Sherwin-Williams ULTIMATE NOVA 1000 Owner's Manual

SUPERSEDES Rw.A Thii manual contains important Warnings and Insuuctions. Read the rnanua! and keep it for rsference. 1 HP, Portable, Electric . . LTIMATE AIRLESS PAINT SPRAYER Model W, Series A Less hdse,.gun. and filter SzW psi (210 bad MAXIMUM WORKING PRESSURE Index .Warnings... ......................... .2 Avertissarnent ....................... 4 Advertencih ......................... .6 Set UptOperation .................. 8 Rushing ............................. 10 Tmubleshooting .................. 11 Repair index ....................... .lS -How To Order Replacement Parts Lists 8 Drawings 32 Shutdown and Care.; ............. 9 .......... Parts ................................ .37 Technical Data ......... Back Cover PATENT NO. 4,323,741 PATENTED 1984,Canada Brevete 1985 _.*. i .I ,, . :, .... . . . . ,:. .A - .. Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc parts.

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 can cause'serious damage. NEVER poim the spray gun at anyone or at any paq 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. nerd Safe ALWAYS have the tip guard in place.on the spray gun when spraying. before cleaning or removing the spray tip or servicing any ALWAYS follow the Pressure Relief Procedure, below, system equipment. N N E R try to stop or deflect leaks with your hand or body. before each use. Be sure aquipment safety devices are operating properly ?! T B edi I rmtmetnt any UI amears to Denetrate vour skin. aet B sJe JI gun s%*E2Zare operating prop& before each use. Do not remove or modifv anv Dan of the wn: this ra G n 8af can cause a malfunction and result'in &Nous bodilykju.ry. Safety Latch the gun safety latch in the closed or "safe" position. making 'Whenever you stop spraying, even for a moment, always set the gun inoperative. Failure to set the safety latch can result in accidental triggering of the gun. Diffuser' T e gun diffuser breaks up spray and reduces the risk of injec- hon 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, pmsure. trigger the gun. If the fluid emitted is not diffused in- holding the gun firmly to the pail. Using the lowest possible to an irregular stream, replace the diffuser immediately. nip Guard. ALWAYS have the tip guard in place~on the spray gun while spraying. The tip guard alerts you to the injection hazard and helps prevent accidentally placing your fingers or any pan of your body dose to the spray tip. a Ti Safe81 e&& cautio 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 clean it. NEVER wipe off build-up around the spray tip until pressure is fully relieved and the gun sa+ty latch is engaged. e thegun safetylatch. (51 Hold prensura. (61 Engage the gun If YOU suspect that the spray tip or hose is completely dogged, or that pressure has not been 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. N o w dear the tip or hose. pi ENGAGE SAFETY TURN SWITCH TO OFF UMPLUG CORD DISENGAGE SAFEW AND TRIGGER GUN; ENGAGE SAFEW A G A I ~ ~ OPEN DRAIN VALVE . .

as overpressurizing, modifying parts, using incompatible . . , chemicals end fluids, or using worn or damaged parts, can cause them to rupture and result in injection or other serious . . bodily injury, fire. explosion or property damage. could cause it to malfunction. NEVER alter or modify any part of this equipment; doing so worn or damaged parts immediately. CHECK all spray equipment regularly and repair or replace Read and follow the fluid and solvent manufacturer's literature regarding the use of protective clothing and equipment. $WEm h@SSMU@ Thb sprayer can develop 3aW psi (210 b8rJ MAXJMUM accessories are rated to withstand the maximum working WORKING PR€SSURE Be sure that all spray equipment and pressure of this sprayer. DO NOT exceed the maximum work- system. ing pressure of any component or accessory used in the Wuid 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 usina them in this spraver. h Static electricity is created by the high velocity flow of fluid through the pump and hose. If every part of the spray equip- ment is not properly grounded, sparking m y occur, and the when plugging in or unplugging a power supply cord. Sparks system may become hazardous. Sparking may also occur dust panicles and other flammable wbstances;whether you can ignite fumes from solvents end the fluid being sprayed, are spraying indoors or outdoors, and.can cause a fire or ex- plosion and serious bodily injury and property damage. Always plug the sprayer inM an outlet at leest 20 feet I6 ml away from the sprayer and the spray area. Do not plug in or unplug any power supply cords in the spray area when there is any chance of igniting fumes still in the air. while using this equipment, STOP SPRAYING IMMEDI- If you experience any static sparking or even a slight shock ATELY. Check the entire system for positive grounding. Do not us8 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 spmy equipment used or located in the spray area. CHECK your local electrical d e for detailed grounding in- structiom 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 equipped with an undamaged three-orona ulug. into - . . tension cords must have three wires and be rated for 15 a properly grounded outlet. Do not use an adapter. ex- amps. High Pressure fluid in the hoses can be very d~KIerous. If the 2, F/ujdhoses: use only grounded hoses with a maximum of hose develops a leak, split or rupture due to any kind of wear. damage or misuse, the high pressure spray emitted from it tan 5M) feet I 1 5 0 ml combined hose length to ensure ground- causa an iniection iniurv or other serious bodilv iniurv or nrc- ing continuity. Refer to Hose Grounding Contlnulty. perty dam& . ,~~~ 3. Sorev nun: obtain oroundino throuah connection to a ALL FLUID HOSES MUST HAVE SPRING GUARDS1 The pioper6 grounded fhid he-and spkyer. spring guards help protect the hose from kinks or bends at or 4. obieecr being sprayed: according to local code. close to the coupling which can result in hose rupture. TIGHTEN 811 fluid connections murely before each use, High 5. A// so1V&7r Pat7s when flushing, according to local pressure fluid can dislodge a loose coupling or allow high code. Use only metalpails, which are conductive. Do not pressure spray to be emitted from the coupling. place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity. NEVER use a damaged hose. Before each use. check the en- tire hose for cuts, leaks, abrasion, bulging cover, or damage or & To m8intah groundins COntinuiV When flushing O r d k V - exist, replace the hose immediately. DO NOT try to recouple movement of the hose.couplings. If any of these conditions ingpressure, always hold a metal part of the gun firmly to the side of a grounded metal pail, then trigger the gun. high pressure hose or mend it with tape or any other device. A ~ ~ M s & p s,fey repaired hose cannot contain the high pressure fluid. HANDLE AND ROUTE HOSES CAREFULLY . D ~ not pull o~ . by fo!owing .the specific flushing procedure given on page 10 Reduce the risk of injection injury, static sparking, or splashing hasas to equipment. Do not use fluids o; which of this manual. Follow the Pressure Rellef Procedure on are not compatible with the inner tube and cover of the hose. '' and the 'pray tip before flu*in6" Hold a metal (82°C) or below - 4 O O F I4!'C). DO NOT expose G~~~ hose temperinures above 1m-F pa* of the gun firmly to the side of a m-1 pail and use the lowest possible fluid pressure during flustiing. Hose G ~ ~ n d i n g Continuity ~~~~~~ PARTS HAZARD Proper hose grounding continuity is essential to maintaining a air and fluid hoses at least once a week. If your hose does not ~ . body parts. KEEP CLEAR of moving parts when starting or groundedspraysystem. Checktheelectrical resistanceof your Moving pans can pincii or amputate. your fingers or other have a tag on it which specifies the maximum electrical operating the sprayer. Unplug the sprayer, and follow .the mau'rnum resistance limits. Use a resistance meter in the ap- ting accidentally. resiaence, contact the hose supplier or manufacturer for the Pressure Relief Procedure on page 2 to prevent it from star- propriate range for your hose to check the resistance. I f the resistance exceeds the recommended limits, replace it im- mediately. An ungrounded or poorly grounded hose can make your system hazardous; Also read FIRE OR EXPLOSION HAZARD. . . . . . . I ... ..i ., . . . ..: IMPORTANT ticutariy the General Standards, Part 1910, and the Construction Standards, Part 1926-should be consulted. United States Government safety standards have been adopted under the Occupational Safety and Health Act. Thee standards-par.

pulv4risti par le pistoiet ou ie fluide sous pression pmvenant de Cet appareii produit un fluida B trh haute pression. LB fluide fuiies ou de ruptures peut p B n h r sous ia peau ou B I'intBrieur du corps et entraher des blessures tds graves, voir mBme une sant ou entrant dans. les yaux paut aussi entrainer des amputation. MCma sans W e sous pression. ie fluide Bclabous- blessures graves. NE JAMAIS pointer ie pistoiet vars quelqu'un ou vers une par- tie quelconque du corps. NE JAMAIS menre ia main ou les doigts sur I'ajutage du pulvdrisateur. NE JAMAIS essayar de meumatique. "refouiar" ia peinture. Cet appareil Nest PAS un compresseur TOUJOURS garder la protection da I'ajutage en piace sur le pistolat pendant la puivbrisation. TOUJOURS observer la March B Suivre pour DBtendre la Pression donnba plus loin. .avant de nettoyer ou d'aniaver que sur una partie de I'appareil. I'ajutage du puivdrisataur, ou d'effactuer un travail quaicon- NE JAMAIS essayer d'arrCtar ou de dbvier les fuites avec la main ou ie corps. Avant chaque utilisation, bian s'assurer que ies dispositifs de sBcuritB fonctionnent correctement. Boins ~ m B d i c ~ X En cas de pbnbtratlon de fluide sous la peau: DEMANDER IMMEDIATEMAENIT DES SQIMS MEDICAUX D'URQERICE. Dire axacternent au medecin qual type ae iiquida a Bt6 inject& UME SIMPLE CQUPURE. Dispositifs de sbcurit6 du pistolet de &curit6 du pistoiet fonctionnent corractament: Ne pas Avant chaque utiiisation, bien s'assure que tous ies dispositifs enlevar ni modifier une partia quelconque du pistoiet: ceci ris- querait d'antrainer un mauvais fonctionnement et des blessures graves: NE PAS memm c m ~ BLESSURE COW" A chaque fois que I'on s'arr6ta de puhrdriser, mCme s'il s'agit Verrou de sdcuritd d'un court instant, toujours mettre le verrou de skuritb du empschar ie pistolat de fonctionnar. Si la varrou de SeCuritB pistolet sur la position "fermbe" ou "sBcurit6" l"safe"1 pour n'est pas rnis, le pistolat peut se dkiencher accidanteiiement. Diffuser Le diffusaur du pistolet seti B diviser le jet et B r&uire les ris- ques d'injection accidantelle quand I'ajutage n'est pas en place. VBrifier le fonctionnament du diffuseur r6guiihramant. Marche B Suivre pour DBtendre la Pression donn6e plus Pour cette vBrification, dhtendre la pression an observant ia +ns un seau en m h i , en le maintenant fermement wntre le loin puis enlever I'ajutage du pulvBrisateur. Pointer ie pistolet seau. Puis, en utiiisant ia pression la plus faible possible, ap- puyer sur la gachette du pistolet. Si le fluida projet4 n'estpas diffuse sous forme de jet irrdguiier. remplacer immediatement le diffusaur. TOUJOURS maintenir la protection de I'ajutage an place sur le Rotection de I'ajutage pistolet du pulvbrisateur pendant la puldrisation. La protec- tion de I'ajutage attire I'attention sur ias risques d'injection et contribue B Bviter que las doigts ou une partie quelconque du I'ajutage du pulv6risateur. corps ne passe accidenteilement B proKimit6 immediate de @Mk6PISs'WN bmsiqnes de a6curit6 concwnmt 1'@,4tagB du Faire extr&nemant attention B I'occasion du nettoyage ou du rempiacement des ajutages du pulv6risateur: Si I'ajutage se verrou de sBcurit6 du pistolat. TOUJOURS bian Observer la bouche pendant ia pulv6risation. mettre imrn4diaternant ie Marche B Suivre pour DBtendre la Pression puis enlever I'ajutage du pulvdrisateur pour ie nettoyer. NE JAMAIS assuyer ce qui s'est accumulh autour de I'ajutage ju pulvbrisateur avant que la pression ne soit completement tombee et qua le vermu de &curite du pistolat ne soit engag6. ies blessures-par injection de fluide ou cell@ causeeS par d'kla boussant ou par 6lectrocytion, toujoun bien observer cena marche B suNre B cha- emplacement des ajutages et d'una manihre gBnBrale B chaque an&. 11 la vdrification ou de la r6paration d'une pika de I'appareil de puivbrisa- nterrupteur Marche-Arrit sur ARRET ("OFF"). 31 DBbrancher le cordon pistolet. 51 En maintenant une partie metalliqua du pistolet fermement ap- r le gachette du pistoiet pour iibBrer la pression. 6) Engager le verrou de ur soit de nouveau pr8t B &re utilis6. prenant Soin d'avoir un recipient prdt B r6cup6rer ie liquide. 81 Laisser la Sil'onsoupconneque menr Jib&e apr& emir I'ajutage ou ie raccord d 3 4.5.6 7

