Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc parts. INDEX WARNINGS .................................................. 2 . 3 INTRODUCTION................................................ 4 SETUP............................................................. 5 OPERATION; ................................................. 6. 7 SHUTDOWN 8 CARE......................................... 7 FLUSHING GUIDELINES ..................................... 8 TROUBLESHOOTING GUIDE Motor Won't Operate ................................... 9-11 Low output .................................................. 12 No Output............................................... 12. 13 Excessive Pressure Fluctuations ......................... 13 Motor Is Hot and Runs Intermittently ..................13 Electrical Short ...................................... : .......14 Spin Test ..................................................... 15 Bridge Test ................................................... 16 REPAIR SECTION General Repair Notes ...................................... 17 List of Tools .................................................. 17 Power Supply Cord Replacement ....................... 18 Filter Replacement ......................................... 18 ON/OFF Switch Replacement ........................... 19 Microswitch Replacement ................................ 19 Bridge Rectifier Replacement ............................ 20 Choke Replacement ........................................ 21 Varistor Replacement ...................................... 21 Circuit Board Replacement ............................... 22 Pressure Control Replacement .......................... 23 Stall Pressure Calibration ................................. 24 Connecting Rod. Drive Housing or Crankshaft Replacement............................................ 25. 26 Motor Brush Replacement ................................ 27 Motor Capacitor Replacement ........................... 28 Motor Replacement ................................... 29. 30 PARTS LISTS 8 DRAWINGS Sprayer .................................................. 32.33 Pressure Control ....................................... 34. 35 How To Order Replacement Parts ...................... 33 TECHNICAL DATA ............................... Back Cover NOTE: See manual 307.793. supplied. for the displacement pump repair instructions and parts list . 307-671 1 HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals, tags, and warnings before operating equipment. FLUID INJECTION HAZARD General Safety This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through 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 penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Note to 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 toxiciry. Toxicity 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 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. If the 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...