corporales
y daños al a propiedad. Enchufar siempre la pulverizadora a un
tomacorriente que se encuentre a por lo menos 6 m (20 pies)
de
la maquina y del area que se va a rociar .
Si
ocurre una chispa de electricidad estática o incluso un ligero
choque electrico mientras se usa el equipo, dejar de pulverizar
de inmediato . Revisar todo el sistema en busca de una tierra
apropiada. No usar de nuevo el sistema hasta haber iden-
tificado
y soluciónado el problema.
Peusta a tierra
Para reducir el reisgo de chispas estáticas, conectar a tierra la
pulverisadora y todo el otro equipo de pulverisar que se use o
se encuentre en el lugar que se va a rociar . CONSULTAR el
codigo
electrico de la localidad para las instrucciónes sobre las
conexiones a tierra exigidas para la zona y tipo de equipo.
ASEGURAR
de conectar a tierra todo este equipo pulverisador:
1. Pulverizadora: enchufar el cordón electrico, o cable exten -
sor
, cada uno un enchuf de très patas en buen estádo, a
un tomacorreinte con puesat a tierra aporpiado. No usar
un adaptador . T otos los cables extensores tienen que
tener très hilos y una capacidad de 15 amperios.
2. Mangueras para fluidos: usar solamente mangueras con
puestá a tierra de una longitud combinada de 150 m (500
pies), para asequrar buena continuidad a tierra. Referirse
también al párrafo sobre continuidad a tierra de la
manugeura.
3.
Pistola: hace la puestá a tierra conectándola a una man -
guera de fluido y pulverizadora bien conectadas a tierra.
4. Suministrar un recipiente: de acuerdo al código de la
localidad.
5.
Objeto que se está rociando: de conformidad con el
codigo local.
6. T odos los baldes de solvente usados durante el lavado,
de conformidad con el código local. Usar solamente
baldes de metal, que sean conductivos. no colocar el
balde en una superficie no conductiva, como papel o
cartón, que interumpe la continuidad a tierra.
7. Para mantenar la continuidad a tierra durante el lavado o
descarga de presión, siempre apoyar una parte metálica
de la pistola bien firme contra el costado del balde de
metal, después apretar el gatillo.
Seguridad durante el lavado
Para reducir el riesgo de que se inyecte o salpique fluido en la
piel, o que ocurra una descarga de electricidad estática,
siempre seguir las INSTRUCCIÓNES PARA EL LAVADO,
dadas
en la página. 15 Seguir el procedimiento de descarga
de presión en la págna 7, y quita la boquilla rociadora antes
de
lavar . Apoyar una parte metalica de la pistola bien firme con -
tra
el costado de un balde de metal y usar le presión más baja
posible de fluido durante el lavado.

 
Setup
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 2750 psi (195 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.
CAUTION
T o avoid damaging the pressure control, which may
result in poor equipment performance and compo -
nent damage, follow these precautions:
1. Always use a nylon spray hose at least 50 ft.
(15 m) long.
2.
Never use a wire braid hose as it is too rigid to
act as a pulsation dampener .
3. Never install any shutof f device between the
pump and the hose. See Fig. 1.
1. Connect the hose (B) and gun (C) and screw it
onto the outlet nipple (A). Don’t use thread sealant,
and don’t install the spray tip yet!
2. Fill the wet–cup (D). Pry of f the wet–cup seal. Fill
the cup 1/3 full with Graco Throat Seal Liquid
(TSL) (68) supplied. Install the seal.
3. Check the electrical service. Be sure it is 120 V ,
60 HzAC, 15 Amp (minimum). Use a properly
grounded outlet. Do not remove the third (ground -
ing) prong of the power supply cord, and do not
use an adapter .
Use a 3-wire, (12 ga recommended), 15 amp ex -
tension cord.
NOTE: Long extension cord lengths af fect sprayer
performance.
4.
Plug in the sprayer . Be sure the ON/OFF switch
(E) is OFF . Plug the cord into a grounded outlet at
least 20 ft. (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 injury and property damage. Also read
FIRE OR EXPLOSION HAZARD on page 4.
continued on the next page
Fig.1
A
B
C
D
E



