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Graco ULTRA AIRLESS 230-963 User's Manual

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1. POWER SUPPLY CORD REPLACEMENT See Fig 12 amp 13 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock 1 Usethe 19 mm open end wrench to remove the nut 337 from the filter stud 310 2 Usethe 13 mm socket wrench to remove the two screws 65 holding the pressure control to the frame 3 Remove the pressure control mounting bracket 50 using a Phillips screwdriver 4 Disconnect the power supply cord wires from the control box terminal strip 336 using a screwdriver 5 Install the new power supply cord 311 in the reverse order of disassembly Install a new plug on the other end the cord Be sure to follow all local codes regarding the type of plug to use FILTER REPLACEMENT See Fig 12 E WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock 1 Remove the pressure control cover and screws 2 Use a needle nose pliers to remove the four wires from the filter 310 3 Use the M8 wrench to remove the lower nut and lockwashers 337 338 on the outside of the pressure control box 4 Remove the old filter and install a new one in the reverse order of
2. open end wrench 7 8 open end wrench High quality motor oil Bearing grease For calibration procedure only 3 8 ignition wrench 0 015 spray tip High pressure oil filled test gauge Part No 102 814 5 gallon pail Clean water Mineral spirits NEW 207 bar 3000 psi high pressure spray hose Part No 214 915 Before repairing any part of the sprayer readthe follow ing general repair notes and the repair procedure Be sure you have the necessary tools and parts available 1 When disconnecting wires in the pressure control assembly use needle nose pliers to separate mating connectors When reconnecting the wires be sure the flat blade of the insulated male connector is centered in the wrap around blade of the female connector when the connection is made CAUTION To reduce the risk of a pressure contro malfunc tion be sure to properly mate connectors and never pull on a wire to disconnect it Pulling ona wire could loosen the connector from the wire 2 Route wires in the pressure control assembly carefully through the legs of the U shaped bourdon tube where appropriate to avoid interfering with the bourdon tube which moves as the pressure set ting changes and to avoid pinching the wires be tween the pressure control box and cover CAUTION Improper wire routing can result in poor sprayer performance or damage to the pressure control 3 Keep all screws nuts washers gaskets and elec trical
3. Read and understand all instruction manuals tags and warnings before operating equipment FLUID INJECTION HAZARD General Safety This equipment generates very high fluid pressure Sprayfrom 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 onto the skin can cause serious damage NEVER point the spray gun at anyone or 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 ALWAYS have the tip guard in place on the spray gun when spraying ALWAYS follow the Pressure Relief Procedure below before cleaning or removing the spray tip or servicing any system equipment NEVER try to stop or deflect leaks with your hand or body Be sure equipment safety devices are operating properly before each use Medical Alert Airless Spray Wounds If any fluid appears to penetrateyour skin get EMERGENCY MEDICAL CARE AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly what fluid was injected Note to Physician injection in the skin is a traumatic n jury Itis important to treat the injury surgically as soon as possible Do not delay treatment to research toxicity Toxicity is s concern with some exotic coatings injected directly into the blood stream Consultation with a plastic s
4. get INSTRUCTIONS PARTS LIST CG e ORACO Rev D SUPERSEDES A and PCNB This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE ULTRA 400 AIRLESS PAINT SPRAYER 192 bar 2750 psi MAXIMUM WORKING PRESSURE Model 230 963 Series D 230 VAC 3 7 Amp 50 Hz Includes Contractor Gun RAC IV DripLess Tip Guard and SwitchTip U S PATENT NO 4 323 741 4 397 610 PATENTED 1983 CANADA AND FOREIGN PATENTS PENDING WARNING Hazard of Using Fluids Containing Halogenated Hydrocarbons Never use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment Such use could result in a serious chemical reaction with the possibility 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 used are compatible with aluminum and zinc parts GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1444 COPYRIGHT 1984 GRACO INC OPERATION sscsssesssccssccneeeseeeeseeesueesseseeenens SHUTDOWN amp CARE sssssnssennneennnnnnnnnnnnnnnnnnnnn nnna FLUSHING GUIDE NED sssrsvsurxvesrssrsressrrsrsuen TROUBLESHOOTING GUIDE Motor Won t Operate ccessseececcesesseeeeeeeees Low output seess seeeeeeeee Excessive Pressure Fluctuation Motor Is Hot and Runs Intermittently Electrical Short sssseessssseseens No OU
5. 112 and spacers 111 from the motor shield f Remove the shield Use a 4 mm 5 32 hex key wrench to remove the two screws 78 and washers 79 from the rear of the motor front end bell L PAD NOA o 307 671 29 Use a plastic mallet to gently tap the displacement pump 19 from the rear to loosen the drive housing 6 from the front end bell Then pull the drive hous ing away from the front end bell CAUTION DO NOT allow the gear cluster 26 to fall when removing the drive housing 6 Itis easy damag ed if dropped The cluster may stay engaged in either the front end bell or the drive housing DO NOT lose the thrust balls 24 located at each end of the gear cluster 26 or allow them to fall between gears The ball which is heavily covered with grease usually stays in the gear recesses but could be dislodged If caught between gears and not removed the balls will seriously damage the drive housing If the balls are not in place the bearings will wear prematurely 14 Use a 6 mm 1 4 hex key wrench to remove the two screws D I and lockwashers 34 from the underside of the motor mounting frame Be sure to support the motor to keep the sprayer from tipping Fig 32 30 307 671 20 Lift the motor assembly off the frame Place the new motor assembly on the frame and align with the frame mounting holes Install the screws 35 and lockwashers 34 tightly Liberally gre
6. BUSHING HOUSING drive LOCKWASHER 114 SCREW cap socket head 1 4 23 x 1 1 2 CONNECTING ROD ASSEMBLY COVER drive housing ae machine fil head 8 32 x TUBE siphon PUMP displacement Refer to 307 793 for parts PIN straight headless SPRING retaining NIPPLE 114npsm x 1 4 np HOSE grounded nylon 1147 ID 29 736mm long spring guard path ends BALL 1 4 SST GEAR CLUSTER LABEL warning CART FRAME LOCKWASHER 5 16 PEREN cap socket head 5 16 18 x CONNECTOR conduit PRESSURECONTROLASSY See separate parts list on page 34 CONDUIT electrical WHEEL WASHER back up RING retaining CAP hub COVER pressure control BRACKET mounting oa thread forming 10 24 x UNION adapter 318 npt m x 318 npsm f swivel FILTER fluid Refer to 307 273 for parts 7 57 108 5 mm QTY gt a aN N gt NaNa 2na mA AnH Una ch ch a NNN A REF PART DESCRIPTION QTY NO NO 54 210 657 BALL VALVE 1 4 npt mbe Refer to 306 861 for parts 1 DD 178 034 TAG warning 1 60 100 508 PLUG pipe 1 61 179 345 ADAPTER elbow 7 16 unfim x 114nptim x 114 npt f 1 62 100 322 WASHER 7 16 1 63 150 513 NUT jam hex 7 16 1 64 100 214 LOCKWASHER 5 16 2 65 100 001 SCREW ER hex 5 16 18 x 518 2 DN 181 073 STRAIN 1 72 210 541 HOSE Godek nyion 114 ID 50 ft 115 m long spring guard both ends 1 73 214701 HOSE grounded nylon 3 16 ID 3 ft 09 m long spring guard both ends 1 74 220955 GUN ai
7. The spray gun includes a trigger safety latch which prevents accidental triggering when it is engaged see the WARNING on page 2 and a trigger guard which prevents accidental triggering if the gun is dropped The Reverse A Clean IV SwitchTip uses high pressure fluid to remove clogs from the spray tip without remov ing it from the gun It includes a safety tip guard which helps reduce the risk of fluid injection injury SETUP 1 Connect Hose and Gun Refer to Fig 1 NOTE Whentighteningfittings at the pressure con trol hold one wrench firmly on the hex of the pressure control fitting to keep it from rotating Use another wrench to tighten the mating fitting a Remove the plastic cap plug from the filter outlet nipple and tightly screw the 15 2m 50 ft fluid hose onto the nipple b Tightly connect the whip hose between the fluid hose and the gun inlet connection c Don t use thread sealant on swivel couplings The sealant can prevent the swivel from rotating freely d Don t install the spray tip yet CAUTION To avoid damaging the pressure control whieh may result in poor equipment performance and component damage follow these precautions 1 Always use nylon spray hose at least 15 2 m 50 ft long 2 Never use a wire braid hose as it is too rigid to act as a pulsation dampener 3 Never install any shutoff device between 4 the filter and the main hose See Fig 1 Always use the main filt
8. GUARDS ON BOTH ENDS The 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 en tire 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 Do not use fluids or solventswhich are not compatible with the inner tube and cover of the hose DO NOT expose Graco hose to temperatures above 82 C 180 F or below 40 C 402F Hose Grounding Continuity Proper hose grounding continuity is essential to maintaininga grounded spray system Check the electricalresistance of your air and fluid hoses at least once a week If your hose does not have a tag on it which specifies the maximum electrical resistance contact the hose supplier ormanufacturer for the maximum resistance limits Use a resistance meter in the ap propriate range for your hose to check the resistance If the resistance exceeds the recommended limits replace it im mediately An ungroun
