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FULLER O’BRIEN PRO 1002 Owner's Manual

Airless paint sprayer 3.5 horsepower, gasoline-powered
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OWNER'S MANUAL
This manual contains IMPORTANT
INSTRUCTIONS and WARNINGS.
READ AND RETAIN FOR REFERENCE.
Model 223-630
3000 psi (210 bar) MAXIMUM WORKING PRESSURE

TABLE OF CONTENTS

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NOTE: This is an example of the DANGER label on your sprayer.
This label is available in other languages, free of charge.
See page 35 to order.
Spray painting, flushing or cleaning equipment with flammable liq-
uids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip-
ment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga-
rettes, arcs from connecting or disconnecting power cords or turn-
ing light switches on and off.
Failure to follow this warning can result in death or serious injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
THE O'BRIEN CORPORATION, 450 E. Grand Avenue, So. San Francisco, CA 94080
PRO 1002
3.5 Horsepower, Gasoline-Powered
2
8
9
10
11
12
13
14
. . . .
27
30
35
35
35
36
FIRE AND
EXPLOSION HAZARD
COPYRIGHT 1990, GRACO INC.
Airless Paint Sprayer
Liquids can be injected into the body by high pressure airless spray
or leaks - especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental trig-
gering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
"Surgical Treatment".
Failure to follow this warning can result in amputation or serious
injury.
308-029
Rev A
SKIN INJECTION
HAZARD

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Summary of Contents for FULLER O’BRIEN PRO 1002

  • Page 1: Table Of Contents

    OWNER’S MANUAL 308–029 Rev A This manual contains IMPORTANT INSTRUCTIONS and WARNINGS. READ AND RETAIN FOR REFERENCE. PRO 1002 Airless Paint Sprayer 3.5 Horsepower, Gasoline-Powered Model 223–630 3000 psi (210 bar) MAXIMUM WORKING PRESSURE TABLE OF CONTENTS Warnings .....

  • Page 2: Warnings

    WARNINGS HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals before operating the equipment. FLUID INJECTION HAZARD General Safety Safety Latch This equipment generates very high fluid pressure. Spray from Whenever you stop spraying, even for a moment, always set the the gun, leaks or ruptured components can inject fluid through gun safety latch in the closed or “safe”...
  • Page 3 MOVING PARTS HAZARD HOSE SAFETY Moving parts can pinch or amputate your fingers or other body High pressure fluid in the hoses can be very dangerous. If the parts. KEEP CLEAR of moving parts when starting or operating hose develops a leak, split or rupture due to any kind of wear , the sprayer.
  • Page 4 AVERTISSEMENT La pulvérisation à haute pression peut causer de blessures très graves. Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité. Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel. RISQUES D’INJECTION Consignes générales de sécurité Verrou de sécurité...
  • Page 5 RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL Consignes générales de sécurité TOUS LES TUYAUX FLEXIBLES DOIVENT AVOIR DES RES- SORTS SPIRALE DE PROTECTION AUX 2 BOUTS! Les spira- toute utilisation anormale de l’appareil du pulvérisation ou des les de protection contribuent à éviter la formation de pliures, de accessoires comme, par exemple, la mise sous une pression boucles ou de nœuds sur les tuyaux qui pourraient entraîner la excessive, les modifications de pièces, l’utilisation de produits...
  • Page 6 ADVERTENCIA EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES. SOLO PARA USO PROFESIONAL. RESPECTE LOS AVISOS DE ADVERTENCIA. Lea y entienda todo el manual de instrucciones antes de manejar el equipo. PELIGRO DE INYECCION DE FLUIDO Seguridad general Aparatos de seguridad de la pistola pulverizadora Este equipo general un fluido a una presión muy alta.
  • Page 7 PELIGRO POR MAL USO DEL EQUIPO Seguridad general Presión del sistema Cualquier mal uso del equipo pulverizador o los accesorios, tal Esta pulverizadora puede desarrollar 210 barías (3000 psi) de como sobre presurización, modificación de piezas, uso de ma- PRESION DE TRABAJO MAXIMA. Asegurar que todo el equipo teriales y productos químicos incompatibles, o utilización de pie- pulverizador y sus accesorios tienen la capacidad para aguan- zas dañadas o desgastadas, puede hacen que se rompan y...

  • Page 8: Setup

    SETUP WARNING CAUTION To reduce the risk of serious bodily injury To avoid damaging the pressure control, caused by static sparking, fluid injection or follow these precautions. over-pressurization and rupture of the hose or gun, be sure: 1. Always use grounded, flexible spray hose at least 50 feet (15.2 m) long.

  • Page 9: Fueling

    SETUP 5. Connect Hose and Gun to the 1/4 npsm(m) 8. Be sure your system is properly grounded fluid outlet. Be sure to remove the plastic cap before operating it. See FIRE OR EXPLO- plug from the outlet nipple. For more flexible SION HAZARD, page 3.