Do
not install any shutof f device here.
Shown in closed, or spray position.
Fill 1/3 full with TSL


02984
3

 
Setup
5. Flush the pump to remove the oil which was left
in to protect pump parts after factory testing. See
page 15.
6. Prepare the paint according to the manufacturer ’s
recommendations. Remove any paint skin. Stir the
paint to mix pigments. Strain the paint through a
fine nylon mesh bag (available at most paint deal
-
ers) to remove particles that could clog the gun
filter or spray tip. This is an important step toward
trouble–free paint spraying.
How to use the gun safety latch
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 2.
WARNING
If the gun still sprays when the gun safety latch is
engaged, adjust the gun. See manual 307–614,
supplied.
How to use the pressure drain valve
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over pressure condition, it opens automati -
cally to relieve fluid pressure. If this happens, stop
spraying immediately, shut of f and unplug the sprayer .
Determine the cause of the problem and correct it be -
fore operating the sprayer again. Refer also to the
T roubleshooting Guide, page 17. See Fig. 3.
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. T urn the pressure control knob fully coun -
terclockwise to obtain the minimum setting. T urn the
knob clockwise to increase pressure. See Fig. 4.
“ON SAFE”
“OFF SAFE”
Fig. 2




01020
Closed, or
spray position
Open or
drain, position
Fig. 3




02985
Fig. 4 02986
+
–

Rotate
to increase (+)
or decrease (–)
pressure

 
Setup
Pressure Relief Procedure
T o 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 elec -
tric shock, always follow this procedure when you
shut of f the sprayer , check or service any part of
the spray system, install, clean or change spray
tips, and whenever you stop spraying.
1. Engage the gun safety latch.
2. T urn 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. T
rigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave it 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 following the steps above, VER Y
SLOWL
Y loosen the tip guard retaining nut or hose
coupling to relieve pressure gradually , then loosen
completely.
WARNING
How to use the RAC IV tip guard
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 pail when checking to see if the tip is clear .
DO NOT try to “blow back” paint; this is NOT an air
spray sprayer .
The tip guard alerts you to the risk and helps prevent
placing any part of the body close to the spray tip. The
tip guard also adjusts the vertical or horizontal spray
pattern. See page 13. The tip guard holds a reversing
spray tip. The tip is in the spraying position when the
tip handle points forward. See Fig. 5.
Clean the front of the tip frequently during the day’ s
operation. First, follow the Pressure Relief Procedure
Warning , left.
Fig. 5
Tip Handle shown in
spraying position.
T urn handle 180 ,
trigger gun to clear clog


 
01023
How to remove a tip clog
1. Release the gun trigger . Engage the safety latch.
Rotate the RAC IV tip handle 180  . See Fig. 5.
2. Disengage the safety latch. T rigger the gun into a
pail or onto the ground to remove the clog.
3. Engage the safety latch. Rotate the tip handle to
the spraying position.
4. If the tip is still clogged, engage the safety latch,
shut of f and unplug the sprayer , and open the
pressure drain valve to relieve pressure. Clean the
spray tip as shown in manual 307–848, supplied.

 
Startup
Fig. 6
Shown
in closed, or spray position.
B
C
D
A
F


Open, or drain position

E
02984
+
–
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: If this is a first–time startup, flush the sprayer .
See page 15.
1. Open the pressure drain valve (A). See Fig. 6.
2. Don’t install the spray tip until the pump is
primed!
3. Put the suction hose (C) into the paint
. If you
are pumping from a 1 gallon (5 liter) pail, push the
drain hose (D) down below the top of the pail to
avoid splashing paint when the drain valve is
opened.
4. T
urn the pressure knob (E) to the minimum
setting.
5. Disengage the gun safety latch.
See Fig. 2,
page 10.
CAUTION
T o reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in
it for more than 30 seconds.
6. T o prime the pump, turn the sprayer switch (F)
on. Slowly increase the pressure until the sprayer
starts. When fluid comes from the pressure drain
valve, close the valve.