UUULUSAUOON DU MAUERjEk Cmsignes g6n6uales $0 sQcuritpB Toute utiiisation,anormale de I'appareil de pulvBrisation ou des Puessi n aaessoires domrne, per example, ia mise sous une pression Ce pulvfrisateur peut produire une PRESSION MAXIMUM DE excessive. Ies modifications de pieces, I'utilisation de produits Bl6ments du Pulv6risateUr et ses accessoires sont concus pour TRAVAIL 210 bar f3cX7V Ib/po.2). Sassurer que tous les chimiqum et de matieres incompatibles et I'utilisation de rbister B la pression maximum de travail de ce pulvbrisateur. pi& udes ou abim6es peut causer des dBg8ts B I'appareil ou des ruptures de p i k et entrainer une injection de liquide ou NE PAS d6passer la pression maximum de travail d'aucun dss 46ments ou accewires utili& avec cet appareil. d'autres blessures drieuses, un incendie, une explosion ou bm slet c A i ~ n i ~~ 88 cou d'autrm d6gAts. BlEN !'A&URER que Tous fes corpf des solvants utilishs NE JAMAIS alt6rer ou mod#ier une piece de cet appareil; ceci sont chimiquement compatibles avec les Parties mouillbas in- risquerait d'enuainer son mauvais fonctionnement. diqubes dans ies "Donn6es techniques", au dos de la couver- VERIFIER r6gulihrement tout I'appareil de pulv6risation et ses du fabricant des fluides a utilisb avant de Sfen servir ture. Toujours lire soigneusement 18s documents et brochures 6quipements et r6parer ou remplacer immddiatement Ies dans ~ pulvBrisateur, , p i h s us& ou abim6es. MEWRES DE SEWROUE CONCERNANU LE$ TUYAUX FBEXIBLES Le fluide B haute pression circulant dans les tuyaux peut &re par tout autre m'oyen. trk dmgereux. En cas de fuite sur le tuyau, mame minuscule, de fissure, dbchirure ou rupture B la suite de I'usure, de d6gats MANIPULER LES TUYAUX ET fluide sous pression. ou d'une rnauvaise utilisation, les projections de fluide haute . CHOISIR solGNEUsEMENT LEUR Ne pas d6placer PreFSion qui en proviennent pauvent entrainer des bl-ur- le fluide en rent sur le Ne ws utiliser de fluides ou de graves par pendtratbn sous la pew ou par contactt. ainSi que qui ne pas compatibles aYBC I~enVeloppe~in. des d 6 g h mat6riels. TOUS LES TUYAUX FLEXIBLES 'DOIWENT AVOlR DES des tempdratures suphrieures B 82°C (169°F) ou infbrieures B ! tBrieure ou endrieure du tuyau. NE PAS expcser le tuyau B RESSORTS SPIRALE DE PROTECTIONI Les spirales de 4 ' C (4°F). boucles ou de nosuds sur 18s tuyaux qui pourraient entrainer la ' Une benne cont,nu# Je la JTa wrre & tuyeux protection contniuent B biter la formation de pliures, de Gonainuiite dQ,la, ,a,ter dss vu 8ux SERRER FERMEMENT tous Ies racmrds avant chaque utilisz- vaporisation. VBrifiez ia rkistance 6iectrique de vos Waux h rupture du tuyau B I'endroit du raccord ou B son voisinag6. essentielle pour maintenir la mise B la terre de I'ensamble de tion. Le fluide sous pression peut faire sauter un raccord desserr6 ou produire un jet B haute pression s'6chappant par le fluides et B air, a.u moins une fois par semaine. Si votre tuyau raccord. que maximum, prenez contact avec le foumimur de tuyaux ne comporte pes d'etiquene qui prBcise ia rbistance Blectri- NE JAMA~S utiliser un tuvau endommagb. Avant c h a w Utiliser un metre de r6sistence de la gamme appropride pour ou la fabricant pour avoir l e s limites de Aistance maximum. coupur-. fuitm. abrasions. boursouflur= de renveloppd ou limiteS recornmand6es, remplacez le tuyau immwiaternent. utiliiation, verifier entihrement chaque tuyau pour deceler les ~ t r e tuyau et v6rifiaz dshnce, si ceile-G dBpasse ies route a m dBt6rioration ou jeu des raccords. Si I'on constate Un tuyau s a n ~ Fisc a terre ou avec une la twre incor. rune de cas detBriorations, iJ faut remplacer le tuvau im- reae peut dm ~sques pour VOtre systeme. ,jsez mbdiatement. NE PAS essayer de refaire le raccord d'un tuyau LES RISQUES D,INCENDIE ou DzmPLOSION ci-dwus, haute pression ni de rbparer le tuyau avec du Nban adhbif ou RISQUES ~ 1 ~ ~ ~ ~ ~ ~ OU WEXPLO$lON De I'6lectricitB statique est produite par le passage du f1uide.B grande vitesse dans la pompe et dans ies tuyaux. Si toutes Ies 2. Tuyaux flexibles: Afin d'assurer la continuit6 de la mise B la pikes de I'appamil de pulv6risation ne sont pas convenable term, n'utiliser que des tuyaux comportant une mise B la terre et avant une longueur maximum cornbin& de 1% m ment reli6es B la masse ou a la terre, des Mrncelles peuvent se produire et I'appareil risque &&re dangereux. Des hinceiles tinuit6 du circuit de mlse B la terre des tuyaux". (1500 pieds). Se reporter 6galement au paragraphs "Con- Peuvent balement se Produire i I'occasion du branchemem 3. mstolet: ~ ~ ~ l i ~ ~ la & la terre en le raccordant un sont suffisantes pour allumer les vapeun de wlvants et le ou du dbbranchemant du cordon d'alimentation. Les Btincelies tuvau fle~ble et +, un pulv6risateur deja convena~ment reli& fluide pulvdris6, les fines particules de poussihre ainsi que B ia terre. d'autres substances inflammables, quend on pulv6rise B I'in- t6rieur ou B I'extBrieur. et elles oeuvent causer un incendie ou 4. Objets, mat.4rid ou surfaces recevant la puldrisation: observer le code ou les dalementations locales. . . . . . . . . .. . . . . . ~. une explosion. ainsi que des blessures g r a ~ k et des db@ts trouvant B au moins 6 m ( 2 0 piedsl de I'appareil et de I'endroit matbriels. Toujoun brencher le pulvdrisateur dans une prise se oh se fait la pulv6risation. Ne pas brancher ou d6brancher un cordon d'alimentation quei qu'il soit dans la zone oh se fait la pulv6risation quand il y a le molndre risque que des vapeurs encore prbsentes dans I'air prennent feu. ressentez la moindre dbcharge, ARRETR IMMEDIATEMENT S'il se produit des 6tincelles d'6lectricitB statique, ou si vous LA PULVERISATION. VBrifiez aue le s W h e entier est bien mis B la terre. Ne vous servez pai du syaihe avant que le pro- bldme soit identifie et corrigd. f i W h la tWPe QU & la lllaS88 Pour r6duire ies rkques de production d'Btincelles d'BlectricitB statique, le pulvbrisateur eitous les 6quipements utilids ou se tmuvent dans la zone de pulvbrisation doivent &re relis B la term ou B la masse. Pour connaitre le detail des instructions de mise B la terre dans la rdgion et le type particulier d'Bquipe ment, CONSULTER le code ou les rdglementations Blectriques tion suivants sont bien rell6s B la terre: locales. S'ASSURER que tous Ies 6quipements de pulvbrisa- rallonge qui doivent &re BquipBs d'une prise B 3 fiches en bon 1. Pulvdrisateur: Brancher le cordon d'alimentation ou la &at, .dam une prise de murant convenablement mise B la terre. Ne pas utiliser d'adaptateur. Toutes les rallonges doivent avoir 3 fils et &re pr6vues pour 15 amp8res. 5. Tousles saaux de solvants utilis& pour le rincage: observer mdtalliques conducteurs de I'Blectricite. Ne pas mettre le seau le code ou ies rbglemenmtions locales. N'uMser que des seaux sur une surface non conductrice comme.sur du papier ou du carton car cela interrompreit ia continuit6 le le mise la terre. 6. Pour conserver la continuit.4 de la mise B la terre quand on rince le mat6riaI ou quand on lib* la pression, toujours contre le cbt4 d'un seau en m.4td puis appuyer sur la d6tente maintenir une partle metaliique du pistoiet fermement appuy6e du pisfolet. ou d'autres parties du corps. SE TENlR A L'ECART des pieces Les pieces en mouvement peuvent pincer ou couper 1 8 5 doi en mouvament pendant la mise en route et la marche du pulv6risateur. Pour Bviter un d6marrage accidentel, ,debran- cher le pulvBrisateur et IibBrer la pression avant d'effectuer des MPORTAWT arations. &B adoptBes en vertu de la Loi sur la SBcurit6 et la Sam6 au Lees nomes de s6curitB du Gouvernement des Ems-Unis ont Travail. Ces normes et, particulidrement, ia Section 1910 des Normes GBn6rales ainsi que la Section 1926 des Normes de la Construction, doivent atre consult&. Rnswm DUS AUX PECES EM ~~~~~~~~~ . . F u n 4 3 E 5

