Page 2 - INDEX; No
INDEX WARNINGS .................................................. . SETUP ............................................................. 5 INTRODUCTION ................................................ OPERATION; ................................................. 6. SHUTDOWN CARE .........................
Page 3 - HIGH; PRESSURE SPRAY C A N CAUSE EXTREMELY SERIOUS INJURY.; FOR; USE; Read; and; understand; instruction; before; operating; FLUID INJECTION; with; soon; to; Devices; all; Latch; Tip; Procedure
HIGH PRESSURE SPRAY C A N 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 G e n e r a l S a f e t y This equipment generates very high fluid pressure. S...
Page 4 - EQUIPMENT MISUSE HAZARD; so; HOSE SAFETY; DO; Grounding; OR EXPLOSION HAZARD; If; M O V I N G PARTS HAZARD
EQUIPMENT MISUSE HAZARD G e n e r a l S a f e t y Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using or damaged parts, can cause them to rupture and result in fluid injection or other serious bodily injury, f...
Page 5 - ONlOFF; at; a t; cause; off; off; Hoses; it
Your new Ultra" Sprayer functions and operates differently than other airless paint sprayers. This section will help you become familiar with the sprayer before operating it. Pressure Control The pressure control includes an ONlOFF switch for the sprayer, the pressure adjusting control knob, and...
Page 6 - SETUP; Hose; is; WARNING; FIRE; OR; HAZARD; bag
SETUP 1. Connect Hose and Gun (Refer to Fig NOTE: When tightening fittings at the pressure con- trol, hold one wrench firmly on the 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...
Page 7 - OPERATION; as; Fig
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 whenever you shut off the sprayer, when or electric shock, always follow this procedure when installin...
Page 8 - the tip is; of
4. Cleaning a Clogged T i p W A R N I N G To avoid a fluid injection injury, 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 ground or into a waste container when checking to see if the I S clear. DO NOT try to "...
Page 9 - FLUSHING; GUIDELINES; left; ON; are
FLUSHING GUIDELINES When t o Flush 1. N e w Sprayer. Your new Sprayer was factory tested in lightweight which was 5. Storage. left in to protect pump parts. spirits and leave the pump, hose and gun filled with Water-base paint: flush with water, then mineral Before using water-base paint, flush with...
Page 10 - ing; go; See; see
TROUBLESHOOTING GUIDE WARNING To reduce the risk of serious Pressure Relief Procedure 6 . Engage the gun safety latch. fluid injection, splashing fluid in eyes 7. Ooen the drain valve. havina a container readv or on the skin, or injury from moving parts or elec- to catch the drainage. tric shock, al...
Page 11 - OF; W O N 7; on; telling; OK; RFI
TYPE OF PROBLEM MOTOR W O N 7 OPERATE Diagnosing circuit board in- dicator lamps. The normal condition is red lamp on, clear lamp on when board is telling pump to run. cedure Warning. Remove Follow Pressure Relief gun from hose. Remove pressure control cover and check for faulty condition of circuit...
Page 12 - TO CHECK; DETECTOR; BOARD; the; WHAT TO; OK refer; continued on next
YPE OF PROBLEM Condition (continued) Condition C R e d lamp on, clear lamp off Unplug TO CHECK f check is OK, go to next check i. Check microswitch With no fluid pressure in the pressure control discon- nect wires and Check con- tinuity across switch terminals with an ohmmeter. Switch contact should...
Page 13 - WHAT; slot
TYPE OF PROBLEM LOW OUTPUT NO OUTPUT Motor runs and pump stroke: WHAT TO CHECK If check is OK. g o t o next check 1. Check for worn spray tip. 2. Check t o 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- tari...
Page 14 - OPTICAL; LOW; ed
TYPE OF PROBLEM NO OUTPUT (Continued) Motor runs but pump does not stroke EXCESSIVE PRESSURE FLUCTUATIONS Spray variations. MOTOR IS HOT RUNS WHAT TO CHECK If check is OK, go t o next check , Check to see if intake valve ball and piston ball are seating properly. See manual . Check for leaking aroun...
Page 15 - ELECTRICAL S H O R T; TO; NOT; umn
TYPE OF PROBLEM ELECTRICAL S H O R T Buildino circuit breaker as as sprayer switch is turned on. CAUTION Any short in any part of motor power circuit, which connected t o the output of the bridge, will cause bridge to burn out immediate Correctly diagnose ing and replacing bridge repair all shorts b...
Page 16 - SPIN; TEST; Relief; two; there are; no; loose
SPIN TEST WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing fluids Relief Procedure Warning o n page 17 to reduce in the eyes or on the skin, injury from moving Darts. or electric shock. For checking armature, motor winding and brush elec- trica...
Page 17 - NO
BRIDGE TEST Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional. continuity tester, such as multi-meter set on the X1 See Bridge Rectifier Replacement, page Use a ohms scale n the bridge fails even one test, it must be replaced. Eight indivi...
Page 18 - Tool; List
GENERAL REPAIR NOTES 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 ...
Page 19 - Use
POWER SUPPLY CORD REPLACEMENT (See Fig 12 131 WARNING 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. Use the 19 mm open end wrench to remove the nut from the fi...