 
Startup
WARNING
T o reduce static sparking and splashing when
priming, be sure the spray tip is not installed on the
gun, and hold a metal part of the gun firmly to the
side of a grounded metal pail.
01024
7. T o prime the hose , lower the pressure to reduce
splashing. Holding the gun against the pail, trigger
the gun and slowly increase the pressure until the
pump starts. Keep the gun triggered until all air is
forced out of the system and the fluid flows freely
from the gun. Release the trigger and engage the
gun safety latch.
8. Check all fluid connections for leaks . Relieve
pressure before tightening any connections.
9. Install the spray tip. Engage the gun safety latch
first! See manual 307–848 for how to install the tip.
10. Adjust the spray pattern
a.
Increase the pressure just until spray from the
gun is completely atomized. T o avoid exces -
sive overspray and fogging, and to extend tip
and sprayer life, always use the lowest pres -
sure needed to get the desired results.
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. T est the spray pattern. T o adjust the direction
of the spray pattern, engage the gun safety
latch and loosen the retaining nut (B). Position
the tip guard horizontally for a horizontal pat -
tern or vertically for a vertical pattern. Hold the
tip guard in place while tightening the retaining
nut. See Fig. 7.
NOTE: Spray patterns will change as tips wear .
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
For a horizontal
spray pattern
For a vertical
spray pattern
Fig. 7




B
01025

14 308-319
Shutdown and Care
WARNING
To reduce the risk of serious bodily injury , always
follow the Pressure Relief Procedure W arning on
page 3 when instructed in this procedure to
relieve pressure.
1. Check the packing nut/wet-cup daily. Relieve
pressure first. Keep the wet-cup 1/3 full of TSL at
all times to help prevent fluid buildup on the piston
rod and premature wear of packings.
2. Tighten the packing nut/wet-cup just enough
to stop leakage.
Over-tightening causes binding
and excessive packing wear . Use a round punch
or brass rod and a light hammer to adjust the nut.
See Fig. 8.
3. Clean the gun’s fluid filter often and whenever
the gun is stored. Relieve pressure first. Refer to
manual 307–614.
4. Lubricate the bearing housing after every 100
hours of operation. Remove the front cover . Apply
several drops of SAE 10 non-detergent oil in the
bearing housing cavity (B). See Fig. 9.
5. Flush the sprayer at the end of each work day
and fill it with mineral spirits to help prevent pump
corrosion and freezing. See page 15.
CAUTION
T o prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold
weather , never leave water or any type of paint in
the sprayer when it is not in use. Freezing can seri
-
ously damage the sprayer or result in a loss of
pressure or stalling.
6. For very short shutoff periods, leave the suction
hose in the paint, relieve pressure, and clean the
spray tip.
7. Coil the hose when storing it, even for overnight,
to help protect the hose from kinking, abrasion,
coupling damage, etc.
WARNING
See the warning section HOSE SAFETY on page
4 for information on the hazard of using damaged
hoses.
Turn packing
nut clockwise to
tighten
Fig. 8