  • Page 10: Startup

    START UP NOTE: Refer to Fig 2 as you start the sprayer. 8. Disengage the gun safety latch. NOTE: When starting a sprayer that IS NOT 9. To start the pump: PRIMED, remove the spray tip. a. Open the pressure drain valve. 1.

  • Page 11: Maintenance

    START UP ENGINE ON/OFF SWITCH ENGINE OIL LIGHT PUMP ON/OFF STARTER ROPE SWITCH GAS FILL CAP PRESSURE THROTTLE ADJUSTING KNOB FUEL SHUTOFF LEVER CHOKE CLUTCH HOUSING AIR FILTER SPARK PLUG CABLE MUFFLER PRESSURE DRAIN VALVE PACKING NUT/ WET–CUP KEEP 1/3 FULL WITH TSL SUCTION TUBE Fig 2...

  • Page 12: Flushing Guidelines

    FLUSHING GUIDELINES WARNING CAUTION To reduce the risk of serious bodily injury, NEVER leave water in the sprayer if there is including fluid injection, follow the Pressure any chance it could freeze. Push the water Relief Procedure Warning on page 13 be- out with mineral spirits.

  • Page 13: Troubleshooting Guide

    TROUBLESHOOTING GUIDE WARNING Pressure Relief Procedure 5. Engage the gun safety latch. To reduce the risk of serious bodily injury, 6. Open the fluid pressure drain valve and including fluid injection, splashing in the eyes leave it open until you start the sprayer again.
  • Page 14 PROBLEM CAUSE SOLUTION Engine operates, but displacement Clutch worn or damaged Service. See page 24. pump doesn’t (continued) Pinion assembly worn or damaged Service. See page 22. Engine starts, but quits when gun is Oil level low, but not low enough for “Oil Add oil.
  • Page 15 PRESSURE CONTROL REPLACEMENT WARNING To reduce the risk of serious bodily injury, fol- low the Pressure Relief Procedure Warning on page 13 before repairing the sprayer. 1. Disconnect both hoses at the pressure control (63), while holding the elbows firmly. Note the original location of each hose.
  • Page 16 PRESSURE CONTROL CALIBRATION WARNING USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury, which can result from component rupture, electric shock, fire, explosion or moving parts. This procedure sets the sprayer to 2600–3000 NEVER attempt to increase the fluid outlet psi (182–210 bar) Maximum Working Pressure.
  • Page 17 BEARING HOUSING & CONNECTING ROD WARNING 9. Install the screws (73) and lockwashers (74) To reduce the risk of serious bodily injury, fol- on the bearing housing. Tighten the screws low the Pressure Relief Procedure Warning evenly to 175 in–lb (20 N.m). on page 13 before repairing the sprayer.
  • Page 18 DRIVE HOUSING WARNING CAUTION To reduce the risk of serious bodily injury, fol- DO NOT drop the gear cluster (18) when re- low the Pressure Relief Procedure Warning moving the drive housing. The gear cluster is on page 13 before repairing the sprayer. easily damaged.
  • Page 19 PINION, CLUTCH, CLAMP, FIELD & ENGINE If starting from the pinion housing , first follow If starting from the clutch , see page 21. Steps 1 to 6 of DRIVE HOUSING, on page 18. PINION HOUSING Removing the Pinion Housing WARNING To reduce the risk of serious bodily injury, fol- low the Pressure Relief Procedure Warning...
  • Page 20 PINION HOUSING 6. Press fit the following parts: 7. Install the shaft assembly (19a), pushing it to the shoulder of the housing (19n). Small bearing (19c) into the rear of the housing (19n). See DETAIL A in Fig 11. 8. Install the rings (19e and 19k). Large bearing (19d) to shoulder of the 9.
  • Page 21 CLUTCH NOTE: The clutch assembly (4) includes the ar- 5. The armature (4a) was removed when pulling mature (4a) and rotor (4b). The armature off the pinion housing. Remove the armature and rotor must be replaced together so from the pinion shaft. they wear evenly.
  • Page 22 ENGINE NOTE: The engine must be removed before the 3. Lift the engine and place it on a work bench. Field, Clamp or Clutch Housing can be re- 4. Remove the Field and Wiring Harness, moved. Clamp and Clutch Housing as instructed on 1.
  • Page 23 FIELD & WIRING HARNESS NOTE: Refer to Fig 16. 3. Pull the plastic caps (B) off the wire screws (33) in both places on the field. Loosen the 1. Remove the engine. See page 22. screws and release the wires (29). 2.
  • Page 24 CLAMP CLUTCH HOUSING NOTE: A standard steering wheel puller is re- NOTE: Refer to Fig 18. quired to remove the clamp. Two 1/4–28 x 1. Remove the four capscrews (8) and lockwash- 3 or 4 in. long screws are also needed. ers (9) which hold the clutch housing (2) to the NOTE: Refer to Fig 17.
  • Page 25 REASSEMBLY 1. Install the clutch housing (2), capscrews (8) and lockwashers (48) on the engine. See Fig 19. 2. Install the engine shaft key (13). See Fig 19. 3. Press the clamp (3) onto the engine shaft. Maintain the 1.41 in. +/– 0.01 (35.8 mm) dimension shown in Fig 20.
  • Page 26 REASSEMBLY 5. Place the engine (1) assembly on the cart. 7. Be sure the face of the armature (4a) is Align the mounting holes. Carefully guide the clean. Assemble the armature to the shaft in engine wire (D) and wiring harness (96) from the pinion housing (19).