alta. 0 rociado de la pistola. 10s escapes de fluido o roturas de los wmponentes pueden inyectar fluido en la piel y el cuerpo y causar lesiones earemadamente graves, incluyendo a veces la necesidad de amputaci6n. Tambih. el fluido inyectado o salpicado en 10s ojos puede causar graves daflos. NUNCA apuntar la pistola hacia alguien o alguna parte del quilla. NUNCA tratar de "hacer retornar la pintura"; este NO cuerpo. NUNCA colocar la mano o 10s dedos encima de la b- es un sistema de rociado de aire. SIEMPRE tener colocado el protector de la boquilla en la pistola mientras se est6 pulverizando. SlEMPREseguir el procedimiento de descarga de presi6n. servicio a cualiquier equipo del sistema. dado m& abjo. antes de limpiar o Sacar la boquilla o de dar NUNCA tratar de parar 0 desviar los'escapes con la mano o ei cuerpo. e d n funcionando bien antes de cada uso. Asegurar que todos 10s aparatos de seguridad del .equip0 Tratamiento mddico Si pareciera que un.poco de fluido.penar6 la piel, conseguir TRATAMllENTO MEDICO DE UROENCIA DE INMEDIATO. NO TRATAR LA HERIDA @DM0 UPJ SIMPLE CORTE. Decir al medico exactamente cua fluido fue. Aparatos de seiuridad de Ira pi5tOl~3 pulverized& Asegurar que todos i o s aparatos protectores de la pistola estsn funcionando bien antes de cada uso. No scar ni modificar ninauna oieza de la oistola Dues oodrla causar el malfuncionamlento be la misma con ias consiguientes [miones personalas. Pestillo de seguridad Cada vez que se deje de pulverizar, aunque sa8 por un breve momento. siempre colocar el pest" de seguridad en la posici6n "cerrada". Io que deja la pistola inoperante. El no hacedo puede llevar al disparo imprevisto de la pistola. Difusor 8 difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyeccidn cuando no est6 instaiada la boquilla. el procedimiento de descaiga de presi6n. dado rnhsabajo. Revisar con reguiaridad e1 funcionamiento del difusor. Seguir mat6lico. sosteni4ndola bien firm contra 61. Utilizando ia y despub sacar la boquilla. Apuntar la pistola a un balde emitido no sale disperso en un chorro irregular, reemplazar de presi6n m6s bajo posible, disparar ia pistola. Si el fluido inmediato el difusor. Rotactor de la boquilla pistola mientras se est6 pulvenzando. Este protector llama ia SIEMPRE tener e1 protector de la boquilla colocado en la atenci6n contra el peiigro de inyecci6n y ayuda a prevenir la colocaci6n accidental de 10s dedos o cualquier otra parte del cuerpo cerca de la boquilla. Sagupidad de la bcqullla pulverizadcra Tener mucho cuidado al limpiar o cambiar las boquillas. Si pestiilo de la pistola de inmediato. SIEMPRE seguir el pio- llegara a obstruirse mientras est6 pulverizando; enganchar el quilla para limpiarla. cedimiento de descarga de presl6n y despub Sacar la bo- NUNCA limpiar la acumuiacibn de pintura alrededor de la bo- quiila antes i13 que se haya descargado por cornpleto la ..esidn y el pmillo est6 enganchado. Procedimiento dedescarga de presi6n choque el6ctriw, Siempreseguir esteprocadimiento al apagarla T6quina pulverizadora, al revisar o dar servicio a cualquier parte Para reducir el riesgo de sufrir graves iesiones corporales, incluyendo inyecci6n o lesiones causadas por piezas en movimiento o del sistema de pulverizaci6n. al instalar, limpiar o cambiar Ias boquillas, y cada vez que se deja de pulverizar. 11) Enganchar e1 elhrico. (4) Desenganchar el pesu'llo de la pistola. 15) Sujetar una parte mdlica de la pistola bien firme contra un balde de Pestillo de la pistola. (21 Mover e1 intenuptor elbctrico ION/OFF) a la posicibn OFF (apagadol. I31 Desenchufar el cord6n metal, y disparar la pistola para descargar la presi6n. 161 Enganchar e1 perstilio de la pistola. 17) Abrir la vhlvula de drenaje y tener pulverizar. list0 un reclipiente para recibir la pintura. 18) Dejar la v6lvula de drenaje abierta hasta que se est6 nuevamente iisto para SiSe sospacha que la boquila o la mnguera estd qutlla o acoplamiento de la pun- de la man despuhs de haber seguido el procedimiento despajar la boquilla o la manguera. ,.. . . .. . . . . . ' . :. ., . . . . ~ . "ERRUPTOR 2

segws~ded gpwasal Cualquler mal us0 de( equipo pulverizador o 10s accesorios. tal como ~brepresurizaci6n. modificaci6n de piezb, UM de matenales y pmductos quimicos incompatibles, o utiliuaci6n y causen la inyecci6n de fluido u otras lesiones corporales graves, incendio, explosi6n o daiion a la propiedad. NUNCA alterar o modficar ninguna pieza de este equipo; el hacerlo podria causar una averia. REVISAR con regularidad el equipo pulverizador y reparar o reemplazar de inmediato las piezas daiiadas o desgastadas. PwiOn del sietema Esta pulverizadora puede desarmllar 210 barlas WM psi) de PRESION DE TRABAJO MAXIMA. Asegurar que todo el equip0 pulverizador y sus accesorios tienen la capacidad para aguantar ia presi6n maxima de trabajo de esta pulverizadora. NO exceder la presi6n maxima de trabajo de ningrln com- ponente o acmorio de m e sistema. Cornpatibilldad de Fluid0 ASEGURAR que todos 10s fluidos y saiventes usados son en.la hoja de datos tbcnicos en la contratapa. Siempre lee las quimicamente compatibles con las piezas mojadas ilustradas instrucciones del fabricante del fiuido y sulvente a n t d de usarlos m esta pulverizadora. El fluido que pasa a aka presidn por 18s mangueras puede ser muy peligroso. Si en la manguera se desarrolla un escape pe- desgaste. daiio o maitrato, el chorro a aka presi6n emitido por queiio. una rotura o rajadura debido a cualquier tip0 de alli puede causar una lesi6n por inyecci6n u otras lesions cor- porales graves o deiion a la propiedad. lTODAS U S MAMGUERAS PARA FLUIDOS TIENEN QUE TENER GUARDAS DE RESORTEI Estas protegen las tos o cerca de ellos, 10s que podrian traducirse en roturas de le mangueras contra dobleces 0 retoreeduras en 10s acopiamien- manguera. Antes de usarlas, APRETAR bien firmes todas las conexiones. o dejar que por bt escape un chorro a aka presi6n. El fluido a alta presi6n puede desalojar un acoplamiento sueito NUNCA usar una manguera que e& daflada. Siempre. revisarla en busca de cortaduras, escapes, abrasih, cubierta abultada, o acoplamientos sueltos o datiados. Si llegara a en- contrarse cualquiera de mas condiciones, reemplazar de in- mediato la manguera. NO intentar reacoplar una manguera de aha presibn o enmendarla con cinta adhesiva u otro material Ruido a aka presi6n. similar. Una manguera que ha sido remendada no aguante el MANEJAR Y PASAR CUIDADOSAMENTE LAS MANGUERAS. No tirar de las mangueras para mover el equipo. No usar fluidos o solventes qua Sean incompatibles con ei tubo interno y la cubierta dela manguera. NO exponer 4 ' C (-4O'F). las mangueras a temperaturas sobre 82°C (180OF) o bajo Continuidad de[ EIPCM~FO ola.puesta 8 tierpa de la manguara esencial para mantener conectado a tierra el sistema La continuidad del circuit0 de puesta a tierra apropiado es pulverizador. Es indispensable revisar la resistencia elktrica vsz a la semana. Si la manguera no tiene una etiqueta en la maxima de Ias mangueras de aire y de fluido par lo menos una cual se especifica le resistencia eltktrica maxima, ponerse en contact0 con el proveedor o fabricante de la manguera para la resistencia en la gama apropiada para comprobar la resisten- informaci6n sobre 10s limites de resistencia. Usar un metro de mediato. Es muy arriesgado tener una manguera sin puesta a cia; si excede 10s limites recomandados, reemplazarla de in- tierra o'con la puesta a tierra en malas condiciones. Leer tam- bi6n la informaci6n sobre RIESGO DE INCENDIO 0 EXPLO- .~ . de piezas daiiadas o desgastadas, puede hacen que se rompan SEGUR!DAD EN EL us0 DE BAS ~ ~ ~ ~ U ~ . . .. SION. d s amba. .. . i : PBBGW6 DE 8NCENDlO 8 EXPLO$lOM El flub a alta velocidad del Ruido al .pasar por la bomba y manguera crea electricidad est6tica. Si todas 18s panes del equipo pulverizador no tienen buena tierra. pueden ocurrir chispas, convirtiendo ai sistema en algo peligmso. Tambibn, d6n el6ctrico. €stas chispas pueden inflamar los vapores de pueden producirse chispas a1 enchufar o desenchufar el cor- 10s solventes y ei chorro de fluido puiverizado, panicuies de polvo y otras sustancias infiamabies, sea al aire libre o bajo techo; Io que podria causar una explosidn o incandio y graves Iesiones corporales y dafios a la propiedad. Enchufar siempre la pulverizadora a un tomacorriente que se encuentre a por io rociar. No enchufar o desenchufar ningrln cord611 elbctrico en menos 6 m ( 2 0 pies) de la mhquina y dd Area que 88 va a posibilidad de que queden vapor- inflamables en el aire. el lugar donde se est6 rociando cuando todavia exista ia Si se observa alguna chispa esthtica, o se siente el mas leve choque elbctrico. APAGAR DE INMEDIATO LA PULVERIZADORA. Revisar todo el sistema en busca de con- exi6n a tierra positiva. No usar nuevamente el sistema hasta haber ubicado y corregido el problema. Para reducir el riesgo de chispas esthticas. conectar a tierra la se encuentre en el iugar que se va a rociar. CONSULTAR el pulverizadora y todo el otro equipo de pulverizar que se use o c6digo elbctrico de la localidad para las instrucciones sobre IBS conexiones a tierra exigidas para la zona y tip0 de equipo. pulverizador: ASEGURAR de conectar a tierra todo este equipo 1. Pulverizadora: enchufar el cord6n elbctrico, o cable exten- sor, cada uno con un enchuf de tres patas en buen estado, a un tomacorriente con puesta a tierra apropiado. No usar un adaptador. Totos 10s cables extensores tienen que tener tres hilos y una capacidad de 15 amperios. , 2. Mangueras para fluidos: usar solamente mangueras con puesta a tierra de una longitud combinada de 150 m tambikn al phrrafo sobre continuidad a tierra de .la ( 5 0 0 pies), para asegurar buena continuidad a tierra. Referirse 3. pistola: hacer la puesta a ti.erra conecthndola a una manguera. manguera de fluido y puiverizadora bien conectadas a tiena. 4. Objeto que $e estd rociando: de conformidad con el cddigo local. 5. Todos 10s baldes de solvente usados durante el lavado, de meta4 que,sesn conductivos. No coiocar el balde en una conformided con el c6digo local. Usar solamente beldes. de superficie no conductiva, como papei o cartbn, que inter- rumpe la continuidad a tierra. 6. Para mentener la continuidad a tierra duranre el lavado o descarga de presidn, siempre apoyar una parte metelica de la pistoia bien firme contra ei costado del belde de metal, despuk apretar el gatillo. Syqldaq .durante el Ba\rgd~ R uclr el rlesgo de lesiones por inyeccibn, chispas elbctricas o salpicaduras. siguiendo el procedimiento de lavado especffico dado en la phgina 10 de este manual. Seguir 81 pro- cedlmlento de descarga de prasi6n en ia phgina 6, v quitar la boquilla rociadora antes de law. Apoyar una pane metblica de la pistola bien firme contra ei costado de un balde de metal y usar la presi6n mhs baja posible de fluido durante el !avado. Pu@sta 61 tierm Las piezas en mowmiento pueden pinchar o amputar dedos u otras partes del cuerpo. MANTENERSE ALEJADO de las piezas en movimiento durante el arranque o funcionamiento de la pulverizadora. Desenchufar la pulverizadora y descargar arranque inesperadamente. la presi6n antes de revisarla o darle servicio, para impedir que IMPORTANT Se han adoptado las normas de seguridad del gobierno de 10s Estados Unidos de Noneambrica bajo el Acta de Seguridad y especial Ias Generales, Parte 1910; y las Normas de Construc- Salud Ocupacionai. Deberhn consultam estas normas, en ci6n. Pane 1926.

Connect at least 50 . f t (15 m) hose to the fluid outlet of the pressure control. See Fig 1. Connect a spray gun to the other end of the hose. Don't use thread sealant, and don't install the spray tip yet! For two gun hookup, remove the plastic cap plug from the secondary hose ball valve and connect an accessory hose and spray gun. See Fig 1. CAUTION To avoid damaging the pressure control, which may result in poor equipment performance and component damage, follow these precautions: 1. Always use at least 50 f-t (15 m) of nylon spray hose. 2. Never use ewire braid hose as it is too rigid to act as a pulsation dampener. 3: Never install any shutoff device beVe6n the fluid outlet of the pressure control and the first 50 ft (15 m) of spray hose. 4. Always use the main fluid outlet for one-gun operation. Never plug this outlet. II Fill Packing NutlWdt Cup Pour throat seal liquid, supplied with the sprayer, into wet-cup filled'to help protect and prolong the life of the the packing nut/wet-cup until it is 1/3 full. Keep the pump throat packings. See Fig 2. Check Electrical Service Be sure the electrical service is 120 V, 60 HzAc, perly grounded. 15 amp (minimum) and that.the outlet you use is pro- Use an extension cord which has3 wires of minimum 12 gauge size, rated for 15 Amps, and a maximum of 1 5 0 h (45 m) long. Longer lengths may affect sprayer performance. Be sure the ON/OFF switch is OFF. Plug the power sup- Plug In Sprayer 20 ft (6 rn) away from the spray area to reduce the ply cord into a grounded electrical outlet that is at least chance of a spark igniting the spray vapors. See Fig 3. Do not remove the third prong of the power supply cord plug, which is the grounding prong, and do not use an adapter. Flush the Pump flush the pump to remove h e No. 10 motor oil which was l e f t in to protect pump parts after factory testing. Refar to page 10 for WHEN and HOW to flush. Prepare the Paint Prepare the paint according. to the manufacturer's formed, and stir the paint to dissolve hard pigments. recommendations. Remove any skin that may have Strain the paint through a fine nylon mesh bag [available at most paint dealers) to remove particles that could clog the spray tip. This is probably the most im- portant step toward trouble-free spray painting. SECONDARY Fig 2 Fig 3 .. ;.: . :,:: , 1, . . , . .. , .; ... ... . . . . .. .. , . .. .. , .