02988
Fig. 9
B
02989

308-319 15
Flushing
When to flush
Determine the material you are going to pump from the
Column 1, then flush with the material indicated in the
Column 2, then, depending on what you plan to do
next, follow the recommendations in one of the next
three columns.
CAUTION
NEVER leave water or water-based fluids in the
sprayer if there is a chance it could freeze. Push
the water out with mineral spirits. Frozen fluid in
the sprayer prevents it from being started and may
cause serious damage.
Column 1 Column 2 Column 3 Column 4 Column 5
If you are going to: Flush with:  Prime with: Clean with: Store unit with: 
Spray latex paint W arm, soapy water ,
then clean water
Latex-base paint W arm soapy water ,
then clean water
Mineral spirits
Spray oil paint Mineral spirits Oil–base paint Mineral spirits Mineral spirits
Change latex to oil paint W arm, soapy water ,
then clean water
Mineral spirits Mineral spirits Mineral spirits
Change oil to latex paint Mineral spirits,
soapy water , and
clean water .
Latex W arm, soapy water ,
then clean water
Mineral spirits
Change colors, same base Compatible solvent
such as water or
mineral spirits
How to flush
1. Follow Pressure Relief Procedure . See page 1 1.
2.
Remove the spray tip and clean it separately . If
you are changing from water–based to oil–based
paints or solvents, be sure that the tip is cleaned
thoroughly.
3.
Remove the filter screen and then reinstall the
bowl, hand tight, without the screen. Clean the
screen separately . See Fig. 10.
Fig. 10 SCREEN
BOWL
02990
4. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal flushing pail. Put the suction
hose in the pail.
5. Open the pressure drain valve. See Fig.1 1.
6. To save the paint still in the pump and hose,
follow Step 7, except put the drain hose in the
paint pail. When solvent appears, close the drain
valve. Put the drain hose in the flushing pail. T
rig-
ger the gun into the paint pail. When solvent ap -
pears, release the trigger . Continue with Step 7.

16 308-319
Flushing
WARNING
T o reduce static sparking and splashing, always
remove the spray tip from the gun, and hold a
metal part of the gun firmly to the side of a
grounded metal pail when flushing.
01024
7. Lower the pressure setting. T urn on the sprayer .
Maintaining metal-to-metal contact, trigger the gun
into the flushing pail. Slowly increase the sprayer
pressure just until the pump starts. Keep the gun
triggered until the solvent flows freely from the
gun. Circulate the solvent to thoroughly clean the
sprayer . Release the gun trigger . Engage the gun
safety latch.
8. Open the drain valve and circulate the solvent
through the drain hose to thoroughly clean it.
Close the drain valve.
9. Remove the suction hose from the pail. Disengage
the gun safety latch. T rigger the gun and run the
pump a few seconds to push air into the hose. Do
not run the pump dry for more than 30 seconds to
avoid damaging the pump packings! Relieve pres -
sure.
10.
Reinstall the clean filter screen.
11. Remove and clean the inlet strainer . Wipe paint of f
the suction hose and drain hose.
12. Leave the drain valve open until you use the
sprayer again.
Open or
drain position
Fig. 1 1


02987

308-319 17
Troubleshooting
WARNING
T o reduce the risk of serious injury , always follow
the Pressure Relief Procedure on page 3 before
checking or repairing any part of the sprayer
.
Check everything in the guide before disassembling
the sprayer .
NOTE: Thaw 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 sprayer
until it has thawed completely or damage to motor and/
or control board may occur. If paint hardened (dried) in
sprayer , the pump packings and/or pressure transduc -
er must be replaced. See page 24 (pump) or 32 (pres -
sure transducer).
Basic Problem Solving
TYPE OF
PROBLEM WHA
T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK, refer to this column
Fluid Pressure 1. Check pressure transducer knob setting. The
pump won’t develop much pressure if it is at mini -
mum setting (fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. Check for a clogged spray tip or fluid filter , if used.
See page 1 1. 2.
If tip is still clogged, relieve pressure;
refer to separate gun or tip instruction
manual for tip cleaning. Clean or replace
filter element. See manual 308–249.
Mechanical 1. Check for frozen or hardened paint in pump (20).
Using a screwdriver , carefully try to rotate fan at
back of motor by hand. See page 28.
1. Thaw . Plug in sprayer and turn on.
Slowly increase pressure setting to see if
motor starts. If it doesn’t, see NOTE
above.
2. Check pump connecting rod pin (17). It must be
completely pushed into connecting rod (15), and
retaining spring (18) must be firmly in connecting
rod groove. See Fig. 18, page 24.
2. Push pin into place and secure with
spring retainer .
3. Check for motor damage. Remove drive housing
assembly (1 1). See page 30. T ry to rotate motor
fan by hand.
3. Replace motor (4) if fan won’t turn. See
page 28.
Electrical 1. Check electrical supply with volt meter . Meter
should read 105–125 V
AC. 1.
Reset building circuit breaker; replace
building fuse. T ry another outlet.
2. Check extension cord for visible damage. Use a
voltmeter or test lamp at extension cord outlet to
check.
2. Replace extension cord.
3. Check sprayer power supply cord (50) for visible
damage such as broken insulation or wires.
3. Replace power supply cord. See page
29.
4. Check motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
d. Broken leads.
e. W orn brushes.
f. Brush leads snagged on spring clip.
NOTE: The brushes do not wear at same
rate on both sides of motor . Check both
brushes.
4. Refer to page 23.
a. Tighten.
b.
Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as
-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.4”
(10 mm) long.
f. Correctly rout e t h e w ires . S e e p ag e 2 3.
5. Check motor armature commutator for burn spots,
gouges and extreme roughness. Remove motor
cover and brush inspection plates to check. See
page 23.
5. Remove motor and have motor shop
resurface commutator if possible. See
page 28.
6. Check motor armature for shorts using armature
tester (growler) or perform motor test. See page
22.
6. Replace motor . See page 28.