  • Page 27: Displacement Pump Repair

    DISPLACEMENT PUMP WARNING To reduce the risk of serious bodily injury, fol- low the Pressure Relief Procedure Warning on page 13 before repairing the sprayer. CAUTION 221* Do not tip the sprayer back and rest it on the starter assembly when removing the pump. Oil will run into the combustion chamber and cause starting problems.
  • Page 28 DISPLACEMENT PUMP Assembling the pump. NOTE: Use repair kit 222–588, and use all the kit parts, for the best results. Reference numbers of the parts included in the kit are marked with an asterisk, (201*). NOTE: Soak the packings in oil, and coat the rod and inside of the cylinder with oil to prevent damage during assembly.
  • Page 29 DISPLACEMENT PUMP 7. Insert the piston rod assembly into the top of the sleeve. Install a gasket (202*) on top of CYLINDER the sleeve. 8. Slide the sleeve assembly into the bottom of the cylinder. Note that the tapered end of the sleeve is the bottom.

  • Page 30: Parts

    PARTS DRAWING – SPRAYER PRO 1002 Sprayer Model 223–630, Series A DANGER LABEL Ref No. 19 SEE PAGE 32 FOR PARTS LABEL 77,92 LABELS 8,48 16,11 95,96 Ref 90 308–029...
  • Page 31 PARTS LIST – SPRAYER Model 223–630, Series A NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 108–879 ENGINE, gasoline 222–011 GROUNDING CLAMP & WIRE 186–228 HOUSING, clutch 104–088 LOCKWASHER 183–517 CLAMP, mounting, rotor 100–078 SCREW, mach; slotted pan hd; No. 8 221–044 CLUTCH ASSEMBLY x 5/16”...
  • Page 32 PARTS LIST – PINION Ref No. 19 Pinion Housing Includes items 19a to 19n NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION NOTE: Items 19g to 19n are not included in a kit. Order 19a 221–043 PINION SHAFT ASSEMBLY them separately as needed. Includes items 19b to 19f 19g 105–684 BEARING, ball, large...
  • Page 33 PARTS DRAWING – PRESSURE CONTROL WIRING SCHEMATIC WHITE CLUTCH FIELD RECTIFIER ENGINE MAIN SWITCH – GROUND BLACK CLUTCH FIELD ADJUSTABLE PRESSURE WHITE SWITCH 314,305,306 REF 323 310,305 WHITE BLACK TOP VIEW 308–029...
  • Page 34 PARTS LIST & DRAWING – DISPLACEMENT PUMP Model 222–580, Series A Sleeved Displacement Pump Includes items 202 to 225 NO. PART NO. DESCRIPTION PTFE 202 108–526* PACKING, o–ring, 203 107–093* SEAL, u–cup, polyurethane 204 105–445* BALL; sst 205 179–810 PLUG 206 178–939* V–PACKING, leather 209*...

  • Page 35: Accessories

    ACCESSORIES Must be purchased separately . SPRAY HOSES DANGER LABELS 223–541 1/4” ID; 50 ft. (15 m); coupled 1/4 npsm (f); spring guards on both ends The English language DANGER label shown on 3300 psi (231 bar) Max. Working Pressure page 1 is also on your sprayer.

  • Page 36: Warranty

    THE GRACO WARRANTY AND DISCLAIMERS WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for twenty–four months from the date of sale and...
  • Page 37 Other Changes See PRO 1002 Sprayer Parts Drawing on the next page of this PCN. Replace steps 7 and 8 of the REASSEMBLY procedure on page 26 and add the note and steps 9 and 10 according to the last page of this PCN.
  • Page 38 PRO 1002 Sprayer Model 223–630, Series DANGER LABEL Ref No. 19 SEE PAGE 32 FOR PARTS LABEL 77,92 LABELS 8,48 16,11 95,96 Ref 90 6/2/95...
  • Page 39 Reassembly 7. Be sure the face of the rotor (4b) and the field is free of all oil and contaminants. Install the rotor, lockwashers (11) and capscrews (16). Torque the capscrews to 7 ft–lb (9.5 N.m). See Fig. 21. 8. Pull the engine recoil rope to assure the engine turns freely, and there is no friction between the rotor (4b) and the field (6).
  • Page 40 Notes 6/2/95...

This manual is also suitable for:

223-630

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