9. INSULATION full speed c Inspectthe brush and commutator contact area BRUSH LEAD BRUSH for excessive arcing Arcs should not trail or circle around the commutator surface SPRING CLIP WARNING Do not touch the brushes leads springs or brush holders while the sprayer is plugged in to avoid electric shock and possible serious bodily injury MOTOR END BELL BRUSH HOLDE ah SAB WTOREK Do not run the sprayer dry for more than 30 seconds while checking the brushes to avoid PACING BACK OF MOTOR damaging the displacement pump Fig 28 307 671 27 MOTOR CAPACITOR REPLACEMENT See Figs 29 amp 30 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 777 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer 1 Remove the control box cover 48 Disconnect the motor leads 2 Remove the fan cover F apg screws G from the rear of the motor See Fig 3 Usea screwdriver to gently lift the fan tab out of the motor shaft groove and remove the fan E 4 Remove the inspection cover J screws H and gasket Kl from each side of the motor 2 See Fig 29 5 Push down slightly on the spring clip and pull the clip out of the brush holder See Fig 30 6 Gently push the brushes out of the brush holder and inspect Replace if necessary See page 27 7 Make
10. a matchmark between the front end bell L and the motor housing and the rear end bell M and the motor housing to use as alignment marks during reassembly Also make a mark on the front of the motor housing Refer to Fig 8 Use a 11 mm 7 16 socket wrench to removethe nuts from the rear end bell M 9 Gently tap alternate ears of the rear end bell with a plastic mallet to loosen it then pull it straight off Do not pull the motor armature out Retain any washers that fall out when the bell is removed 10 To replacethe capacitor removethe brush leadter minal screws Y and the screw Z going into the insulation plate of the rear end bell Install a new capacitor X making sure the ceramic case of the capacitor S not cracked Maintain a 3 mm DIS clearance betweenthe capacitor and any grounded metal parts Always replace both capacitors at the same time 11 Position the rear end bell M over the tie bolts and push it onto the motor housing Align the match marks carefully and install the lockwashers and nuts 12 Position the fan E over the motor shaft and push it into place making sure the fan tabs engage in the motor shaft groove 13 Install the fan cover and screws 14 Reconnect the motor leads in the pressure control box and reinstallthe conduit 41 Push conduit seal 105 into conduit elbow around the motor lead o the pressure control cover 48 and screws 1 28 307 671 Fig 23 INSU ATION BRU
11. caught between gears the crank must be lowered manually and not removed the balls will seriously damage carefully rotate the blades of the fan with a the drive housing If the balls are not in place the screwdriver bearings will wear prematurely 1 Remove the front cover and screws 11 13 2 Unscrew the suction tube 14 from the pump 11 Inspect the drive housing for wear or damage and holding a wrench on the pump intake valve to keep replace if needed th from loosening s LASS 12 Pull th Crankshaft 81 out Inspect for wear or 3 Disconnect the pump outlet hose 23 from the damage and replace if needed Be sure the bear pump outlet nipple 22 ings 81a and 81b are in place on either side of the 4 Use a screwdriver to push aside the retaining spring crankshaft assembly 21 at the top of the pump Push the pin 20 out 13 Evenly lubricate the inside of the bronze bearing in the rear the drive housing with high quality motor oil 5 Loosen the jam nut 86 with an adjustable wrench Liberally pack the roller bearings and gears with Unscrew and remove the displacement pump 19 bearing grease 6 Removethe connecting rod 9 inspect for wear or 14 Install the crankshaft meshing the gears damage and replace if needed 15 Clean the mating surfaces of the drive housing and 7 Usea5mm 3 16 hex key wrench to remove the front end bell three screws and lockwashers 8 7 from the recess 16 Carefully align the drive housing and fro
12. commutator if possible See page 27 Replace motor See page a Replace bridge See page 20 Reset circuit breaker or replace outlet fuse If circuit breaker or fuse continues to open see Electrical Short page 14 Unplug sprayer Check continuity of both poles of ONIOFF switch 302 from TP1 to TP2 and TP2 to TP3 Replace switch if faulty Check continuity of RFI filter 3101 from TP4 to TP6 and TP3 to TP5 Replace filter if faulty Check power supply cord 3111 for con r tinuity from TPS to TP7 and TP6 to TPS Replace cord if faulty Check for any loose connections Replace damaged terminals and recon nect securely Replace electric motor if switch doesnot close when motor is cool See page T HECK WHAT TO DO Condition B i Check microswitch 306 With no fluid Replace microswitch See page 19 continued pressure in the pressure control discon nect wires TP18 and TP19 Check con tinuity across switch terminals with an ohmmeter Switch contact should be closed Depress actuator button An audible click indicates the contacts have opened Ohmmeter should read in finity Check circuit board 340 by Se 3 Replace circuit board See page 2 with a good board See page Condition C Check circuit board 340 by removing Replace circuit board See page 2 Red lamp on clear lamp off from box without disconnecting wires Unplug sprayer sea page 22 for rem
13. disassembly Fig 13 18 307 671 ON OFF SWITCH REPLACEMENT See Figs 14 amp 15 WARNING Before doing this procedure follow the Pressure Relief ProcedureWarning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock 1 Remove the pressure control cover and screws 2 Remove the wires attached to the switch 302 at TP1 and TP2 using a screwdriver See page 22 Fig 21 3 Usea 16 mm socket wrench to loosen and remove the nut and rubber boot 303 from the top of the pressure control box Remove the switch guard 304 4 Remove the ON OFF switch 5 Removethe wires attached to the switch TP4 and TP3 using a screwdriver See page 22 Fig 21 6 Attach the wires to TP4 and TP3 of the new switch 7 Installthe new switch so the internal tab of the anti rotation ring W engages with the vertical groove in the threads of the switch and the external tab engages with the blind hole D of the pressurecon Fig 14 trol box 8 Install the switch guard 304 aligning the internal tab with the groove in the threads 303 9 Powder the inside of the rubber boot 303 with 304 talcum then shake excess out of boot SSS 10 Install the nut and rubber boot and tighten 11 Reconnect the wires to TP1 and TEZ 12 Reinstall the pressure control cover and screws MICROSWITCH REPLACEMENT See Fig 15 WARNING Before do
14. fittings removed during repair procedures These parts are not normally provided with replace ment assemblies 4 Test your repair before regular operation of the sprayer to be sure the problem is corrected If the sprayer does not operate properly review the repair procedure again to verify that everything was done correctly If necessary refer to the Troubleshooting Guide pages 9 16 to help identify other possible problems and solutions WARNING To reduce the risk of serious bodily injury in cluding electric shock DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair Shut off the sprayer and unplug it as soon as you complete the inspection Reinstall all covers gaskets screws and washers before operating the sprayer CAUTION Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings 5 Reinstall the motor cover before regular operation of the sprayer and replace it if it is damaged The cover directs cooling air around the motor to help prevent overheating It can also help prevent burns fire or explosion see the WARNING below WARNING During operation the motor becomes very hot and could burn your skin if touched Flammable materials spilled on the hot bare motor could cause a fire or explosion Always have the motor cover in place during regular operation to reduce the risk of burns fire or explosion 307 671 17
15. gun into a grounded metal waste container and with a metal part of the gun firmly touching the metal container squeeze the gun trig ger This procedure helps avoid static sparking which can cause fire or explosion and splashing With the gun triggered turn the ONIOFF switch to ON and slowly turn the pressure adjusting knob clockwise just until the sprayer starts Keep the gun triggered until clean solvent comes from the nozzle Release the trigger and engage the gun safety latch 8 307 671 WARNING Always remove the spray tip from the gun before flushing to reduce the risk of a fluid injection in 9 10 5 Storage Water base paint flush with water then mineral spirits and leave the pump hose and gun filled with mineral spirits Shutoff and unplug the sprayer open the drain valve to relieve pressure and leave open Oil base paint flush with mineral spirits Shutoff and unplug the sprayer open the drain valve to relieve pressure and leave open 6 Startup after storage Before using water base paint flush out mineral spirits with soapy water and then a clean water flush When using oil base paint flush out the mineral spirits with the fluid to be sprayed and the sprayer is ready to use MAINTAIN FIRM METAL TO METAL CONTACT WHEN FLUSHING Fig 8 7 Check all fluid connections for leaks If any leak follow the Pressure Relief Procedure Warning on page 6 Now tighten the connections start the sprayer and recheck the