Close the main drain valve and the secondary ball valve. See Fig 2. Plug in the sprayer. Don't install the spray tip in the gun yet1 - -. Place the suction tube into the paint container. Turn the . . lower the pressure setting. See Fig 3. Disengage the pressure control knob all the way counterclockwise to gun safety latch. grounded metal pail, and trigger the gun into the pail. Hold a metal part of the gun firmly against the side of a increase the pressure setting until the sprayer starts. Hold the trigger open, turn the sprayer ON, and slowly ed out of the system, and the paint ROWS freely from the Refer to Fig 4. Keep the gun triggered until all air is forc- gun. Release the trigger and engage the safety latch. / .... ... ~ . . ..._ . .. .._. METALTO METL CONTACT BETWEEN GUN AND CONTAINER Fig 4 MOTE: If the paint is hard to prime, open the drain valve. When fluid comes from the valve, close it. Then disengage the gun safety latch and follow the paragraph above. Check all fluid connections for leaks. If any are found, follow the Pressure Relief Procedure Warnlng on page 2 or 11, before tightening connections, Be sure the gun safety latch is engaged. Install the tip Install the Spray Tlp and Tip Guard and tip guard as instructed in the separate gun or tip iv- struction manual. Adjusting the Spray Pattern spray from the gun is completely atomized. To avoid ex- Increase the pressure adjusting knob setting just until and extend the lie of the sprayer, always use the lowest cessive overspray and fogging, and to decrease tip wear possible pressure needed to get the desired results. If more coverage is needed, use a larger tip rather than increasing the pressure. Test the spray pattern. To adjust the direction of the spray pattern, engage the gun safety latch and loosen horizontal for a horizontal pattern or vertical for a ver- tical pattern. Then tighten the retaining nut. .~ the retaining nut. Position the tip so the groove is I .:; ,, . .~ ',? .., .. :. . . . ,. . ... : . . i . . .. 'L..s ____ ._.... ~ , , ~ . . ~ . ,.., ~~ ,,... ~,,, ...*i,~~,"~-,.L. ..... ._. .ll.,..,) . . . ~ ~ - ".LX&& ...................................................... ~ '.~. . . ~ ~ .-.- 1_..L ~~~~~ ~ ~ ,_","-mid -..,, Cleaning a Clogged Tip DO NOT try to "blow back" paint; this is NOT an Follow the instructions given in your separate gun or spray tip instruction manual for cleaning a spray tip. SHUTDOWN AND CARE Check the packing nut/wet-cup daily. First follow the Pressure Rellef Procedure Warning on page 2 or 11. times to help prevent fluid buildup on the piston rod and Keep the wet-cup 113 full of throat seal liquid at all premature packing wear. The packing nut should be tight enough to stop leakage, but no tighter. Over- tightening may cause binding and excessive packing wear. Use a screwdriver and light hammer to adjust the nut. See Fig 5. en adjusting the packing nut, be careful not to nick the cylinder threads which may be protruding above the bearing housing. Nicks to these threads may strip the threads in the bearing housing when the displacement pump is removed or installed. Fig 5 Flush the sprayer at the end of each work day and fill it freezing. See "Flushing Guidelines" on page 10. withmineral spirits to help prevent pump corrosion and ious 'sprayer damage. pints for the final flush, ave the mineral spirits in For very short shutoff periods, leave the suction tube in the paint, follow the Pressure Relief Procedure Warning, and clean the spray tip. Coil the hose and hang it on the hose rack when storing the sprayer, even for overnight, to help protect the hose from kinking, abrasion, coupling.darnage, etc.

1. New Sprayer. Your new Ultimate NovaTM lo00 Sprayer was factow. tested in No. 10 motor oil which was left in to protect pump parts. Before using wafer-base palnt, flush with mineral spirits, followed by soapy water, and then a clean water flush. Before uslng oibbase palnt, flush with mineral spirits only. 2. Changing Colors. flush with a compatible solvent such as mineral spirits or water. 3. Changing from water-base to oll-base paint. flush with soapy.water, then mineral spirits. 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. Oll-bese paint: flush with mineral spirits. Shutoff and unplug the sprayer, open the drain valve to relieve pressure and leave open. Before using water-base paint, flush out mineral spirits with soapy water and then a clean water 6. Stenup after storage. Rt m h 4. Changing from oil-base to water-base paint. When using 011-base paint, flush out the mineral Flush with mineral spirits, followed by soapy water, then a aean water flush. spirits with the material to be sprayed and the sprayer is ready to use. ..I"... How to Flush 1. Engage the gun safety latch, turn the ON/OFF switch to OFF, release the gun safety, trigger the gun to relieve pressure, engage the gun safety and open the drain valve. 2. Pour one-half gallon (2 liters) of compatible solvent into a bare metal pail. Put the suctiolrtube in the pail. 3. 4. 5. 6. 7. Close the drain valve. Remove the spray tip from the gun. Point the spray gun into a metal waste container and with a mepl part of the gun firmly touching the metal container, squeeze the gun trigger. 'See and splashing. With the gun triggered, turn the Fig 6. Thk procedure helps awoid stetlc sparking ONIOFF switch to ON and slowly turn the pressure starts. Keep the gun triggered until clean solvent adjusting knob clockwise lust untll the sprayer engage the gun safety latch. comes from the nozzle. Release tha trigger and Check all fluid connections for leaks. If any leak, first turn the ON/OFFswitch to OFF, then open the drain valve slowly to relieve pressure. Now tighten fig 6 the connections, start the sprayer, and recheck the connections for leaks; 1 from the ho&.bo nG-let thspump. run dry ior sprayer again. pump packingsl Then turn ON/OFF switch to OFF more then 30 seconds to avoid damaging the 9. If you flushed with mineral spirits and are going to and engage the gun saftey. use a water-base paint, flush with soapy water fol- lowed by a clean water flush. Then repeat Step 1. ., . . .. .. . . . ... I ~.

2. Turn the ONIOFF switch to OFF. 3. Unplug the power supply cord. 4. Disengage the gun safety latch. 5. Hold a metal part of the gun firmly to the side of a metal pail, and trigger the gun to relieve pressure. 6. Engage the gun safety latch. 8. Leave the drain valve open until you are ready to spray again. Basic Mechanical Problems 1. Check for fmzen or hadened material in the 1. Thaw'. Plug in sprayer and turn on. Slowi) pump (39) and/or pressure control bourdon increase pressure setting to see if motor tube. Using a screwdriver, carefully try to rotate fan at back of motor by hand. See stam. If it doesn't, replace the displacemei page 77 the bare pressure control box (306)'. pump packings (see page 26) andlor replac 2. Check displacement pump connecting rod 2. Push pin into place and secure with the connecting md (3) and spring retainer 135) ' pin 1201. It must be completely pushed into - spring retainer. should be firmly in grmw of connecting rod. See page 28. 3. Cheok for motor damage. Remove driw 2. Replace motor (1) if fan won't turn. housing assembly (2). Try to rotate fan by hand. See uaae 30. lsic Electrical Problems 1. Check sprayer circuit breaker 1309'button to 1. Depress circuit breaker button to reset. If be sure it has not popped up. ciicuit breaker continues to open, see "Elec 3 trical Short", page 16. 2. Check electrical supply with volt meter. 2. Reset building circuit breaker; replace Meter should read 105 to 125 VAC. building fuse. Try another electrical outlet. 3. Check extension cord for visible damage. 3. Replace axtension cord. Use a volt meter or test lamp at extension cord outlet to check. 4. Ch,eck sprayer power supply cord (31 1) for 4. Replace power supply cord. See page 20. wlble damage such as broken insulation or wires. 5. Check motor brush leads, terminals and 5. Tighten terminal screws; replaw brushes. brush length. Brush length should be 9/16" See page 25. minimum on the longest side. Sea page 25. ..:; .. . . . . .. ,. . '~~ ,. 'Thaw the sprayer if water or water-based material has frozen W e n replacing the bare presure contml box litem 306). ." in it, due to exposure to low temperatures, by placing it in a warm area. Do not try to start the sprayer until it has thawed remove the circuit breaker, ON/OFF switch, bridge. circuit board and electrical hardware and reinstall these parts in the completely. If the bourdon tube was not damaged by the freezing. the pump should operate. If material hardened bare box. pressure control must be replaced. See page 23 or 26. (dried) in the sprayer, the pump packings and/or bare " .^.. ..

Iicator lamps. The normal andition is red lamp on, $ear lamp on when board I elling pump to run. :allow Pressure Relief Pro- ndure. Remove gun from lose. Remove pressure cor rol cover and check for fat ondition of circuit board mps. :ondtion A both lamps On; lump won't operate and mor is not running Dndition 8 fh lamps off refer to *is colu~ sure they are securelyjastened and properl) mated. 1. Check leads from bridae 1 3 0 8 1 to motor to be 1. Replace any loose terminals and crimp to I leads. Be sure male terminal blades are straight and firmly connected to mating pa 2. Check G1 and 62 connections between cir- or loose terminals. cuit board 1121) and bridge 1308) for damagl 3. Check for loose motor brush lead wnnec- tions and terminals. See page 25. 4. Check brush length which should be 9/16" minimum on longest side.Sea page 25. 5. Check for broken or misaligned motor brush squarely on top of brush. See page 25. springs. Rolled portion of spring must rest 6. Check motor brush& for binding in brush holders. See page 25. I 7. Check moior armature commutator for burn spots, gouges and extreme roughness. plates to check. See page 25. Remove motor cover and brush inspenion 3. Check motor armature for shorts using ar- mature tester (growler) or perform spin test. See page 17 good bridge or performing bridge test. See page 18. CAUTION: Do not perform this check until armature is determined to be good. A bad armature will immediately bum out a good bridge. I. Check circuit breaker (309) button to be sure it has not popped up. 3. Check bridge ( 3 0 8 ) by substituting with a !. ChecA sprayer power supply cord (31 1). Disconnect TP6 female and TP1 female and sprayer. Meter should read 105 to 125 VAC. connect volt meter to these leads. Plug in Unplug sprayer. Reconnect TPl. . Check ON/OFF switch 1 3 M I . Disconnect TP2 ~ ~~ ~ and connect volt meter to TP6 female and should read 105 to 125 VAC. Turin offand TP2 male. Plug in sprayer and turn on. Meter , ~~~. unplug sprayer. Reconnect TPZ. . Check jumper wire 1305). Disconnect TP3 and connect volt meter to TP6 female and TP3 female. Plug In sprayer and turn on. and unplug sprayer. Reconnect TP3. Meter should read 106 to 125 VAC. Turn off meter to TP6 female and TP4. Plug in Check circuit breaker (309). Connect volt sprayer and turn on. Meter should read 105 to 125 VAC. Turn off and unoiuo soraver. 1 i 2. Clean circuit board male terminals. Replacl loose or damaged terminals. Securely reco nect leads. 3. Tighten terminal screws. Replace brushes i leads are damaged. Sea page 25. 4. Replace brushes. Sea page 25. 5. Replace spring if broken. Realign spring wi brush. See page 25. 6. Clean brush hoiders. Remove carbon with slot in brush holder to assure free vertical SWall cleaning brush..Align brush lead with brush movement. 7. Remove motor and have motor shop resur- face commutator if possible. See page 31. 8. Replace motor. See page 31. 3. Replace bridge. See page 21. I . Depress circuit breaker bunon to reset. If cil cuit breaker continues to open, see "Elec- trical Short", 16. ?. Replace power supply cord. See page 20. I. Replace ON/OFF switch. See page 20. .. .. Replace jumper wire. . Replace circuit breaker. See page 21. Continued) (Continued) .:: ! . . . . . . , . .