 
Basic Problem Solving
TYPE OF
PROBLEM WHA
T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK, refer to this column
Electrical
(continued)
7. Check leads from pressure transducer and motor
to motor control board (47) to be sure they are se -
curely fastened and properly mated.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Check motor control board (47) by substituting with
a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
8. Replace board. See page 29.
9. Check power supply cord (50). Disconnect black
and white power cord terminals; connect volt
meter to these leads. Plug in sprayer . Meter should
read 105–125 V AC. Unplug sprayer .
9. Replace power supply cord. See page
29.
10. Check ON/OFF switch (52). Disconnect the “L”
wire between motor control board (47) and switch
and connect volt meter between exposed terminal
switch and power cord’ s white wire. Plug in
sprayer and turn ON . Meter should read 105–125
VAC. T urn of f and unplug sprayer .
10. Replace ON/OFF switch. See page 29.
11. Check motor thermal cutout switch. Connect ohm -
meter between motor ’ s red leads. Meter should
read 1 ohm maximum.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor .
12. Check the transducer (29) by replacing it with a
new one.
12. Replace pressure transducer . See page
32.
13. Check pressure adjustment potentiometer (64) by
replacing it with a new one.
Intermediate Problem Solving
TYPE OF
PROBLEM WHA
T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK refer to this column
Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure
W arning then replace tip. See your
separate gun or tip manual.
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and
turn on sprayer . Prime with paint. T rigger gun mo -
mentarily
, then release and engage safety latch.
Relieve pressure, turn of f and unplug sprayer .
2. Service pump. See page 24.
3. Release gun trigger . Observe resting position of
pump rod (107).
3. If pump consistently comes to rest
with rod (107) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 24.
4. Check electrical supply with volt meter . Meter
should read 105–125 V
AC. 4.
Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Check extension cord size and length. 5. Replace with a correct, grounded exten -
sion cord. Note that long lengths and/or
smaller gauges reduce performance.
6. Check motor brushes. See Electrical – What T o
Check, item 4, on page 17.
6. See page 23.