16. in the closed mode WHAT TO DO If check ig NOT OK refer to this col umn Repair or replace any damaged wiring or terminals Securelv reconnect all wires Correct faulty conditions Replace motor See page 29 Replace bridge See page 20 2 Replace ON OFF switch See page 19 SPIN TEST WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 47 te reduce the risk of a fluid injection injury splashing fluids in the eyes or on the skin injury from moving Darts or electric shock For checking armature motor winding and brush elec trical continuity Setup Remove the drive housing from the sprayer as des cribed in Steps 1 9 page 25 Remove the pressure control cover and screws the motor cover the fan cover F and the inspection covers J See Fig 9 Disconnect the two leads from the motor to the bridge 308 See Fig 10 Armature Short Circuit Test Quickly turn the motor fan by hand ff there are no shorts the motor will coast two or three revolutions before coming to a complete stop Ifthe motor does not spin freely and resists rotation the armature is shorted and the motor must be replaced See page 29 Armature Brushes and Motor Wiring Open Circuit Test Continuity Connect the two black motor leads together with a test lead Turn the motor fan by hand at about two revolutions per second Fig 9 If there is uneven or no tu
17. nut 86 to 94 N m 70 ft lb very tight to prevent it from looseningwhich will damage the bearing housing See Figures 25 and 26 WARNING Be sure the retaining spring 21 is firmly in the groove of the connecting rod ail the way around io prevent the pin 20 from working loose due to vibration See Fig 26 If the pin works loose it or other parts could break off due to the force of the pumping action These parts could be projected through the air and result in serious bodily injury or property damage in cluding damage to the pump connecting rod or bearing housing 86 TORQUE TO 34 Nm 70 ft tb Fig 26 21 Reinstall the front cover and screws 11 13 Reconnect the suction tube 14 and pump outlet hose 23 26 307 671 MOTOR BRUSH REPLACEMENT See Figs 27 amp 28 amp NOTE New motor brushes are included with each 11 Reinstallthe brush inspection covers gaskets and Packing Repair Kit Replace them when screws Reinstall the motor shield and screws replacing the packings and or when they have been worn to a minimum of 9 16 on the longest side WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17to reduce the risk of fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer 1 Remove the four short screws 110 and the two long screws 112 and sp
18. spray tip as shown in manual 307 848 supplied with the RAC IV DripLess tip guard SHUTDOWN AND CARE 1 Check the packing nut wet cup daily First follow the Pressure Relief Procedure Warning on page 6 Be sure the wet cup is 773full of TSL at all times to help prevent fluid buildup on the piston rod and premature wear of packings The packing nut should be tight enough to stop leakage but no tighter Overtightening may cause binding and ex cessive packing wear Use a screwdriver and light hammer to adjust the nut See Fig 6 2 Glean the fluid filter often and whenever the sprayer is stored First follow the Pressure Relief Procedure Warning on page 6 Refer to manual 307 273 supplied for the cleaning procedure Fig 6 3 Lubricate the bearing housing after every 100 hours of operation Fill the cavity of the bearing housing with SAE 10 nondetergent oil 6 Coil the hose and hang it on the hose rack when storing it even for overnight to help protect the 4 Flushthe sprayer at the end of each work day hose from kinking abrasion coupling damage etc and fill it with mineral spirits to help prevent pump corrosion and freezing See Flushing Guidelines on page 8 WARNING Refer to the warning section HOSE SAFETY on page 3 for information on the hazard of using damaged hoses CAUTION To prevent pump corrosion and to reduce the chance of fluid freezing in the pump or pressure control in cold weather never leave w
19. suction tube or fittings WHAT TO DO Ifcheck is NOT OK refer to this column Follow Pressure Relief Procedure Warning then replace tip See your separate gun or tip manual Service pump See manual 307 793 Reset building circuit breaker replace building fuse Repair electrical outlet or try another outlet Replace with a correct grounded exten sion cord Clean circuit board male terminals Replace loose or defective lead ter minals Securely reconnect lead ter minals to board Calibrate pressure control See page 24 Be sure male terminal biades are centered and firmly connected to female terminals Replace any loose terminal or damaged wiring Securely reconnect wires to bridge Tighten terminal screws Replace E if leads are damaged See page Replace brushes See page 2 Replace spring if SS Realign spring with brush See page 1 Clean brush holders remove carbon dust with small cleaning brush Align brush lead with slot in brush holder to assure free vertical brush movement 12 Replace circuit board See page 2 13 Replace motor See page 29 14 Repiace bridge See page 20 1 Refilland rsprime pump 2 Remove and clean then reinstall 3 Tighten use thread sealant or sealing tape on threads if necessary TYPE OF PROBLEM NO OUTPUT Continued Motor runs but pump does not stroke EXCESSIVE PRESSURE FLUCTUATIONS Spray pattern variations WHAT TO CHECK
20. until the fluid pressure stabilizes then the motor will shut itself off However there will still be power to the sprayer and it will stay pressurized and ready to use unless you manually shut it offand relieve pressure Because the motor is DC it is less sensitive to low voltage or voltage fluctuations than an AC motor and an extension cord of up to 45 m 150 feet can be used Drive Assembly The sealed drive assembly transfers power from the DC motor to the displacement pump 4 307 671 ON OFF SWITCH PRESSURE CONTROL KNOB 4 DISP ACEMENT z rumr DRAIN VALVE Displacement Pump The positive displacement volume balanced pump pro vides equal fluid delivery on both the up and down pump strokes The pump has a wet cup which when filled with Graco Throat Seal Liquid helps prevent damage to the throat packings and piston rod Fluid Filter The fluid filter provides the final paint straining to help avoid clogs in the hose and spray tip The filter includes a reusable element and a drain valve for relieving fluid pressure when shutting off the sprayer Hoses Two grounded nylon spray hoses with spring guards are includedwith the sprayer The 15 2 m 50 foot hose has a 1 4 in ID The 0 9 m 3 foot 3 16 in ID whip hose allows flexible gun movement The nylon hose material acts as a pulsation dampener to absorb pressure fluctuations Spray Gun amp Reverse A Clean IV DripLess Tip Guard
21. 1 WARNING USE EXTREME CAUTION WHEN PERFORMINGTHIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from splashing component rupture electric NEVER attempt to increase the fluid outlet pressure by performing this calibration in any other way NEVER EXCEED 192 bar 2750 psi MAXIMUM WORKING PRESSURE Normal operation of the sprayer at higher pressures could result in compo nent rupture fire or explosion AVOID touching he wires in the pressure control assembly with your fingers or tools when the control box cover is removed to reduce the risk of electric shock Fig 24 CONNECTING ROD DRIVE HOUSING or CRANKSHAFT REPLACEMENT See Fig 25 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer CAUTION DO NOT allow the gear cluster 26 to fall when remowimg the drive housing 6 It is easy damag ed if dropped DO NOT lose the thrust balls 24 located at each end of the gear cluster 26 or allow them to fall between gears The ball which is heavily covered NOTE Stop the sprayer at the bottom of its stroke with grease usually stays in the shaft recesses to get the crank 81 inits lowest position If but could be dislodged If
22. E FILTER CORDSET power supply no plug SCREW mach slotted pan head No A x 5 16 CONNECTOR conduit ELBOW street 1 4 nptim x f ADAPTER 3 8 nptitm x 1 4nptim NIPPLE 114npt HARNESS wire HARNESS wire HARNESS wire HARNESS wire HARNESS wire HARNESS wire SCR QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PAR NO NO 107 438 100 975 101 792 157 021 108 295 107 258 180 041 101 273 100 179 100 718 178 797 178 035 8 88888 GR EBBES RE DESCRIPTION SCREW machine fil head No 5 40 x 518 long NUT hex machine No 5 LOCKWASHER external shakeproof No 5 LOCKWASHER No 8 internal BUSHING strain relief TIP pin black plastic PIN SCREW machine flat head No 10 24x 518 long NUT hex mscr No 10 24thd LOCKWASHER internal shakeproof No 10 LABEL WARNING LABEL WARNING TERMINAL STRIP NUT hex M8 x 1 25 LOCKWASHER external shakeproof 5 VARISTOR CIRCUIT BOARD Extra Warning labels and tags supplied at no charge See How To Order Replacement Parts on page 3 QTY e och Ach bi NN aN Naaa N NN WIRING DIAGRAM THESE WIRES ARE CONNECTED TO TWO TERMINALS ON THE OTHER SIDE OF THE ONIOFF SWITCH 321 WHITE PURPLE RED 339 340 306 YELLOW WHITE Ki GROUND WIRE Wa az SERVICE INFORMATIONE Listed below by the assembly changed are OLD and NEW parts ASSEMBLY PART REF CHANGED STATUS