WHAT TO CHECK If check is OK, go to next check 6. Check motor thermal cutout switch. female. Plug in and turn on sprayer. Meter Connect volt meter to TP6 female and TP9 should read 105 to 125 VAC. Turn off and unplug sprayer. 7. Check microswitch 1301). Reconnect TP6 connectors. Connect volt meter to TP15 VAC. male and TP4. Meter should read 50-125 8. Visually inspect microswitch 1301) button. Adjustment stud 101 should not depress th microswitch bunon when fluid pressure is with small screwdriver; an audible click in- zero. Manually check by depressing button dicates.micmswitch is in normal position. 9. Check microswitch 1301) continuity with oh meter. Be sure sprayer is unplugged1 Mete! should read zero ohms with no fluid pressu in the sprayer. 10.Check all terminals for damage or loose fit. Reconnect Tffi connectors. 11.Check circuit board l307) by substituting w'kh a good board. See page 22. I. Check circuit board 1121) by removing from box without disconnecting wires; see page 22 for removal procedure. - WARNING: Removing the circuit board while Su'll wired over-rides the optical detec tor which could causa the sprayer to ovar- tion properly. Turn the sprayer on ONLY pressurize. if the microswitch does not func long enough to check lamp condition, then WARMING: To reduce the risk of electric shut off immediately. shock, handle board by edges onbl Do not with the board1 allow any metal objects to come in contact Plug in and turn on sprayer. Clear lamp should be on now - removing the circuit off and unplug sprayer. board over-rides the optical detector. Turn . Check bourdon tube flag and detector posi- tion. Reinstall circuit boar@ (see page 2). Tum pressure setting to maximum; flag detector slot from the bottom. should extend less than half way into optical D m C T O R OPTICAL IRCUIT BOARD VIEW OF OPTICAL DETECTOR AND FLAG When replacing the bare pressure control box 13081. remove the cirwtt breaker,bridge. circuit board and electrical hardware and reinstall in the new bare box. When check is not OK refer to thk colu WHAT TO DO 6. Allow motor to cool. Correct cause of ove heating. If switch remains open after motc cools, check continuity W e e n TW fama and TPlO with ohmmeter. if open, replacs motor. 7. Clean microswitch male terminals. Raolact nect leads. loose or damaged terminals. Securely rex ~~~- ~~ 8. Microswitch is faulty. Return sprayer for repair. 3. Microswitch is faulty. Return sprayer for remir. I0.Replace damaged terminals and reconnect I1.Replace circuit board. See page 22. securely. . Replace circuit board. See page 22. Calibrate pressure contml to see if that cor- rects problem. See page 24. (306)'. see page 23. If not, replace bare pressure control box

If check is OK. go to next check 1. Check for worn spray tip. 2. to stroke when gun trigger is released. Plug Check to see that pump does not continue in and turn on sprayer. Prime with material. engage safely latch. Relieve pressure, turn Trigger gun momentarily, then release and off and unplug sprayer. 3. Check electrical supply with volt meter. Meter should read 105 to 125 VAC. 4. Check extension cord size and length; must be et least 12 gauge wire and no longer thal 150 ft (15.2. m). i. Check G1 and 62 leads from bridge ( p 8 1 to circuit board (3071 for damage or loose wire! or connectors. Refer to page 22. Procedure on page 24. 3. Check stall pressure. Refer to Calibration 7. Check bridge (3081. + and - leads and ter- and terminals for signs of overheating. See minals to motor. Inspect wiring insulation page 18. I. Check for loose motor brush leads and ter- minals. See page 25. I. Check for worn motor brushes which should be 9/16 minimum length on longest side. See page 25. 0.Check for broken and misaligned motor brush springs. Rolled portion of spring must resf squarely on top of brush. 1.Check motor brushes for binding i:. orush holders. See page 25. 2.Check circuit board (307) by substituting with a good circuit board. See page 22. 3.Check motor armature for shorts by.using an armature tester (growler) or perform spin test. See page 18. 3 4.Check bridge (308) by substituting with a test. See page 18. good bridge or by performing the bridge CAUTION: Do not perform this check until armature is determined to be good. A bad armature will immediately bum out a gcd bridge. Check material supply. Check for clogged intake strainer. See page 26. Check for loose suction tube or fittings. Sea Page 26. WHAT ro DO When check Is not OK refer to this colul 1. Follow Pressure Relief Procedure then replace tip. See your separate gun or tip manual. 2. Service pump. See page 26. 3. Reset building circuit breaker; replace building fuse. Repair electrical outlet 01 another outlet. 1. Replace with a correct, grounded extension cord. i. Clean circuit board mete terminals. Replace lease or defective lead terminals. Securely reconnect lead terminals to board. i. Calibrate pressure control. See page 24. '. Be sure male terminal blades are centered and firmly connected to female terminals. ing. Securely reconnect wires to bridge. Replace any loose terminal or damaged wir- i. Tighten terminal screws. Replace brushes if . Replace brushes. See page 25. leads are damaged. See page 25. 0.Replace spring if broken. Realign spring witt brush. See page 25. 1.Clean brush holders. remove carbon dust with slot in brush holder to assure free ver- with small cleaning brush. Align brush lead tical brush movement. Z.Repiace circuit board. See page 22. Meplace motor. See page 31. 1.Repiace bridge. See page 21. Refill and reprime pump. Remove and clean, then reinstall. Tighten; use thread sealant or sealing tape on threads if necessary. (Continuedl [Continued)

. .. YO OUTPUT Continued) dotor mns but pump doe ot stroke KCESSIVE PRESSURE IUCTUATIONS ,ray pattern variations. ITOR IS HOT e NS INTERMlllENTLY WHAT TO CHECK If check is OK, IIO to next check 4. Check to see if intake valve ball and piston ball are seating properly. See page 26. 5. Check for leaking around throat packing nt which may indicate worn or damaged pack ings.See page 26. 1. Check displacement pump connecting rod pin. See page 28. 2. Check connecting rod assembly for damage 3. Be SUA mnk in drive housing rotates; piu( in sprayer and turn on momentarily to chec Turn off and unplug sprayer. See page 30. see page m. I 4. Check to see if pinion gear in motor front sprayer and turn on momentarily to check. end bell is slipping. See page 31. Plug in Turn off and unplug sprayer. 1. Be sure both G1 and G2 leads from bridge ( 3 0 6 ) to circuit board (121) are firmly connected. See page 22. 2.- Check stall presure.'kefer to Calibration procedure on page 24. 3. Check bourdon tube flag and detector posi- tion. Turn pressure setting to maximum; fla! should not drag or bind in optical detector slot of circuit board. rClRCUlTBOAR0 VIEW OF OPTICAL DETECTOR AND FLAG 4. Check circuit board 1307) by substituting with a good board. Sea page 22. 5. Check LOW OUTPUT section on page 14. 1. Check to see if sprayer has bean o erating a high pressure with small tips, whicR muses low motor RPM and results in excessive hear build up. 2. Check to see if ambient temperature where sprayer is located is more than 90°F ( 3 2 W or if sprayer is located in direct sun. 3. Check to see if sprayer has been left in a stalled condition (sprayer turned on, perlods of hme. preqrized but not operating) for long " It ! " 3. : k. 4 " 1 2 3 3. 4. " t 1. 2. 3. WHAT TO DO When check is not OK refer to this COIU 4. Remove intake valve and clean. Check bal and seats for nicks; replace if neceaary. .$ 5. Replace packings. See page 26. Also chec piston valve seat (224) for hardened mater1 or nicks and replace if necessary. .page 26. I. Reolace Din if rnissino. Be sure retainer spring is7fully in groob all around connect ing rod. See 28. ~ ~ ~~~ ~ i. Replace connecting rod assembly. See pag I. Check drive housing assembly for damage and replace if necwry. See page 30. m. .. Replace motor. See page 31. . Reconnect securely. See page 21 and 22. . Calibrate pressure control See page 24. , Carefully bend flag into alignment with detector slot to see if that corrects problem assembly (306)'. Calibrate pressure control If not, replace bare pressure control after reassembly. Replace circuit board. See page 22. SUE. Decrease pressure setting or increase tip Move sprayer to shaded, cooler area if possible. Turn off sprayer whenever you stop spraying for a while and relieve fluid pressure. When replacing the bare pmure conuol box 1306). rarnove the circuit board, bridge, urcuit board, and siecuical hardware and reinstall in the new bare box.

Building circuit bkake! opens turned on. CAUTION Any short in any part of tk motor power circuit, which mnnected to the output sid Ji the bridge, will muse tb ]ridge to bum out immediatt repair ail shorts before checl y. Correctly diagnose an ng and replacing bridgf Wilding circuit breaker opens is soon as sprayer is plugged nto outlet and sprayer is NO: umed on. iprayer circuit breaker opens fter sprayer operates for onl) .to 10 minutes. 1. Check all electrical wiring for damaged in- sulation, and ail terminals for loose fit or damage. Be sure to check wires between pressure control and motor which are enca ed in conduit (22). See page 30. 2. Check for missing inspection plate gasket (sea page 251, bent terminal forks or other cause a short. metal to meta.wntact points which could I 13. Check motor armature for shorts by using i armature tester (growler) or perform spin test. See page 17. Inspect windlngs for burns. ~ 4. Check bridge 1308) by substituting with a good bridge or by peiiorming bridge test. See page 18. CAUTION: Do not perform this chyk unti armature is determine&to be good. A bad armature will immediate@ burn out a good bridge. 1. Check 'Basic Electrical Problems' on Page 1 2. Check ONlOFF switch (302) See page 20. 'Be sue the sprayer is unpiuggedl Disconnet wires from switch and check switch with ohm meter. The ohm meter should read in- with the switch ON. finity with the ON/OFF switch OFF, and Zen CAUTION: A short in the motor circuit wi bum the bridge out immediately, which in fur! closed mode. usuallycauses the ON/OFFswitch to faii.in th 1. Check electrical supply with volt meter. Meter should read 105 to 125 VAC. 2. Check tightness of pump packing 'nut. Over- tightening nut tightens packings on rod, packings: See page 26. restricts pump action, and damages 3. Check stall pressure. Remove the elbow (€3) and secondan/ ball valve (301 from the tee 5ooD psi (350 bar) fluid-filled pressure gauge (124) at the pressure control outlet. Install a turn on sprayer. Slowly increase prasslre in the tee (124). See page 24. Plug in and 28M)3wo psi U S 2 1 0 bar). Turn off and setting to maximum. Pump should stall at unplug sprayer. 1. After determining that there is no short in system, reset circuit breaker bunon. I 1. Repair or replace any damaged wiring or ter- minals. Securely reconnect all wires. 2. Correct faulty conditions. 3. Replace motor. See page 31. 4. Replace bridge. See page 21. 2. Replace ON/OFF switch. See page 20. 1. if voltage is too high, do not operate spraye until corrected. 2. Loosen packing nut. Check for leaking around throat. Replace pump packings. if necessaty. See page 26. Calibrate pressure control. See page 24. 1. If circuit breaker continues to open (bunon pops up), replace the circuit breaker. See page 21.

setup Remove the drive housing from the sprayer as des- page 30. Remove the pressure control cover and screws, the motor cover, the fan cover (Fl, and the inspection covers (Jl. See Fig 7. Disconnect the two leads from the motor to the bridge (5081. See Fig 8 and 9. Armatu'ie Short Circuit Test shorts, the motor will coast two.or three revolutions Quickly turn the motor fan by hand. If there are no before coming to a complete stop. armature is shorted and the motor must be replaced. If the motor does not spin freeiy and resists rotation, the See page 31. Armature, Brushes, and Motor Wiring Open Connect the two black motor leads together with a test Circuit Test (Continuity) lead. Turn the motor fan by hand at about two revolutions, per second. If there is uneven or no turning resistance, check the following: a) broken brush springs; b) broken brush el broken motor leads; fl loose motor lead terminals. leads: c) loose brush terminal screws; d) worn brushes; Repair parts as needed. See page 25. If there is still uneven or no turning resistance, replace the motor. See page 31. j cribed in "Drive Housing Replacement", Steps 1-6, Fig 7 Fig 8