Page 20 - REPLACEMENT; STALL
SWITCH REPLACEMENT (See Figs 14 WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 t o 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 pressure control cover and screw...
Page 21 - CAUTION; FRONT; DETAIL
BRIDGE RECTIFIER REPLACEMENT (See Fig 161 WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 t o reduce eyes or on the skin, injury from moving parts or electric shock. 1 1. Remove the pressure control c...
Page 22 - CHOKE REPLACEMENT; VARISTOR; W A R N I N G; eyes
CHOKE REPLACEMENT (See Fig 1. Remove the pressure control cover and screws. 2. Remove the grounding screw and remove the lead. Loosen the appropriate screw on the terminal lead. strip (336) and the choke 3. Use the M8 wrench to remove the upper nut and lockwasher on the outside of the pressure contr...
Page 23 - Also; ALL; bottom; PLUQ
CIRCUIT BOARD REPLACEMENT (See Figs 20 WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts, or electric shock. sure to rhe BOARD PRESSURE CONTROL Re...
Page 25 - new; minimum; does; into; does nor; Slowly; mm; nut; until; prevent pump corrosion,; tools
STALL P R E S S U R E C A L I B R A T I O N I I USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from splashing, component rupture, electric shock, fire, explosion, or moving parts. This proc...
Page 27 - ple; io
19. Install the connecting rod 20. Screw the displacement pump about 3/4 of the way into the bearing housing Hold the pin up to the pin hole in the connecting rod assembly and continue screwing in the pump until the pin slides easily into the hole. Back off the pump until the top threads of the pump...
Page 28 - MOTOR; BRUSH; Be sure to unplug the; Loosen
MOTOR BRUSH REPLACEMENT (See Figs 27 New motor brushes are included with each Reinstall brush Packing Repair Kit. Replace them when screws. Reinstall the motor shield and screws. replacing the packings, and/or when they the longest side. have been worn t o a minimum of 9 / 1 6 on Before doing this p...
Page 29 - tap; pull; tabs
M O T O R CAPACITOR REPLACEMENT (See Figs 29 WARNING the of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts or 1. Remove the control box cover Disconnect the motor leads. 2. Remove the fan cover and screws from th...
Page 30 - Be; unplug the; one
MOTOR REPLACEMENT (See Fig 31 W A R N I N G Before doing this procedure, follow the Pressure 6. Loosen the connector nut at the motor and pull the conduit away from the motor, then pull the Relief Procedure Warning on page reduce the risk of a fluid injection injury, in the leads through the conduit...
Page 31 - sure
Use a plastic mallet t o gently tap the displacement pump from the rear to loosen the drive housing ing away from the front end bell. ( 6 ) from the front end bell. Then pull the drive CAUTION DO NOT allow the gear cluster to fall when removing the drive housing It is damag- ed if dropped. The clust...
Page 33 - Model; Series; Includes items
PARTS DRAWING Model Ultra" Series D Includes items 1-112 11
Page 34 - REF; HOW; TO ORDER REPLACEMENT PARTS; PART; PART
Includes items 1-112 REF PART NO. NO. 1 2 4 3 5 6 7 8 9 11 13 14 19 22 21 23 24 26 27 34 35 41 42 43 44 45 48 50 51 52 53 107-267 107-264 105-510 107-209 220-647 162-453 218-361 107-212 218-353 101-242 104-81 1 218-326 179-936 1 155-665 DESCRIPTION SHIELD, motor MOTOR, electric: 112 HP 1 5, one of i...
Page 35 - Ref; PRESSURE; PARTS; LIST; QTY; Warning labels and tags supplied at no charge.; Order Replacement
Ref No. Includes i t e m s to PRESSURE C O N T R O L A S S E M B L Y 313 PARTS LIST REF PART NO. NO. 301 302 107-255 310 311 312 DESCRIPTION BARE PRESSURE CONTROL BOX Includes items to SWITCH .BOOT, ONIOFF switch .GUARD, locking BRIDGE, rectifier, SCR CHOKE . ... , power supply; no plug SCREW, slott...
Page 36 - OLD; DISCONTINUED MODEL
WIRING DIAGRAM TO TWO TERMINALS ON THE OTHER THESE WIRES ARE CONNECTED SIDE OF THE ONlOFF SWITCH SERVICE INFORMATION Listed below by the assembly changed are OLD and NEW parts. NOTE: This manual now includes complete service procedures. The parts list has new reference numbers. ASSEMBLY P A R T REF ...
Page 37 - TECHNICAL; DATA; Box; PTFE; PTFE; PTFE; PTFE; PTFE
TECHNICAL DATA Power Requirements : VAC, 50 Hz, 1 Phase, 3.7 AMP minimum (gallon) : 124 Operating Range : 0-192 bar psi) Power Cord : 2.5 0 (13 3 wire, 6 m (20 long Inlet Paint Strainer : 16 mesh, 1190 micron, Outlet Paint Filter : 60 mesh, 250 micron, Stainless Steel Screen, reusable Stainless Stee...