23. Ifcheck 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 indicate worn or damag ed packings See manual 307 793 Check displacement pump connecting rod pin See page 26 Check connecting rod assembly for damage See page 25 Be sure crank in drive housing rotates plug in sprayer and turn on momentarily to check Turn off and unplug sprayer See page 25 Be sure both G1 and G2 leads from bridge 308 to circuit board are firmly connected See page Check stall pressure Refer to Calibration procedure on page 24 Check bourdon tube flag and detector position Turn pressure sening to max imum flag should not drag or bind in optical detector slot of circuit board CIRCUIT BOARD OPTICAL DETECTOR FLAG VIEW OF OPTICAL DETECTORAND FLAG d Check circuit board 340 by Syppiituting with a good board See page Check LOW OUTPUT section on page 12 Check to see if sprayer has been operating at high pressure with small tips which causes low motor RPM and results in excessive heat build up Check to see if ambient temperature where sprayer is located is more than 32 C 90 F or if sprayer is located in direct sun Check to see if sprayer has been left ina stalled condition sprayerturned on pressurized but not operating for long periods of time WHA
24. NO 230 963 Sprayer Series 218 618 Motor Cover 181 612 Motor Shield 217 583 Gun 220 955 Gun 218 215 Displ Pump Displ Pume Hose Hose Pin Ri Strainer 181 073 Strainer j 320 Hh 318 RED d 319 wHITE RED Ai YELLOW GREEN GROUND WIRE NOTE This manual now includes complete service procedures The parts list has new reference numbers Other major changes to the sprayer are the upright cart 33 and changes to the suction tube 14 DISCONTINUED MODEL NOTE Model 230 964 is obsolete and has been deleted from the manual 307 671 35 ULTRA 400 TECHNICAL DATA Power Requirements Operating Range Power Cord Inlet Paint Strainer Outlet Paint Filter Pump Inlet Size Fluid Outlet Size Weight Wetted Parts Dimensions 230 VAC 50 Hz 1 Phase 3 7 AMP minimum 0 192 bar 0 2750 psi Cycles Liter gallon 124 470 2 5mm 0 13ga 3 wire 6 m 20ft long 16 mesh 1190 micron Stainless Steel Screen reusable 60 mesh 250 micron Stainless Steel screen reusable 314 npt w 30 LD chamfer 1 4 npsm from fluid filter 36 Kg 80 Ib approximately Aluminum Dalrin Nitralloy Nylon Ultra High Molecular Weight Polyethylene Polyurethane Rubber impregnated leather Stainless Steel PTFE Tungsten Carbide Zinc plated steel Width 546 1 mm ee Height Handle extended 938 8 mm 37 in Handle down 723 9 mm 28 5 in Length Handle extend
25. SH LEAD SPRING CLIP Fig 30 HOLDER DETAIL OF MOTOR BRUSH SHOWN WITH MOTOR LEAD FACING BACK OF MOTOR BRUSH MOTOR REPLACEMENT See Fig 31 amp 32 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injecfiom injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer 1 Disconnect the pump outlet hose 23 from the displacement pump outlet nipple 221 2 Remove the screws 51 and pressure control cover 48 and disconnect the four motor leads 3 Use an adjustable wrench to loosen the conduit connector nut 313 at the pressure control assembly 401 4 Swing the conduit 41 away from the pressure control elbow 313 5 Pull the motor leads through the elbow one at a time CAUTION Always pull the motor leads one at a time to avoid loosening the terminals 11 Fig 31 12 Loosen the connector nut 39 at the motor and pull the conduit 41 away from the motor then pullthe leads through the conduit one ata time See Fig 31 Unscrew the elbow 39 from the motor Pull the wires through the elbow one at a time Remove the front cover and screws 11 13 Use a 5 mm 3 16 hex key wrench to remove the two screws 8 and washers 7 from the recess of the drive housing Remove the four short screws 110 and two long screws
26. T TO DO If check is NOT OK refer to this column Remove intake valve and clean Check balls and seats for nicks replace if necessary See manual 307 793 Replace packings See manual 307 793 Also check piston valve seat for harden ed paint or nicks and replace if necessary Replace pin if missing Be sure retainer spring is fully in groove al around connecting rod See page 26 Replace connecting rod assembly See page 25 Check drive housing assemblv for katy ang repiace if necessary See page Reconnect securely See page 2 Calibrate pressure control See page 24 Carefully bend flag into alignment with detector slot to see if that corrects pro blem If not replace bare pressure control assembly 301 Calibrate pressure con trol after reassembly Replace circuit board See page 2 Decrease pressure sening or increase tip size L Move sprayer to shaded cooler area if possible Turn off sprayer whenever you stop spraying for awhile and relieve fluid pressure When replacing the bare pressure control box 301 remove the ON OFF switch i ircui f i j Il in th box bridge circuit board and electrical hardware and reinstall in the new bare box 307 671 13 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 outp
27. WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury in cluding fluid injection splashing fluid in the eyes or on the skin or injury from moving parts or elec tric shock always follow this procedure whenever you shut off the sprayer when checking or servic ing any part of the spray system when installing cleaning or changing spray tips and whenever you stop spraying Engage the gun safety latch Turn the ON OFF switch to OFF Unplug the power supply cord Disengage the gun safety latch Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure Engage the gun safety latch Open the drain valve having a container ready to catch the drainage Leave the drain valve open until you are ready to spray again f you suspect that the spray tip or hose is com pletely clogged or that pressure has notbeen fully relieved after following the steps above VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely Nowclear the tip or hose Tool List The following tools are needed when repairing this sprayer Phillips screwdriver Small flatolade screwdriver Needle nose pliers Plastic mallet Adjustable wrench 2 adjustable open end wrench Torque wrench 1 4 hex key wrench 3 16 hex key wrench 5 8 socket wrench 3 8 open end wrench 1 2 open end wrench 3 4
28. acers 111 from the motor shield 1 Remove the shield See Fig 27 2 Remove the screws HI inspection covers J and gaskets Ki on each side of the motor See Fig 27 3 Loosen the brush lead terminal screw and remove the lead 4 Push down on the spring clip slightly then pull the clip away from and out of the brush holder Referto Fig 28 Keep the spring clip 5 Remove and discard the brush 6 Inspectthe commutator for excessive pitting burn ing or gouging Fig 27 NOTE A black color on the commutator is normal Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to be wearing too fast 7 Place a new brush in the holder so the beveled edges are as shown in the first part of Fig 23 and the brush lead is routed as shown inthe second part of Fig 28 8 Slowly push the tabbed end of the spring clip into the brush holder until the clip tab engages in the holder and the rolled portion of the tension spring rests squarely on the brush 9 Routethe brush lead to the terminal and tighten the CAPACITOR terminal screws Be sure the brush lead does not touch any part of the armature or motor housing 10 Test the brushes TERMINAL SCREW a With the ON OFF switch OFF turn the pressure control knob all the way counterclock wise to minimum pressure Plugin the sprayer b Turn the ON OFF switch ON and slowly in crease the pressure until the motor comes upto
29. ainage 8 Leave the drain valve open until you are ready to spray again If you suspect that the spray tip or hose is com pletely clogged or thatpressure has notbeen fully relieved after following the steps above VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve oressure gradually then loosen completely Nowciearthe tip or hose EES EE TEEN TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO i If check is OK go to next check If check is NOT OK referto this column MOTOR WONT OPERATE Basic Fluid Pressure Problems 1 Check the pressure control knob sening The motor will not run if it is at the minimum sening fully counterclockwise 1 Slowly increase the pressure setting to see if the motor starts wam area freezing t the sprayer t mum be replaced See page Check for a clogged spray tip Refer to your separate gun or tip instruction manual Check for frozen or hardened paint in the pump 19 andlor pressure control bourdon tube Using a screwdriver carefully try to rotate fan at back of motor See page 15 Basic Mechanical Problems Check A pacemon pump connecting rod pin 20 It must be completely pushed into connecting rod 9 and spring retainer 21 should be firmly in groove of connecting rod See page 26 Check for motor da Remoye drive housing assem e See page 20 Try to rotate fan bv hand Basic Electrical Problems Check electrical supply with volt mete
30. and pressure con trol cover These precautions are essential to reduce the risk of malfunction 7 Perform the STALL PRESSURE CALIBRATION on page 24 if you installed a new board 302 S 320 i ity 318 RED 319 WHITE RED Hh TPe TP10 MOTOR YELLOW GREEN GROUND WIRE TP7 PLUQ PRESSURE CONTROL REPLACEMEN WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer 1 Disconnect the main fluid hose 72 and the secon dary fluid hose if used from the sprayer 2 Disconnect the fluid hose 23 from between the displacement pump outlet nipple 22 and pressure control inlet elbow 314 3 Loosen the filter bracket nut 63 and washer 62 using a 19 mm open end wrench 4 Hold the pressure control adapter 315 firmly with a 19 mm open end wrench Use an adjustable wrench to loosen the swivel union 52 then remove the fluid filter 53 5 Removethe pressurecontrol cover and screws and disconnect the four motor leads at the appropriate terminals 6 Refer to CIRCUIT BOARD REPLACEMENT on page 2 remove the circuit board and retain 7 Remove the conduit 41 Use a 13 mm open end wrench to loosen and remove the pressure control mounting screws 65 and washers 64 located below the pressure co