Remove the bridge from.the pressure control box and X1 ohms scale ( 0 1. Use a continuity tester, such as multi-meter set on the Eight individual checks, or tests, must be performed. If the bridge fails even one test, it must be replaced. Using the chart at the right, connect the meter wires as indicated 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 indlcated by the black dots:Touch the indicated "G" wire to one meter wire, and then to the other. You should get NO continuity one way, and YES continuity the other way. Fig 9

. . . . . . . . .- ' . .: Procedure Page General Repair Notes ......................................... 19 ONIOFF S ~ t c h Power Supply 20 ................................................ Circuit Breaker ................................................. 21 Circuit Board 22 Bridge 21 Calibration 24 Pressure Control 23 Motor Brush .................................................... 25 Displacement Pump ........................................... 26 Bearing Housing Et Connecting Rod ...................... 28 Drive Housing .................................................. 30 Motor ............................................................. 31 Parts Drawing & List, Ultimate Novam 1000 ............ 32 Parts Drawing 8 List, Pressure Control ................... 34 P,arts Drawing & List, Displacement Pump .............. 36 ........................................... ................................................. .................................................... ............................................... ....................................................... The following tools are needed when repairing this sprayer. Phillips screwdriier Small flatblade screwdriver Needle nose pliers Adjustable wrench Plastic mallet 2" adjustable, open-end wrench Torque wrench 114" hex key wrench 3/16" hex key wrench 518" socket wrench 318" open end wrench 112" open end .wrench 314" open end .'wrench 718" open end wrench Bearing grease High quality motor oil For cafibration procedure only: 318" ignition wrench 0.015" spray tip 5 gallon pail High pressure, oil-filled test gauge, Part No. 820-455 Clean water NEW 3000 p 7 bar) high pressure spray hose Mineral spirit! GENERAL REPAlR MOTES Before repairing any part of the sprayer, read the 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 wrap-around blade of the female connector when of the insulated male connector is centered in the the connection is made. tion, . b e sure to properly mate connectors, and wire could loosen the connector from the wire. never pull on a wire to disconnect it. Pulling on a 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 bet- ween the pressure control box and cover. CAUTION performance or damage to the pressure control. Improper wire routing can result in poor sprayer 3. Keep all screws, nuts, washers, gaskets, and elec- trical 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. . . repair procedure again to verify that everything was If the sprayer does not operate properly, review the done correctly. If necessary, refer to the Troubleshooting Guide to help identify other possi- ble' problems and solutions. including electric ing parts or elec- or a tool while inspecting the repair. Shut off the sprayer and unplug it as soon as you complete the inspection. before operating the sprayer. Reinstall all covers, gaskets, screws and CAUTION -. Do-not run the sprayer dry for.. more !han 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 bums, fire or explosion; see the WARNING, below. . . 820-408 19 ' : ,.

1. Remove the pressure control cover and screws. 2. Disconnect the power supply cord lead from the ON/OFF switch /XU). the white wire ooino to the bridge (W), and the.green wire to~the grounding " screw (341). see Fig 10. 3. Loosen the strain relief bushing 1328). Remove the 4. Install the new cord in the reverse order of 5. Reinstall the cover and screws. power supply cord (311). disassembly. QNIQFF SWITCH REPLACEMENT Fig 10 1. Remove the Dressure control cover and screws. n 2. 3. 4. 5. 6. 7. 8. 9. 10. Use a needle nose pliers to disconnect the upper terminal wire from the microswitch (301) for ease in removing the ONlOFF switch ~302). Refer to Fig 10. from the ON/OFF switch 1302). Refer to Fig 10. Use the pliers to disconnect the two black wires the nut and rubber boot 13G3) from the toD of the Use a 5/8" socket wrench to loosen and remove pressure control box. Remove the switch ' guard (3041. See Fig 9. Remove the ON/OFF switch. Install the new switch so the internal tab of the anti- in the threads of the switch, and the external tab rotation ring (W) engages with the vertical groove engages with the blind hole (D) of the pressure con- CONTROL BOX trot box. See Fig 11. Install the switch guard (304). aligning the internal 302 tab with the groove in the threads. See Fig 11. Install the nut and rubber boot (303) and tighten. See Fig 11. and reconnect the wire to the microswitch (301). Reconnect the wires to the ON/OFF switch (302) Refer to Fig 10. Reinstall the pressure control cover and screws. Fig 1'1 -. :. .. i j ...,. . ,... :.:.: . , . . . . .. .: ' .. .:

! 6. Make sure the bridge is flush with the side of the box 7. Connect all wires. Carefully route the wires. ~. and tighten the screws securely. 1. Remove the pressure control cover and screw. 2. Disconnect all wires from the bridge 1308) a1 the ap- propriate terminals. 3. Outside the pressure control box on the right side are two screws (331). Loosen, but don't remove the screw near the back of the control box. Then loosen and remove the front screw. Slide the bridge out. Route all wires carefully to avoid interference with 4. Slide the new bridge (308) into the box being sure the movement of the bourdon tube, circuit board, the lockwasher (3331 on the rear screw (3311 is /N 'FRONTof the bridge. Refer to the Detail in Fig 12. The lockwashers (333) must be in &nt of the CAUTION bridge to avoid overheating which will result in bridge failure. Refer to the Detail in Fig 12. :: 5. Install the front screw, lockwasher and nut (332). 8. Reinstall the pressure control cover and screws. CIRCUIT BREAKER REPLACEMENT ~ ~~~~ 1. Remove the pressure control cover and screw. 2. Use a small screwdriver to slide the terminal adapter _..~ 3. Disconnect the single black wire from the circuit breaker (3091 to the ON/OFF switch (3G21 Refer to Fig 72. 4. Use a 5/8" socket wrench to loosen the nut and boot (310) on the circuit breaker button. . . .. . . . . . . off the circuit breaker terminal. . . .. . 5. Push down on the top of the circuit breaker and pull . 6. Install the new circuit breaker in the reverse order of 7. Reinstall the pressure control cover and screws. it out of the box. disassembly. , CAUTION . the bourdon tube, which will cause a short. : Tighten the circuit breaker nut firmly to prevent the circuit breaker from turning. . / -~- ." "

. . over ana screws. 2. Turn the pressure control knob all the way counter- clockwise to the minimum setting to release spring tension on the circuit board. Also check to be sure only three or four threads of the pressure control knob shaft are exposed below the pressure adjust- ment nut IS). Back down the nut, if necessary. See Fi 13. 3. Disconnect ALL wires from the board, including the two heavy black wires. Refer to Fig 14..Pay close attention to where connections are made. 4. To. remove the board from the box, pull out the black DhstiC-tipped Din (330). Push the botfom 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. Reconnect the wires as indicated in Fig 14. paround blade of the fe- male connector are cen- connections are made. to avoid interference with 6. Perform the Stall Pressure Calibration on page 24 before operating the sprayer. CIRCUIT BOARD 1 .. . .. i:. . . .. . . . .

on page 11 to reduce .- ry. i n w from moving . . . . ., . . . . . ,. . 1. Disconnect the main fluid hose and'the secondary fluid hose, if used, from the sprayer. 2. Disconnect the fluid hose (471 from between the control inlet elbow (342). displacement pump outlet nipple 1 4 6 ) and pressure 3. Remove the drain tube (126) from the elbow (123). 4. Hold the pressure control oudet nipple (344) firmly with a 3/4" open end wrench, end screw the tee I (124) off of the nipple. 5. Remove the pressure control cover and screws 136.87). and disconnect the four motor leads at the appropriate terminals. See Fig 14, page 22. 6. Refer to "Circuit Board Replacement" on page 22, remove the circuit board and retain. 7. Remove the conduit 1221. 8. Use a llr' open end wrench to loosen and remove the pressure control mounting screws (44) and washers (40) located below the pressure control box. Remove the box. 9. Install the new pressure control assembly in the the conduit seal ( I s n o t shown1 around the wires reverse order of disassembly. Be sure to reinstall prevent motor contamination from entering' the in the conduit elbow 1 7 7 b l at the pressure control to control box. 10. Perform the pressure control calibration procedure or installing the new. pressure control starting-on page 24, before regular operation of the Turning it can damage the sensitive sprayer. ube. Hold the adapter firmly with a 3/4" wrench while screwing on the tee (124). Fig 15

NEVER attempt to increase the fluid outlet pressure MAXIMUM WORKING PRESSURE. This procedure by performing this calibration in any other, way. must be performed whenever a new or used circuit NEVER EXCEED 3000 psi (210 bar) MAXIMUM board, or pressure control assembly is removed and WORKING PRESSURE. Normal operation of the reinstalled or replaced, to be sure the sprayer is pro- sprayer at higher pressures could result in compo- pedy calibrated. nent rupture, fire or explosion. pressurize and result in component rupture, fire or Improper calibration can cause the sprayer to over- AVOID touching the wires in the pressure control assembly with your fingers or tools when the control explosion.4t may also prevent the sprayer from ob- taining the maximum working pressure which would box cover is removed to reduce the risk of electric shock. result in poor sprbyer performance. 1 10.Remove the test gauge assembly. Flush out water with mineral spirits. Caiibratlon Setup 1See Fig 15) 1. Follow the Pressure Relief Procedure Warning on 0.015 spray tip in the gun. Connect the gun to the page 11. Remove the spray hose and gun. Install a outlet. new test hose and connect the hose to the sprayer 2. Remove the pressure contml screws and cover. 3. Remove the secondary ball velve 150) and elbow 188). Holding the nipple (344) with a wrench to pre- vent it from turning, rotate the tee (124) up and in- stall the test gauge 0 0 in the tee 1124). See Fig 16. 4. Place the pump suction tube in a 5 gallon pail of clean water. 5. Be sure the gun safety latch is engaged. 6. Use a 3 / 8 ignition wrench to turn the pressure ad- justment nut 1s) counterclockwise about two full turns. See Fig 17. 7. With the pressure control knob at the minimum set- ting, turn the sprayer svyitch ON. See Fig 16. THE SPRAYER SHOULD NOT STARTI If it does srart shut the sprayer switch OFF, waste container until pressure is relieved; Engage the disengage the gun safety latch, trigger the gun into a gun safety latch. Turn the pressure adjustment nut (SI a little further counterclockwise. Turn the sprayer on to be sure it does not start. 8. Slowly turn the pressure control knob clockwise to the maximum setting and hold it there. Use a 3/8" ignition wrench to slowly turn the Dressure adiust- ment nut (S) clockwise until the test gauge reads EXACTLY 3000 psi (210 bar). 9. The calibration procedure is now completed. . i .. . . \ .. . .

brushes when replacing the packings, Packing Repair Kit No. 820041. Replace the . . and/or when the brushes have been worn to a minimum of 9/16 on the longest side. ! . .- I I I 1. Remove the six motor cover screws (321 and motor cover (141. See Fig 18. 2. Remove the screws (H), inspection covers (J) and gaskets iK1 on each side of the motor. See Fig 18. 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. Refer fo Fw 19. Keep the spring clip. 5. Remove and discard the brush. 6. Inspect the commutator for excessive pitting, burn- ing or gouging. NOTE: A black color on the commutator is normal. qualified motor repair shop if the brushes Have the commutator resurfaced by a 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 19, and the brush lead is routed as shown in the second part 8. Slowly push the tabbed end of the spring clip into the brush holder until the clip tab engages in the holdwand the rolled portion of the tension spring rests squarely on the brush. 9. Route the brush lead to the terminal and tighten the terminal screws. Be sure the brush lead does not touch any pert of the armature or motor housing. of Fig 19. 10. Test the brushes: a. With the ON/OFF switch OFF, turn the wise to minimum pressure. Plug in the sprayer. pressure control knob all the way counterclock- b. Turn the ON/OFF switch ON and slowly in- full speed. crease the pressure until the motor comes up to c. Inspect the brush and commutator contact area for excessive arcing. Arcs should not "trail" or circle around the commutator surface. CAUTION Do not run the sprayer dn/ for more than 30 seconds while checking the brushes to avoid damaging the displacement pump. . . . .. ~.. .. . . .. . ....., 17. Reinstall the brush inspection covers, gaskets, and screws. Reinstall the motor cover and screws. a :.. .... fin SPMNICLIP 1 rBRUSH HOLDER T O R SIDE, VIEW OF MCTOR BRUSH INSTALLATION INSULATION PIATE TERMINALSCREW BRUSH LEAD SPRING CLIP DETAIL OF MOTOR BRUSH SHOWN WITH MOTOR LEAD FACING BACK OF MOTOR Fig 19 820-408 25