 
Intermediate Problem Solving
TYPE OF
PROBLEM WHA
T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK, refer to this column
Low Output
(continued)
7. Check motor control board (47) by substituting with
a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
7. Replace board. See page 29.
8. Check motor armature for shorts by using an arma -
ture tester (growler) or perform motor test. See
page 22.
8. Replace motor . See page 28.
Drain V alve Leaks 1. Check drain valve for correct torque and/or worn
parts. Check for debris trapped on seat.
1. T ighten to 185 in–lb (21 N.m). Clean
valve and replace with new gasket (42a)
and sealant (42e). See page 35.
No Output: Motor
Runs And Pump
Strokes
1. Check paint supply . 1. Refill and reprime pump.
2. Check for clogged intake strainer . 2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. See
page 34.
3. T ighten; use thread sealant on
npt threads of inlet tube (38). Check for
damaged o–ring (27).
4. Check to see if intake valve ball and piston ball are
seating properly . See page 24.
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as need -
ed. See page 24. Strain paint before us -
ing to remove particles that could clog
pump.
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 24.
5. Replace packings. See page 24. Also
check piston valve seat for hardened
paint or nicks and replace if necessary .
T ighten packing nut/wet-cup.
6. Release gun trigger . Observe resting position of
pump rod (107).
6. If pump consistently comes to rest
with rod (107) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 24.
No Output: Motor
Runs But Pump
Does Not Stroke
1. Check displacement pump connecting rod pin (17).
See Fig. 18, page 24.
1. Replace pin if missing. Be sure retainer
spring (18) is fully in groove all around
connecting rod.
2. Check connecting rod assembly (15) for damage.
See page 30.
2. Replace connecting rod assembly . See
page 30.
3. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. T urn of f and
unplug sprayer . See page 30.
3. Check drive housing assembly for dam -
age and replace if necessary . See page
30.
Spray Pattern
Variations 1.
Spray tip worn beyond sprayer pressure capability . 1. Replace spray tip.
NOTE: A smaller size tip will provide
longer life.
2. Check motor control board by replacing it with a
new one.
2. Replace board. See page 29.
3. Check pressure transducer (64) by replacing it
with a new one.
3. Replace pressure transducer . See page
32.

 
Intermediate Problem Solving
TYPE OF
PROBLEM WHA
T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK, refer to this column
Spray Pattern
Variations
(continued)
4. Check pressure adjustment potentiometer (64) by
replacing it with a new one.
(continued)
5. Check Low Output section, page 18.
Motor Is Hot and
Runs Intermittently
1. Determine if sprayer was operated at high pressure
with small tips, which causes excessive heat build
up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer is lo -
cated is no more than 90  F (32 C) and sprayer is
not located in direct sun.
2. Move sprayer to shaded, cooler area if
possible.
3. Check motor. 3. Replace motor . See page 28.
Building Circuit
Breaker Opens As
Soon As Sprayer
Switch Is Turned
O
1. Check all electrical wiring for damaged insulation,
and all terminals for loose fit or damage.
Also check wires between pressure transducer
and motor . See page 28.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
Switch Is Turned
On. 2.
Check for missing motor brush inspection plate
gasket (see page 23), bent terminal forks or other
metal to metal contact points which could cause a
short.
2. Correct faulty conditions.
3. Check motor armature for shorts. Use an
armature tester (growler) or perform motor test.
See page 18. Inspect windings for burns.
3. Replace motor . See page 28.
4. Check motor control board (47) by substituting with
a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
4. Replace board. See page 29.
Circuit breaker
opens after sprayer
operates for 5 to 10
minutes.
1. Check ‘Basic Problems – Electrical’ on page 17.
Building circuit
breaker opens as
soon as sprayer is
plugged into outlet
and sprayer is NOT
turned on.
1. Check ON/OFF switch (52). Be sure sprayer is
unplugged! Disconnect wires from switch. Check
switch with ohmmeter . The reading should be
infinity with ON/OFF switch OFF , and zero with
switch ON.
CAUTION:
A short in motor circuit can damage
switch and or motor control board (47).
1. Replace ON/OFF switch. See page 29.
2. Check for damaged or pinched wires in junction
box (59).
2. Replace damaged parts.
Unit will not run on
generator but does
run on AC power
1. Check the generator ’s “peak” voltage. This sprayer
will not run if the peak voltage is above 190V or
below 100V .
1. Use AC power or a dif ferent generator .