31. ase the gear cluster 26 and pinion gear O and pack all bearings in the motor front end bell Check to be sure the thrust balls 24 are in place Be sure the bronze colored bearing 81a and the silver colored bearing 81b are properly placed on the crank shaft 81 Align the gears and push the drive housing 6 straight onto the front end bell and locating pins Starting at Step 13 and working backwards con tinue to reassemble the sprayer NOTE Use a turning motion on the conduit when feeding wires through it 20 Reinstall the motor shield and pressure control cover PART DRAWINGS AND PARTS LISTS 307 671 31 PARTS DRAWIN Model 230 963 Ultra 400 Series D Includes items 1 112 NS A 11 A D Gate SU e A c AN ANE e D 32 307 671 Model 230 363 Ultra 400 Series D Includes items 1 112 REF PART NO NO 1 181 612 2 218 415 3 107 267 4 107 264 5 107 219 6 220 270 7 105 510 8 107 445 9 218 359 11 218 363 13 107 209 14 180 192 19 220647 20 176 818 21 176 817 22 162 453 23 218 083 24 100 069 26 218 364 27 178 934 33 218 361 34 104 008 35 107 212 39 102 932 40 218 353 4 065 099 42 106 062 43 176 884 44 101 242 45 104 811 48 218 326 50 179 936 51 06 075 52 155 665 53 214 570 DESCRIPTION SHIELD motor MOTOR electric 112 HP Includes items 3 4 5 one of item 24 and one of item 27 TERMINAL insulated TERMINAL insulated
32. ater or any type of paint in the sprayer when it is not in use Freezing can seriously damage the sprayer and result in loss of pressure or stalling 5 Forvary short shutoff periods leave the suction tube in the paint follow the Pressure Relief Pro cedure Warning on page 6 and clean the spray tip 307 671 7 FLUSHING GUIDELINES When to Flush 1 New Sprayer Your new Ultra 400 Sprayer was factory tested in lightweight motor oii which was left in to protect pump parts Before using water base paint flush with mineral spirits followed by soapy water and then a clean water flush Before using oil base painl spirits only 2 Changing Colors Flush with a compatible solvent such as mineral spirits or water 3 Changing from water base to oil base paint Flush with soapy water then mineral spirits 4 Changing from oil base to water base paint Flush with mineral spirits followed by soapy water then a clean water flush flush with mineral How to Flush 1 Follow the Pressure Relief Procedure Warning on page 6 2 Remove the filter bowl and screen see manual 307 273 supplied Clean the screen separately and install the bowl without the screen d sen VALVE SHOWN OPEN Fig 7 3 Close the filter drain valve 4 Pour 2 liters 1 2 gal of compatible solvent into a bare metal pail Put the suction tube in the pail jury 5 Disengage the gun safety latch 6 Point the spray
33. connections for leaks 8 Remove the suction tube from the pail Disengage the gun safety and trigger the gun to force solvent from the hose Do not let the pump run dry for more than 30 seconds to avoid damaging the pressure control Then turn ON OFF switch to OFF and engage the gun safety latch Unplug the power supply cord Open the drain valve and leave open until you are ready to use the sprayer again Unscrew the filter bowl and reinstall the clean screen Reinstall the bowl hand tight only If you have flushed with mineral spirits and are go ing to use a water base paint flush with soapy water rye by a clean water flush Then repeat Step 1 TROUBLESHOOTING GUIDE Pressure Relief Procedure e To reduce the risk of serious bodily injury in cluding fluid injection splashing fluid in the eyes or onthe skin or injury from moving parts or elec tric shock always follow this procedure whenever you shut off the sprayer when checkingor servic ing any part of the spray system when Installing cleaning or changing spray tips and whenever you stop spraying 1 Engage the gun safety latch 2 Turn the ON OFF switch to OFF 3 Unplug the power supply cord 4 Disengage the gun safety latch 5 Holda metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure WARNING 6 Engage the gun safety latch 7 Ooen the drain valve havina a container readv to catch the dr
34. d with an undamagedthree prong plug into a properly grounded outlet Do not use an adapter All ex tension cords must have three wires and be rated for 15 amps 2 Fluidhoses use only grounded hoseswith a maximum of 500 feet 150 m combined hose length to ensure ground ing continuity Referto Hose Grounding Continuity 3 Spray gun obtain grounding through connection to a properly grounded fluid hose and sprayer 4 Fluidsupply container according to local code 5 Object being sprsyed according to local code 6 Allsolvent pails used when flushing according to local code Use only metalpails which are conductive Do not place the pail on a non conductive surface such as paper or cardboard which interrupts the grounding continuity 7 Tomaintaingrounding 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 specific flushing procedure given on page 8 of this manual Follow the Pressure Relief Pro cedure on page 2 and remove the spray tip before flushing Hold a metal part of the gun firmly to the side of a metal pail and use the lowest possible fluid pressure during flushing MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers or other body parts KEEP CLEAR of moving parts when starting or operating
35. ded or poorly grounded hose can make yout an hazardous Also read FIRE OR EXPLOSION FIRE OR EXPLOSION HAZARD Static electricity is created by the flow of fluid through the pump and hose If every pan 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 particles and other flammable substances whether you are spraying in doors or outdoors and can cause a fire or explosion and serious bodily injury and property damage Always plug the sprayer into an outlet at least 6 m 20 feet away from the sprayer and the spray area Do not plug in or unplug any power supply cords inthe spray area when there is any chance of igniting fumes still in the air If you experience any static sparking or even a slight shock while using this equipment STOP SPRAYING IMMEDI ATELY Check the entire systemfor proper grounding Do not use the system again until the problem has been identified and corrected 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 the power supply cord or extension cord each equippe
36. e of the spray equipment or accessories such as overpressurizing modifying parts using incompatible chemicals and fluids or using wom or damaged parts can cause them to rupture and result in fluid injection or other serious bodily injury fire explosion 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 Read and follow the fluid and solvent manufacturer s literature regarding the use of protective clothing and equipment System Pressure This sprayer can develop 192 bar 2750 psi MAXIMUM WORKING PRESSURE Be sure that all spray equipment and accessories are rated to withstand the maximum working pressure of this sprayer DO NOT exceed the maximum work ing pressure of any component or accessory used in the system Fluid Compatibility BE SURE that all fluids and solvents used are chemically com patible with the wetted parts shown in the Technical Data on the back cover Always read the fluid and solvent manufac turer s literature before using them in this sprayer HOSE SAFETY High pressurefluid 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 pressurespray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage ALL FLUID HOSES MUST HAVE SPRING
37. ean it NEVER wipe off build up around the spray tip until pressureis fully relieved and the gun safety latch is engaged Pressure Relief Procedure you are ready to spray again completely Now clear the tip or hose TURN SWITCHTO OFF UNPLUG CORD ENGAGE SAFETY LATCH 2 307 671 To reduce the risk of serious bodily injury including fluid injection injury from splashing fluid or solvent in the eyes or on the skin moving parts or electric shock alwaysfollow this procedure whenever you shut off the sprayer when checking or servic ing any part of the spray system when installing cleaning or changing spray tips and whenever you stop spraying i the gun safety latch 2 Turn the ON OFF switch to OFF 3 Unplug the power supply cord 4 Disengagethe gun safety latch 5 Hold a metal pan of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure 6 Engagethe gun safety latch 7 Open the drain valve having a container ready to catch the drainage 8 Leave the drain valve open until Hou suspect that the spray tip or hose is completely clogged or that pressure has not been fully relievedafter following the steps above VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen Engage DISENGAGESAFETY AND TRIGGER GUN ENGAGE SAFETY AGAIN OPEN DRAIN VALVE EQUIPMENT MISUSE HAZARD General Safety Any misus
38. ed 660 4 mm 26 in Handle down 609 6 mm 24in Delrin andPTFE are registered trademarks of the Du Pont Company Factory Branches Atlanta Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affillate Companies Cansda England Switzerland France Germany Hong Kong Japan GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1444 PRINTED IN U S A 307 671 1 84 Revised 7 87