1. Flush the pump, if possible, and relieve pressure again. Stop the pump with the piston rod (2231 in its loweq position. To lower it manually, carefully rotate the blades of the 'Tan with a screwdriver. 2. Remove the clamps holding the drain tube (126) to the displacement-pump. 3. Unscrew the suction tube (42) from the pump. Hold the purhp from loosening. the wrench on the pump intake valve (222) to keep 4. Unscrew the hose (47) from the nipple (46) on the pump outlet and remove the hose. . ' 5. Use a screwdriver to push the retaining spring i35) aside and push out the pin (20). 6. Loosen the locknut (38) and unscrew the pump from the bearing housing (27). Disassembling the Pump (Refer to Figures21 and221 1. Unscrew the intake valve (222) from the cylinder (2161.. Remove the gasket (2061, ball guide (215). stop pin (207) and ball (204) from the valve. Clean and inspect the parts for wear or damage, replacing parts as needed. Always usea new gasket (includ- ed in Repair Kit 820-041 1. 2. Unscrew and remove the packing nut (221) and 3. . Use a plastic mallet to tap the piston rod down, then pull the rod out through the boftorn of the cylinder. 4. Remove the throat packings (209. 218) and glands (211,212). 5. Clamp the flats of the piston rod in a vise. Use a 7/8 in. wrench to loosen the retaining nut (214). Then from the rod. use the wrench to unscrew the piston valve (224) 6. Remove the backup washer (219). wiper (205), packings (208, 217) and glands (213, 2 2 0 1 . plug (201). Fig P 26820-408 Fig 21 ! \I-PACKING IN LIPS OF THROAT FACE DOWN *2171PLASTICI LIPS OF V-PAC Fig 22

(1) Use Repair Kh 82C-041 to repair the displacement asterisk, for exsmple, (210*), show the parts includ- pump. Reference numbers in parentheses with an ed in the kit. Use all the new parts even if the old ones still look good for the best results. (2) Alternate leather and plastic packings as shown in Fig 22. Notice that the lips of the throat "Vpack- ings face down, against pressure, and the lips of the piston "r'packings face up, against pressure. The lips of the U-cup wiper (205"). face dawn. In- c o r m installation damages the packings and results in the pump leaking. 13) Cost the piston rod, inside of the cylinder and the packings with a lightweight oil to help prevent , packing damage when inserting the piston rod. 1. Check the outside of the piston rod (223) and the in- side of the cylinder (216) for scoring or scratches. If the parts are damaged, new packings will not segl property. Replace these parts if needM. 2. Stack the backup washer (219"). wiper (205*), female gland (2209, packings (217", 208') and male gland (213") onto the piston. valve. See Figures 23 and 24. 3. lighten the packing retaining nut (214) onto the piston valve (224) and torque to 3 to 4 in-lb (0.34 to 0.35 Nm)-about finger tight. 4. Use a pen to make a light mark on the packings where they align with one of the flats on the nut. See fig 23. 5. Place ball (203') on piston valve (224). Apply one valve. Then hand tighten the valve assembly into drop of thread locking compound on threads of the piston rod just until the nut meets the face of the rod. See Fig 24. 6. Place the flats of the rod in a vise. 4 critical. Follow the procedure carefully to avoid damaging the packings by overtightening. 7. Without changing ?he tightness of the nut ag8inst the packings, tighten the nut (214) into the piston rod to 18 to 20 fi-lbs (24 to 27 Nm). If the pen mark and try again. on the packings loses alignment, back the nut off 8. Stack the male gland (2119, packings (218'. 209') and female gland (212"). one at a time, into the top c,.:. ,; ,.7? ... . j , . .. ,,. . . .. . ., .,.. . . ... of the cylinder. See Fig 22. .-. MARK PACKINGS AND HiX ALIGNMENT Fig 24 9. Install the packing nut (221) and plug (201) but :. 10. Insert the piston rod (223) through the bottom of the pump cylinder, pushing it up until the top of the piston rod extends 1-718 in. (32.2 mm). beyond the : top of the cylinder. See Fig 22. . leave loose for now. 11. Screw down the cylinder locknut (38) until it is threads. finger tight at the bottom of the external cylinder 12. Place flats of the intake valve in a visa. Install a new gasket ( 2 0 6 1 ) and screw the pump cylinder into the valve. See Fig 21. :. !,

3/4 of the way into the bearing housing (27). Hold the pin (201 up to the pin hole in the connecting rod assembly slides easily into the hole. Back oif the pump until (31 and continue screwing in the pump until the pin the top threads of the pump cylinder are flush with the face of the bearing housing and the outlet nip- ple (46) is straight back. Push the retaining spring ting rod. Tighten the locknut (38) very tight-about, 135) into the groove all the way around the connec- 70 ft-lb (94 Nm)-with a 2 in. open-end wrench and a light hammer. Refer to Fig 25. ~ ~~ 14. Tighten the packing nut (221) just enough to stop leakage, but no tighter. Fill the wet-cup/packing nut 1/3 full with Graco TSL. 3 € 15. Replace the motor brushes, included with the repair Fig 25 kit. See page 25.

the crank (E) in its lowest position. If the crank (E) must be lowered manually, carefully rotate the blades of the fan with a screwdriver. 2. Remove the front cover and screws (31, 32). 3. Remove the clamp holding the drain tube (126) to the displacement pump. 4. Unscrew the suction tube (42) from the pump, holding a wrench on the pump inmke valve to keep thepump from loosening. 5. Disconnect the pump outlet hose (47) from the displacement pump outlet nipple (46). I 6. Use a screwdriver to push aside the retaining spring 31 (35) at the top of the pump. Push the pin (20) out the rear. 7. Loosen the jam nut (38) with an adjustable wrench. Unscrew and remove the displacement pump. 8. Use a 3 / 1 6 hex key wrench to remove the four screws (33) and lockwashen (49) from the bearing housing. 9. Lightly tap the lower rear of the bearing housing housing. Then pull the bearing housing and the (27) with a plastic mallet to loosen it fmm the dtik connecting rod assembly (3) straight off the drive housing. 10. Inspect the crank (E) for excessive wear and replace pans es needed. 11. Evenly lubricate the inside of the bronze bearing in the bearing housing with high quality motor oil. Liberally pack the roller bearing in the connecting rod assembly (3) with bearing grease. 12. Assemble the connecting rod and bearing housing (27). 13. Clean the mating surfaces of the bearing and drive housings. 14. Align the connecting rod with the crank (E) and carefully align the locating pins in the drive housing' with the holes in the front cover (31). Push the bearing housing onto the drive housing or tap it into place with a plastic mellet. CAUTION 15. Install the screws (33) and lockwashen (49) on the bearing housing and tighten evenly. 16. Screw the displacement pump about 3/4 of the way into the bearing housing (2). Hold the pin (20) (3) and continue screwing in the pump until the pin up to the pin hole in the connecting rod assembly 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 (46) is facing back. Push the retaining spring Fig 26 (351 into the groove all the way around the connect- 70 ff-lb (94 Nm)-with a 2'in. open end wrench ing rod:Tighten the locknut (38) very tight-about and a light hammer. See Fig 25,' page 28. jury or property damage, in- cted through the air and result the pump, connecting rod or 17. Reinstall the front cover and screws (31,321. Recon- nect the suction tube (42) and pump outlet hose (471.

to get the crank (E) in its lowest position. To of the fan with a screwdriver. lower it manually, carefully rotate the blades 1. Remove'the'front cwer and screws (31,32). 2. Disconnect the pump outlet hose (47) from the displacement pump outlet nipple (46). 3. Remove the clamps holding the drain tube (1261 to the disp!acement pump. 4. Use a 3/16" hex key wrench to remove the-four screws (33) and lockwashen (49) from the bearing housing. 5. Lightly tap the lower rear of the bearing housing ( 2 7 1 with a plastic mallet to loosen it from the drive necting rod assembly straight off the drive housing. housing. Then pull the bearing housing and con- 6. Use a 1/4" hex key wrench to remove the two the drive .busing and the two screws (301 and screws (51 I and lockwashers (651 from the recess of lockwashers (651 from the rear of the motor front end bell (lb). 7. 30 Fig CAUPlON ' DO NOT allow the gear cluster (9) to fall when ed if dropped. The gear may stay engaged in removing the drive housing (2). It is easi& damag- either the front end bell or the drive housing. DO'NOT lose the thrust balls (10) located at each end of the gear cluster (91 or allow them to'fall be- with grease, usually stays in the shaft recesses, tween.gears. The ball, which is heavily covered 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 prematureiy. 8. Liberally apply bearing grease to the gear cluster place. (91. Check to be sure the thrust balls (IO) are in 9. Place the bronze-colored washer' (2a) on the shaft (2). Align the gears and push the new drive housing straight onto the front end bell and locating pins. + protruding from the big gear in the drive housing 13. Starting at Step 6 and working backwards, con- tinue to reassemble the sprayer. 820-408

Needle nose pliers Bearing grease . . 114" hex key wrench 1. Remove the clamps holding the drain tube 1126) to 2. Disconnect the pump outlet hose-(47) from the displacement pump outlet nipple (46). 3. Remove the screws (871 and presshre control cover (36) and disconnect the four motor leads. 4. Use an adjustable wench to loosen the conduit connector nut ( n a ) at the pressure control assembly (43). 5. Swing the conduit ( 2 2 1 away from the conduit elbow (77b). 6. Pull the motor leads through the elbow, one at a time. , the displacement pump. .. . 7. Loosen the nut of the connector (77a) at the motor and pull the conduit ( 2 2 1 a h y from the motor, then pull the leads through the conduit, one at a time. 8. Unscrew the connector elbow (77b) from the 9. Pull the wires through ttie elbow, one at a time. 10. Remove the front cover and screws (31,32). 11. Use a 114" hex key wrench to remove the two screws (51 ) and washers 165) from the recess of the drive housing, and the two screws (30) and washers ' ( 6 5 1 from the lower rear of the motor front end bell (lb). motor. . . 12. Remove the motor cover (14) and screws (32). 13. Use a plasn'c mallet to gently tap the displacement pump (39) from the rear to loosen the drive housing from the front end bell. Then pull the drive housing away from the end bell. CAUTION removing the drive housing (2). It is easiM damag DO NOT allow the gear- cluster (9) to fall when ed il dropped. The cluster may stay engaged in either the front end bell or the drive housing. end of the gear cluster (9) or allow them to fall DO NOT lose.the thrust balls (10) located at each between gaan. The ball, which is heavily covered with grease, usually stays in the gear recesses, but could be dislodged. If caught betwaen 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 114" hex key wrench to remove the two screws 141) and lockwashers (62) from the under- side of the motor mounting frame. Be sure to sup- port the motor to keep the sprayer from tipping. 15. Lift the motor assembly off the frame. 16. Place thenew motor assembly.on'the frame and align with the frame mounting holes. Install the screws (411 and lockwashen (62) tightly. 17. Liberally grease the gear cluster (9) and pinion gear bell. Check to be sure the thrust balls (10) are in (01 and pack all bearings in the motor front end place. 18. Place the bronzecolored washer (2) on.the.shaft protruding from the big gear in the drive housing (2). 19. Align the gears and push the drive housing (21 straight onto the front end bell and. locating pins. 20. Starting at Step 12 and working backwards, con- tinue to reassemble the sprayer. NOTE: Use a turning motion on the conduit when feeding wires through it. 21. Reinstall the conduit seal (138not shown) around the wires in the conduit elbow I 7 7 b ) at the pressure control to keep contaminants .from entering the pressure control. 22. Reinstall the motor cover and pressure'control cover. ! ,. : :Y . .. . ,.. . . . . .. . .. ... . .. . , . . . -..<&.*'