39. er outlet for one gun operation Never plug this outlet 2 Fill Packing Nutiwet Cup See Fig 2 Fill the packing nut wet cup 1 3 full with Graco Throat Seal Liquid TSL supplied 3 Check Electrical Service a Be sure the electrical service is properly rated for your sprayer and that the outlet you use IS properly grounded b Attach an appropriate plug to the power supply cord according to your local electrical codes c Use an extension cord which has 3 wires of a minimum 12 gauge size and a maximum of 45 m 150 ft long Longer lengths may affect sprayer performance 4 Plug inthe Sprayer a Be sure the ONIOFF switch is OFF Refer to Fig 3 Then plug the cord into a grounded elec trical outlet at least 6 m 20 ft away from the spray area WARNING Proper electrical grounding is essential o reduce the risk of fire or explosion which can result in serious bodily injury and property damage Refer to the warning section FIRE OR EXPLOSION HAZARD on page 3 for more detailed grounding instructions 5 Flush the pump to remove the lightweight oil which was left in to protect pump parts after fac tory testing a Before using water base paint flush with mineral spirits followed by soapy water and then a clean water flush INSTALL A SHUTOFF DEVICE HERE DO NOT ON OFF SWITCH b Before using oil base paint flush with mineral spirits only c See Flushing Guidelines on page 8 for flushing pr
40. ing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the oye or on the skin injury from moving parts or electric shock 1 Remove the pressure control cover and screws 2 Disconnect both wires from the microswitch 306 3 Usethe socket wrench to remove the nuts from the microswitch 4 Check to see if the flag X is loose If it is be sure the fluid pressure is O bar psi then loosen the two 6 mm hex nuts behind the microswitch Adjust the distance from the top of the flat to top inside of the pressure control box to 40 79 0 254 mm 1 606 0 010 in Tighten the screwsand recheck the dimension Refer to Fig 1 5 Perform the STALL PRESSURE CALIBRATION on page 24 before regular operation of the sprayer 6 Reinstall the cover and screws Fig 15 307 671 19 BRIDGE RECTIFIER REPLACEMENT See Fig 161 WARNING CAUTION Before doing this procedure follow the Pressure The lockwashers 333 must be in front of the Relief Procedure Warning on page 17to reduce bridge to avoid overheating which will result in the risk of a fluid injection injury splashing in the bridge failure Refer to the Detail in Fig 16 eyes or on the skin injury from moving parts or electric shock 6 Make sure the bridge is flush with the side of the box and tighten the screws securely 1 Remove the pressure control cover and screws 7 Connect a
41. k Be sure to unplug rhe spraver 1 Remove the pressure control cover and screws 2 Turnthe pressure control knob all the way counter clockwise to the minimum setting to release spring tension on the board Also check to be sure only three or four threads of the pressure control knob shaft are exposed below the pressure adjustment nut S Back down the nut if necessary See Fig 20 CAUTION Step 2 is essemtiiall to reduce the risk of damaging hoe circuit boardi while removing or installing it 3 Disconnect ALL wires from the board including the two heavy black wires Pay close attention to where connections are made See Fig 21 4 To remove the board from the box pull out the black plastic tipped pin 330 Push the bottom of the circuit board toward the wall of the box and carefully slide the board out 5 Install the board in the box at the Same angle as it was removed 6 Reconnect all wires Refer to the wiring diagram in Fig 21 Ref 321 REF 320 TP1 TP2 Te3 4 Km Ref 318 REF 319 punpLE 340 309 TP6 TP3 TP8 Fig 21 22 307 671 SCH GROUND 310 312 EA WHITE 323 322 ris A BLACK KI NIE nl 77 D WAX PRESSURECONTROLKNOS Be sure the flat blade of the insulated male con nector is centered exactly in the wrap around blade of the female connector when connections are made Route all wires carefully to avoid interference with the circuit board bourdon tube
42. ll wires Carefully route the wires 2 Disconnect all wires from the bridge 308 at the ap propriate terminals CAUTION 3 Outside the pressure control box on the right side are Be sure the flat blade of the insulated male con two screws 331 Loosen but don t remove the nector is centered in the wrap around blade of the screw near the back mounting plate 50 Then female connector when the connections are loosen and remove the front screw Slide the bridge made Improper connections may cause the out sprayer to malfunction 4 Slide the new bridge 308 into the box being sure Route all wires carefully to avoid interference with the lockwasher 333 on the rear screw 331 is N the movement of the bourdon tube circuit board FRONT of the bridge Referto the Detail in Fig 16 or control box cover which could cause a maifunc 5 Install the front screw lockwasher and nut 332 ton 8 Reinstall the pressure control cover and screws BRIDGE INSTALLATION DETAIL Fig 16 20 307 671 CHOKE REPLACEMENT See Fig 17 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Be sure to unplug the sprayer 1 Remove the pressure control cover and screws 2 Remove the grounding screw 312 and remove the lead Loosen the appropriate screw on the termi
43. n trol box Remove the box 9 Install the new pressure control assembly in the reverse order of disassembly CAUTION Do not allow the adapter 315 to turn while in stalling the new pressure control assembly Turn ing it can damage the sensitive bourdon tube GTI TB I Hold the ad pter firmly with a 19 mm open end wrench while screwing on the swivel union 52 10 Perform the STALL PRESSURE CALIBRATION starting on page 24 before regular operation of the sprayer 307 671 23 STALL PRESSURE CALIBRATION shock fire explosion or moving parts This procedure sets the sprayer to 192 bar 2750 psi MAXIMUM WORKING PRESSURE This procedure must be performed whenever a new or used circuit board or pressure control assembly is removed and reinstalled or replaced to be sure the sprayer is pro perly calibrated Improper Calibration can cause the sprayer to over pressurize and result in component rupture fire or explosion It may also prevent the sprayer from ob taining the maximum working pressure which would result in poor sprayer performance Calibration Setup See Fig 23 and 24 1 Follow the Pressure Relief Procedure Warning on page 17 Removethe spray hoseand gun Install a0 015 spray tip in the gun Connect the gun toa new test hose and connect the hose to the sprayer outlet Remove the pressure control screws and cover Remove the plug from the top of the fluid filter and install the tes
44. nal strip 336 and disconnect the yellow green choke lead 3 Use the M8 wrench to remove the upper nut and lockwasher 337 338 on the outside of the pressure control box 4 Remove the old choke 309 and installa new one in the reverse order of disassembly VARISTOR REPLACEMENT See Figs 18 amp 19 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shock Remove the control box screws and cover 2 Remove the two screws A B the wiring harnesses 318 319 and the old varistor from the ONIOFF switch 302 3 Trim the leads on the new varistor 339 to 28 5 mm 1 7 8 in Turn each lead outward to form a loop that is large enough for the screws A B to pass through 4 Place a wiring harness on each screw then place a loop of the varistor leads on each screw and thread the screws into the switch 5 Wrap the varistor under the switch Fig 17 gt zm E B A A B 339 339 FRONT VIEW SIDE VIEW Fig 18 28 5 mm 1 1 8 OS Fig 19 307 671 21 CIRCUIT BOARD REPLACEMENT See Figs 20 amp 21 WARNING Before doing this procedure follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or electric shoc
45. nections for leaks If any are found follow the Pressure Relief Procedure Warning above before tightening connec tions 2 Installthe Spray Tip and Tip Guard a Be sure the gun safety latch is engaged b Install the spray tip If using the RAC IV refer to manual 307 848 supplied with the gun for installation instructions 6 307 671 4 Cleaning a Clogged Tip ROTATE RAC IV WARNING KANDLE 180 To avoid a fluid injection injury DO NOT hold your hand body or a ragin front of the spray tip when cleaning or checking a clogged tip Always point the gun toward the ground or into a waste container when checking to see if the tip ts clear DO NOT try to blow back paint this is NOT an air spray sprayer a Clean the front of the tip frequently during the day s operation First follow the Pressure Relief Procedure Warning on page 6 Then use a solvent soaked brush to keep fluid from building up and clogging the tip LATCH PEREENDICUIA R TO GUN 80D b Ifthe spray tip does clog release the gun trig ger engage the gun safety ae rotate the 5 RAC IV handle 180 See Fig 5 Fig c Disengage the gun safety and trigger the gun into a waste container Engage the gun safety again d Return the handle to the original position disengage the gun safety and resume spray ing e if the tip is stif dogged engage the gun safety shutoff and unplug the sprayer and open the drain valve to relieve pressure Clean the
46. nt end bell of the drive housing 6 with the locating pins then push the drive housing 8 Remove the four short screws 110 and two long onto the front end bell or tap it into place with a screws 1121 and spacers 1111 from the motor plastic mallet shield 1 Remove the shield 17 Reinstall the motor shield 1 using the two long 9 Use a4mm 5 32 hex key wrench to removethe screws 112 and spacers 111 and the four short two screws and lockwashers 78 79 from the top screws 110 rear of the front end bell L 18 Install the screws and lockwashers 8 7 and 10 Lightly tap the lower rear of the drive housing with tighten evenly a plastic malletto loosen itfrom the motorfront end bell Then pull the housing off CAUTION P 9 O NOT use the drive housing screws to try to align or seat the housing which would cause im 81 proper alianment and premature bearina wear 111 Wi NN dl 26 Fig 25 307 671 25 19 Install the connecting rod 9 20 Screw the displacement pump about 3 4 of the way into the bearing housing 6 Hold the pin 20 up to the pin hole in the connecting rod assembly 3 and continue screwing inthe pump until the pin slides easily into the hole Back off the pump until the top threads of the pump cylinder are flush with the face of the bearing housing and the outlet nip ple 22 is facing back Push the retaining spring 21 into the groove all the way around the connect ing rod Tighten the jam
47. ocedure 6 Preparethe paint according to the manufacturer s recommendations a Remove any skin that may have formed b Stir the paint to dissolve hard pigments c Strain the paint through a fne nylon mesh bag availableat most paint dealers to remove par ticles that could clog the filter or spray tip This is probably the most important step toward trouble free spray painting 307 671 5 OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury in cluding fluid injection injury from splashing fluid or solvent in the eyes or on the skin moving parts or electric shock always follow this procedure whenever you shut off the sprayer when check ing or servicing any part of the spray system when installing cleaning or changing spray tips and whenever you stop spraying Engage the gun safety latch Turn the ON GFF switch to OFF Unplug the power supply cord Disengage the gun safety latch Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure Engage the gun safety latch Open the filter drain valve having a con tainer ready to catch the drainage 8 Leave the drain valve open until you are ready to operate the sprayer again MAINTAIN FIRM METAL TO METAL CONTACT BETWEEN GUN AND CONTAINER Fig 4 NR NN No 3 Adjusting the Spray Pattern a Increase the pressure adjusting knob setting just un
48. oval procedure WARNING Removingthe circuit board while still wired over rides the optical detector which could cause the sprayer to over pressurize if the microswitch does not function properly Tum the sprayer on ONLY long enough to check lamp condition then shut off immediate ly WARNING To reduce the risk of elec tric shock handle board by edges only Do not allow any metal objects to come in contact with the board Plug in and turn on sprayer Clear lamp should be on now removing the circuit board over rides the optical detector Turn off and unplug sprayer Check bourdon tube flag and detector Calibrate pressure control to sea if that position Reinstall circuit board see page corrects problem See page 24 22 Turn pressure setting to maximum flag should extend less than half way into ont Z 2 ponton Dox optical detector slot from the bonom VIEW OF OPTICAL DETECTOR AND FLAG When replacing the bare pressure control box 301 remove the ON OFF switch bridge circuit board and electrica hardware and reinstallin the new bare box Troubleshooting continued an next page 307 671 11 TYPE OF PROBLEM LOW OUTPUT NO OUTPUT Motor runs and pump stroke WHAT TO CHECK If check is OK go to next check Check for worn spray tip Check to see that pump does not con tinue to stroke when gun trigger is released Plug in and turn on sprayer Prime with paint Trigger gun momen ta
49. r Meter should read 190 250 Volts Check extension cord for visible damage Use a volt meter or test lamp at extension cord outlet to check Check pa for visible dar sulation or wires Check motor brush leads terminals and brush length Brush length should be 14 mm minimum See page 28 r power suppi cord 311 such as broken in Thaw the sprayer if water or water based paint has frozen in it due to e ure to low temperatures by placing it in a Do not try to start the sprayer until it has thawed O If the bourdon tube was not damaged by the e pump should operate If paint hardened dried in e pump packings and or bare pressure control or manual 307 793 Relieve pressure refer to your separate gun or tip instruction manual for tip Cleaning Thaw Plug in sprayer and turn on Slowly increase pressure setting to see if motor starts If it doesn t replace the displacement pump packings see manual 307 793 andlor replace the bare NE control box 301 See page Push pin into place and secure with the spring retainer Replace motor 11if fan won t turn Reset building circuit breaker replace buiding fuse Try another electrical outlet Replace extension cord Replace power supply cord See page 18 4 lighten terminal replace brushes See page 2 When replacing the bare pressure control box item 301 remove the ONIOFF switch bridge circuit board and elec trical ha
50. rdware and reinstall these parts in the bare box Troubleshooting continuedon nextpage 307 671 3 TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check Ifcheck is NOT OK refer to this column MOTOR WON7 OPERATE Diagnosing circuit board in dicator lamps The normal condition is red lamp on clear lamp on when board is telling pump to run Follow Pressure Relief Pro cedure Warning Remove gun from hose Remove pressure control cover and check for faulty condition of circuit board lamps Condition A both lamps on pump won t operate and motor is not running Condition B Both lamps off 10 307 671 Check leads from bridge 308 to motor to be sure they are securely fastened and properly mated Check G1 and G2 connections between circuit board 349 and bridge 1308 for damage or loose terminals Check for loose motor brush lead con nections and terminals See page 27 Check brush length which should be 14 mm minimum See page 27 NOTE also that the brushes do not wear at the same rate on both sides of the motor Check for broken or misaligned motor brush springs Rolled portion of spring must pt squarely on top of brush See page 2 Check motor brus hes for binding in brush holders See page 27 Check motor armature commutator for burn spots gouges and axtreme rouohness Remove motor cover and PRZ plates to check See page 2 Check motor arma
51. rily then release and engage safety latch Relieve pressure turn off and unplug sprayer Check electrical supply with volt meter Meter should read 190 250 Volts Check extension cord size and length must be at least 12 gauge wire and no longerthan 15 2 m 150 ft Check G1 and G2 leads from bridge 308 to circuit board 340 for damage or loose wires or connectors Refer to page Check stall pressure Refer to Calibration Procedure on page 24 Check bridge 308 and leads and terminals to motor Inspect wiring in sulation and terminals for signs of overheating See page 20 Check for loose mot rush leads and terminals See page I Check for worn motor brushes which should be 14 mm 8 16 minimum See page 27 10 Check for broken and misaligned motor brush springs Rolled portion of spring must rest squarely on top of brush 11 Check motor brushes for binding in brush holders See page 27 12 Check circuit board 340 by SE with a good circuit board See page 13 Check motor armature for shorts by us ing an armature tester growler or per form spin test See page 15 14 Check bridge 308 by substituting with a good bridge or by performing the bridge test See page 16 or 20 CAUTION Do not perform this check until armature is determined to be good A bad armature will immediately burn out a good bridge Check paint supply Check for clogged intake strainer Check for loose
52. rless contractor See 307 614 for parts 1 78 107 423 SCREW cap button head 1 4 20 x 5 8 2 79 100 028 LOCKWASHER 1 4 2 81 218 242 CRANKSHAFT ASSEMBLY Includes items 81a 81b 1 81a 180 131 BEARING 1 81b 107 434 BEARING 1 86 176 762 NUT hex 1 105 107 447 SEAL conduit see page 34 for location 1 108 178 460 ADAPTER 3 8 nptim x 1 2 nptif 1 110 108 865 SCREW machine pan head 8 32 x 3 8 4 111 108 663 SPACER 2 112 108 709 TORN machine pan head 10 24 x 2 306 amp 307 numbers in descriptionsrefer to separateinstruction manuals Warning labels and tags supplied at no charge HOW TO ORDER REPLACEMENT PARTS 1 To be sure you receive the correct replacementparts kit or accessories always give all of the information requested in the chart below 2 Check the partslist to identify the correct part number do not use the ref no when ordaring 3 Order all parts from your nearest Graco distributor 6 digit PART NUMBER ary PART DESCRIPTION 307 671 33 Ref No 40 PRESSURE CONTROL ASSEMBLY Includes items 301 to 340 303 313 301 218 351 107 437 107 435 218 400 218 386 107 427 311 065 140 100 035 102 932 100 840 157 350 162 453 218 365 218 368 218 369 321 218 370 218 371 218 372 34 307 671 DESCRIPTION BARE PRESSURE CONTROL BOX Includes items 302 to ON OFF SWITCH BOOT ONIOFF switch GUARD locking MICROSWITCH BRIDGE rectifier CHOK
53. rning resistance check the following a broken brush springs b broken brush leads cl loose brush terminal screws dh worn brushes e broken motor leads f loose motor lead terminals Repair parts as needed See page 27 If there is still unang no turning resistance replace the motor See page Fig 10 307 671 15 BRIDGE TEST Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional See Bridge Rectifier Replacement page 20 Use a continuity tester such as multi meter set on the X1 ohms scale N Eight individual checks or tests must be performed If the bridge fails even one test it must be replaced Fig 11 shows the position of the wires on the bridge Us ing the chart atthe right connect the meter wires as in dicated by the black dots for each test then check the continuity In Tests 1 2 and 3 there should be NO continuity In Tests 4 5 and 6 connect the and meter wires as indicated check continuity then switch the meter wire connections and check continuity again You should get NO continuity one way and YES continuity the other way In Tests 7 and 8 connect the meter wires as indicated by the black dots Touch the indicated G wire to one meter wire and then the other You should get NO con tinuity one way and YES continuity the other way 16 307 671 ALINNILNOD BRIDGEWIRES GENERAL REPAIR NOTES