,,., :-?.i::;::> ...,... ~ ~ - ; . - : , : ~ : ~ ~ ~ , ~ ~ : : ~ - : . ~ ~ ~ - ~ ~ ~ . ~ ~ - ~ ~ . ~ : - PARTS LET ULTIMATE NOVAm 1m Model 82LM40 Includes kerns 1-139 REF PART DESCRIPTION NO. NO. . . QTY 1 820369 MOTOR, elecnic l b 820-453 .HOUSING, motor (front end bell) 1 1 2 8 2 0 3 7 1 DRIVE HOUSING ASSEMBLY IC 820379 .FAN, motor 1 2a 820-380 .WASHER. Includes item 2a. 2b 1 1 2b glo-405 .GREASE, gear, 10oz.(not shown) ' 1 6 820364 CART FRAME 3 820365 CONNECTING ROD ASSEMBLY 1 9 820373 GEAR CLUSTER 1 1 Includes items lb, IC REF PART DESCRIPTION NO. NO. am 58 820-401 CLIP, spring 59 820263 CAP, hub 60 820265 WHEEL 62 820310 LOCKWASHER, spring; 5/16" 63 820-452 BUSHING, 3/4 npt(mJ x 112 nptlf) €6 820-319 TAG. wamina 65 820273 LOCKWASHER, spring; 1/4" 2 2 2 2 5 1 2 1 67 n 820a RIVET. blind- 820014 THROAT SEAL LIQUID, 8 oz. 820322 CONNECTOR, conduit 820325 SCREW, machine,'oval head; thread forming; No. 10-24. Tvpe C; 0.5" long 820410 ELBOW, street; 1/4x 1/4 nptlrnxfl 820-398 MOUNTING BRACKET 820435 LABEL, identification 820037 LABEL, identification . 8 2 M x 3 6 LABEL. identification 'V7-762 LABEL, WARNING '"178934 LABEL, warning 820-486 CAPSCREW, button head socket; 820423 CIRCUIT BOARD, see page 35 €20415 ELBOW, female, XIo; 1/4 npt one 1/4-2oxo.6Y end 2 1 E4 E7 10 820457 BALL, 1/4"; stainless steel 14 820-372 MOTOR COVER ASSEMBLY; 20 820308 PIN 2 Includes labels 37,91 1 - 1 88 89 .. 22 820323 CONDUIT, electrical 27 820-359 BEARING HOUSING ASSEMBLY 8 in. 1 91 93 31 820-370 FRONT COVER; includes label &l 32 820307 SCREW, machine, filh; No. E32 x 1" 33 820-416 CAPSCREW. socket head: 318 x long 10 1 2 1 109 119 1.75" long . . 33 820305 SPRING. retainina 4 1 2 1 1 1 1 1. 1 1 2 1 1 1 1 1 121 123 36 820367 COVER,.pressure-contml; indudes 38 820353 NUT, hex; 1-5/8" thread 37 ~ 7 9 8 8 5 'LAEEL, 'Warning" 39 820356 PUMP, displacement; ssa separate four of item 87 and labels 93 & 109 1 1 1 1 2 0.5" lono 2 parts list on page 36 40 820258 LOCKWASHER, 5/16" 41' 820-417 CAPSCREW, socket head; 5/16 x 124 125 TEE. IFxFxM1 TEE, 1/4 npt(fJ 127 126 130 129 131 132 134 133 1m TUBE, drain CLIP. sDrina CLIP; ;brine STRAINER. fluid PLUG, tube HANDLE, frame SLEEVE, frame PIN, spring, straight SCREW, mach. pnh; No. 10-24 BUTTON, snap x 0.25" 4~ 820-399 TUBE. siction 43 820-361 PRESSURE CONTROL ASSEMBLY; 44 820-406 CAPSCREW. hex head 1/2 x 0.625" ~ 1 See separate parts list on page 37 1 long' ~~ ' . 2 45 820329 PLATE, designation 46 820421 NIPPLE, 1/4 npt(mJ x 114 npsm(mJ 2 1 47 820378 HOSE, grounded, nylon; 1/4" ID; cpld 1/4 npsmlf); 29" (715 mml Ig; 49 820315 LOCKWASHER, spring; 3/8" spring guard both ends 1 50 820-368 BALL VALVE, 1/4 npt(mbeJ 4 51 820-419 CAPSCREW, socket head; 1/4 x 2 55 E20-260 SPACER 2.75" long 7 1 135 136 82Q-m NUT- 137 820490 ' CAPSCREW. soc hd 138 820-491 SEAL, conduit (see page 3 4 1 139 820413 SCREW, machine, flat hd **Warning labeh.and tags supplied at no charge. See "How To Order Replacement Pam" on page 37. . .. . . ..~ "~ ~ . . -~ 68 820-261 AXLE 5? 820264 WASHER, plain; W8" . . ..I .. ,: .- -, , ::. .. i . . . . . , ,.: . :\. , ..,'. . . . . ..., . ...: , . . . : . , . ..~ . . . . 32820-108

MOTE: A circuit board is not induded with the pressure control assembly 820-361. Order part no. I@. no. 121, page 32) separately. the wiring diagram on page 35. The terminals listed in this parts list are shown in REF PART DESCRIPTION NO. NO. QT\I REF PART DESCRIPTION No. NO. 301 820-450 MICROSWITCH 303 820341 BOOT, ON/OFF switch 302 820342 ONlOFF SWITCH 304 820-433 GUARD, locking 305 82C-451 JUMPER WIRE 306 0-375 BARE PRESSURE CONTROL BOX 308 820362 BRIDGE, rectifier, SCR 309 820-366 CIRCUIT BREAKER 310 620-43 BOOT, circuit breaker 31 1 0-363 CORD, power supply 314 820-4ill TERMINAL, male 312 820-442 ADAPTER, terminal 316 W-444 .TERMINAL, male 318 820-437 TERMINAL, female 317 8 2 0 4 4 5 , TERMINAL, male 320 620-440 TERMINAL, female 319 820-435 TERMINAL, female 322 820430 TERMINAL, female 321 820-423 TERMINAL, male 324 62046 TERMINAL, female 323 0-439 TERMINAL, female 325 %&&a TERMINAL, ring 327 820448 LOCKWASHER, No. 8, internal 329 820434 TIP, pin, black plastic 328 820-431 BUSHING, Strain relief Includes items 302,303,304 34ElZkm3 1 1 1 1 1 1 1 1 3 2 1 1 3 1 1 1 QTY 330 820449 PIN 3 3 1 820427 SCREW, machine, flat head; 1 3 3 2 4 820425 - NUT, hex, m r , NO. 10-24 thd 2 3 3 820-426 LOCKWASHER, internal, shakaproof; 2 No. 10 2 No. 10-24 x-5/8" long 334 **178797 LABEL, WARNING 335 *'178035 LABEL. WARNING - 1 1. EO-W TERMINAL, mala 337 820-446 TERMINAL, female 1 1 3 4 1 820-424 SCREW, mach. slotted pan hd; No. 342 820-410 ELBOW; street; 1/4 n p t h x f ) 1 343 820-322 CONNECTOR, conduit 1 1 345 & W 1 NIPPLE, 114 npt(m) x 1/4 npsm 344 82fi4U NIPPLE, 1/4 npt 1 1 307 number in description refers to separate instruction manual. i . . . ,. 2 338 820447. TERMINAL, mala . . . . . 8x5116" long '> : "Warning labels and tags supplied at no charge. . . .. . . . See "How To Order Replacement Pam" on page 37. ..

Includes items 201 to 224 216- (Must be purchased separately) Repair Kit 820041 For pump packings and motor brushes. Includes all starred ( 1 Items In parts list below, plus two motor brushes. REF PART DESCRIPTION NO. NO. I 213f @ 217' '207 - .. . .. , I .. . .. . . . . a n REF PART DESCRIPTION 'NO. NO. a n . . 201 820-395 PLUG 1 214 820-388 NUT, hex 1 204 *820-277 BALL 203 '820-276 BALL 1 1 206 '820352 GASKET 1 218 '820-391 V-PACKING, plastic 3 207 '820-382 PIN, ball stop 2 1 203 *820-3&1 V-PACKING, leather 1 2 1 212 '820-386 GLAND, packing, female 1 ' 223 820-357 ROD, piston 1 215 820-389 GUIDE, ball 1 216 820354 CYLINDER 1 219 *E20492 WASHER, backup 205 . *820-381 SEAL, u-cup 1 217 *820-390 V-PACKING, plastic 3 .. :,.:... , :./ , .: .. ., ;. ... .::. . , . . . . , , . 2tQ1 *820-?83 V-PACKING, leather 220 W0-393 GLAND, packing . . . :.. . 221 820-394 NUT. packing/wet-cup 1 211 '620-385 GLAND, packing, male 222 820-365 VALVE, intake 1 213 *82a387 GLAND. packing, male 1 224 820-360 VALVE, piston 1 .. . . . . . ..: 1 , .: 36 820-408 See "How To Order Replacement parts" on page 37. ~ . ... .. . . .. . ..

ADDED, and DELETED parts. . . . . .. , ..: ASSEMBLV PART 'CHANGED. STATUS NO. NO. NAME REF PART 8p-040 ADDED (6) 32 820-307 Screw Sprayer DELETED (61 33 820-416 Screw OLD 820-268 Ball Valve ADDED 14) 57 820-264 Washer NEW 50 820-368 Ball Valve DELETED I l l 65 820273 Lockwasher DELETED 118 820407 Lockwasher OLD 820418 Capscrew NEW 119 8xl" capscrew OLD 820-409 Tee NEW 124 820-487 Tee IN ch; OLD NEW NEW ADDED ADDED ADDED ADDED 820-356 OLD PUmD NEW 820-392 Washer 219 KZC-492 Washer to series B TERCHANGEABtLITY NOTE The NEW part is intel angeable with the OLD part listed directly above it. QUANTITY CHANGE NOTE: The number in paren- theses in the Status column indicate the quantiq changed. HOW TO ORDER REPLACEMENT PART§ 1. To be sure you receive the correct replacement parts, kit or accessories, always give all qf the information requested in the chart below. 2. Check the parts l i i to identify the c o r n part number; do not use the ret. no. when ordering. 3. Order all parts from your nearest Graco distn'butor. I 6 &@it NUMBER PART PART DESCRIPTION ... . . . . i: .. ... . . ... . .. . . ~ . .

Cycles/Gallon (liter) : 200 (53) Operating Range : 5OR3GDO psi (35-210 bar) Maximum Delivery : .85 GPM (3.2 liter/min) Inlet Paint Strainer : 16 mesh, 1190 micron, Power Cord : No. 14 AWG, 3 wire, 8'6" 12.5 m) long Stainless Steel Screen, reusable Pump Inlet Size : 3/4 npt w/3Oo I.D. chamfer Fluid Outlet Size : Primary: 1/4 npsm(m) Secondary: 114 npt(m) Weight : ,100 Ib ( 4 5 Kg) approximately Wetted Parts : Aluminum; Delrin, Nitralloy, Nylon, Polyethylene, Polyurethane, Rubber impregnated leather, Stainless Steel, Tungaen Carbide, Zinc-plated Steel Dimensions : width: 22.5 1571.5 mm) Height: 28.0" (71 1.2 mm) Length: 26.0" (660.4 mm) . . .. .: .. . ..- :..: ., . . . .. . . . . ,:: ', . . . . . ,..: :; . ,. ... , .. .. .,. ... . .. . . .. ~