54. t gauge W Place the pump suction tube in a 5 gallon pail of clean water on R 5 Be sure the gun safety latch is engaged 6 Use a 9 mm 3 8 ignition wrench to turn the pressure adjustment nut S counterclockwise about two full turns See Fig 24 With the pressure control knob B at the minimum setting turn the sprayer switch ON THE SPRAYER SHOULD NOT START N If it does start shut the sprayer switch OFF disengagethe gun safety latch trigger the gun into a grounded waste container until pressureis reliev ed Engage the gun safety latch Turn the pressure adjustment nut 3 a littlefurther counterclockwise Turn the sprayer on to be sure it does nor start 8 Slowly turn the pressurecontrol knob B clockwise to the maximum setting and hold it there Use a 9 mm 3 8 ignition wrench to slowly turn the pressure adjustment nut S clockwise until the test gauge reads EXACTLY 192 bar 2750 psi WARNING Followthe Pressure Relief Procedure Warning on page 17 CAUTION To prevent pump corrosion flush the water out of the pump hose and gun with mineral spirits Be sure to close the drain valve first Use the lowest pressure necessary to flush Follow the Pressure Relief Procedure Warning on page 17 Leave the mineral spirits in the pump to protect it until you are ready to spray again 9 Remove the test gauge assembly and reinstall the plug Flush out water with mineral spirits 24 307 67
55. tDUt sssccceeeeeeeeeeeeeeeeees ET Spin Test ees seev deems iGo Wdy Bridge Test ess kkKKRSEEREEEEERRRRKEREREEEREEEEE KEEN REPAIR SECTION General Repair NoteS 111111 List Of TOOIS sssseseeeceeeeseeeenees Power Supply Cord Replacem S p EE E REEE E Filter ReplaceMent ss ssssusnnnnnnnnnnnnnnnnnnnnnnnnnnnnn ON OFF Switch Replacement Microswitch Replacement 1111 21121 2 111 12 19 Bridge Rectifier Replacement 111111211121111112 20 Choke Replacement ssccceeceeeeeeeeeesseeneesneneeees 21 Varistor Replacement sssssssssnunnnunnnnnnnnnnnnnnnnnnnnnn 21 Circuit Board Replacement 22 Pressure Control Replacement asssssssas11222 23 Stall Pressure Calibration ss n eassnoneenananom 24 Connecting Rod Drive Housing or Crankshaft etdatCetment ee ENNEN Zeg 25 26 Motor Brush Replacement 2112122 2111 2 27 Motor Capacitor ReplaceMent sssssssssscseens 28 Motor Replacement s sx1 ssx1 s211 31 30 PARTS LISTS amp DRAWINGS Sprayer see EEEREERRRRRRRR ozna aaa naa nuon KEE RRE F 33 Pressure CONtTOl ssssssssssnnnnnnnnnnnnnnannnannnannnnn 35 How To Order Replacement Parts nn 33 TECHNICAL DATA nasaenaaaeenaaaennaa Back Cover NOTE See manual 307 793 supplied for the displacement pump repair instructions and parts list 307 671 1 WARNING HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS
56. the sprayer Unplug the sprayer and follow the Pressure Relief Procedure on page 2 to prevent itfrom star ting accidentally IMPORTANT United States Governmentsafety standards have been adopted under the Occupational Safety and HealthAct These standards par ticularly the General Standards Part 1910 and the Construction Standards Pan 1926 should be consulted 307 671 3 INTRODUCTION ULTRA 400 BASIC COMPONENTS ELECTRIC MOTOR FLUID FILTER DRIVE ASSEMBLY MAIN FLUID HOSE WET CUP TIP GUARD WHIP HOSE SPRAY GUN Your new Ultra 400 Sprayer functions and operates differentlythan other airless paint sprayers This section will help you become familiar with the sprayer before operating it Pressure Control The pressure control includesan ONIOFF switch for the sprayer the pressure adjusting control knob and a pressure sensing device Its function is to control the motor speed so that the sprayer maintains constant fluid pressure at the pump outlet Motor The DC motor has sealed bearings and replaceable motor brushes Its function is to drive the displacement pump at the rate needed to supply sufficient paint volume at the selected pressure Working together the pressure control and motor cause the pump to cycle whenever there is fluid or pressuredemand When the pump is cycling the motor sounds like an automobile starter cranking When the pump is not cycling the motor may hum intermittently
57. til spray from the gun is completely atomized To avoid excessive overspray and Fone the Sprayer with Paint fogging and to decrease tip wear and extend Close the filter drain valve the life of the sprayer always use the lowest possible pressure needed to get the desired b Don t install the spray tip yet results c Put the suction tube into the paint container b If more coverage is needed use a larger tip rather than increasing the pressure d Turn the pressure adjusting knob all the way counterclockwise to the lowest pressure set c Test the spray pattern To adjust the direction ting of the spray pattern engage the gun safety and loosen the retaining nut Position the tip guard e Disengagethe gun safety latch horizontallyfor a horizontal pattern or vertically for a vertical pattern Then tighten the retaining f Hold a metal part of the gun firmly against and nut aimed into a metal waste container See Fig 4 Squeeze the trigger and hold it open turn the ON OFF switch to ON and slowly increase the pressure setting until the sprayer starts Keep the gun triggered until all air isforced out of the system and the paint flows freely from the gun Release the trigger and engage the safety NOTE Ifthe pump is hard to prime place a con tainer under the drain valve and open the drain valve When fluid comes from the valve close it Then disengage the gun safety and proceed as in Step 1f above g Check all fluid con
58. ture for shorts using armature tester growler or perform spin test See page 15 Check bridge 308 by substituting with a good bridge or performing bridge test See page 16 CAUTION Do not perform this check until armature is determined to be good A bad armature will immediately burn out a good bridge Check electrical supply Connect voltmeter to electrical outlet Meter should read 190 250 Volts Check power supply to circuit board with sprayer turned ON Measure voltage at TP and TP2 Meter should read 190 250 Volts See page 22 Check all terminals and wires fo damage or loose fit Check motor thermal cutout switch Unplug sprayer Allow motor to cool Disconnect motor thermal switch leads at TP9 to TP10 Use ohmmeter to check continuity Switch should be closed when motor is cool Replace any loose terminals and crimp to leads Be sure male terminal blades are straight and firmly connected to mating part Clean circuit board male terminals Replace loose or damaged terminals Securely reconnect leads Tighten terminal screws Replace brushes if leads are damaged See page 27 Replace brushes See page 27 Replace spring if ey Realign spring with brush See page Z Clean brush holders Remove carbon with small cleaning brush Align brush lead with slot in brush holder to assure free vertical brush movement Remove motor and have motor shop resurface
59. urgeon or reconstructive handsurgeon may be advisable exe 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 Failureto set the safety latch can result in accidental triggering of the gun Diffuser The gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed Check diffuser operation regularly Follow the Pressure Relief Procedure below then remove the spray tip Aim the gun into a metal pail holding the gun firmly to the pail Using the lowest possible pressure trigger the gun Ifthe fluid emitted is not diffused in to an irregular stream replace the diffuser immediately Tip Guard ALWAYS have the tip guard in place on the spray gun while spraying The tip guard alerts you to the fluid injection hazard and helps reduce but does not prevent the risk of accidental ly placing your fingers or any part of your body close to the spray tip Spray Tip Safety Use extreme caution when cleaning or changing spray tips If the spray tip clogs while spraying engage the gun safety latch immediately ALWAYS follow the Pressure Relief Pro cedure and then remove the spray tip to cl
60. ut side of the bridge will cause the bridge to burn out immediate ly Correctly diagnose anc repair all shorts before check ing and replacing bridge Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NO turned on 14 307 671 WHAT TO CHECK If check s OK go to next check Check all electrical wiring for damaged insulation and all terminals for loose fit or damage Be sure to check wires bet ween pressure control and motor which 38 encased in conduit I See page Check for missing inspection plate gasket see page 27 bent terminal forks or other metal to metal contact points which could cause a short Check motor armature for shorts by us ing an armature tester growler or per form spin test See page 15 Inspect windings for bums Check bridge 308 by substituting with a good bridge or by performing bridge test See page 16 CAUTION Do not perform this check until armature is determined to be good A bad armature will immediately burn out a good bridge Check Basic Electrical Probleme on page 9 Check ON OFF switch 302 See page 19 Be sure the sprayer is unplugged Disconnectwires from switch and check switch with ohm meter The ohm meter should read infinity with the ONIOFF switch OFF and zero with the switch ON CAUTION A short in the motor circuit will burn the bridge out immediately which in turn usually causes the ONIOFF switch to fail

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