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O'Brien FULTRONIC 1000 Owner's Manual

Series a airless paint sprayer
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OWNER'S MANUAL
This manual contains IMPORTANT
INSTRUCTIONS and WARNINGS.
READ AND RETAIN FOR REFERENCE.
FULTRONIC 1000 Airless Paint Sprayer
Model 235-040, Series A
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 42 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
cigarettes, arcs from connecting or disconnecting power cords or
turning 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
1 GPM, Electric
2
8
10
11
12
13
14
21
37
42
43
43
44
FIRE AND
EXPLOSION HAZARD
COPYRIGHT 1992, GRACO INC.
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.A void accidental
triggering 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.
308-209
Rev A
SKIN INJECTION
HAZARD

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  • Page 1: Table Of Contents

    OWNER’S MANUAL 308–209 Rev A This manual contains IMPORTANT INSTRUCTIONS and WARNINGS. READ AND RETAIN FOR REFERENCE. FULTRONIC 1000 Airless Paint Sprayer 1 GPM, Electric Model 235–040, Series A 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 Whenever you stop spraying, even for a moment, always set from the gun, leaks or ruptured components can inject fluid the 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 High pressure fluid in the hoses can be very dangerous. If the body parts. KEEP CLEAR of moving parts when starting or hose develops a leak, split or rupture due to any kind of wear, operating 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 RESSORTS SPIRALE DE PROTECTION AUX 2 BOUTS! toute utilisation anormale de l’appareil du pulvérisation ou des Les spirales de protection contribuent à éviter la formation de accessoires comme, par exemple, la mise sous une pression pliures, de boucles ou de nœuds sur les tuyaux qui pourraient 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, Esta pulverizadora puede desarrollar 210 barías (3000 psi) de tal como sobre presurización, modificación de piezas, uso de PRESION DE TRABAJO MAXIMA. Asegurar que todo el materiales y productos químicos incompatibles, o utilización equipo pulverizador y sus accesorios tienen la capacidad pa- de piezas dañadas o desgastadas, puede hacen que se...

  • Page 8: Setup

    SETUP WARNING CAUTION To reduce the risk of serious bodily injury To avoid damaging the pressure control, fol- caused by static sparking, fluid injection or low these precautions. over–pressurization and rupture of the hose 1. Always use flexible, grounded hose at or gun: least 50 feet (15.2 m) long.
  • Page 9 SETUP FLUID FILTER HOSE RACK PACKING NUT/ WETCUP KEEP FILLED ON/OFF SWITCH WITH TSL SUCTION TUBE STRAINER PRESSURE CONTROL KNOB PRESSURE DRAIN VALVE PUMP 1/4 NPSM(M) FLUID OUTLET DO NOT INSTALL A SHUT OFF DEVICE HERE Fig 9–1 OPERATION WARNING Pressure Relief Procedure 5.
  • Page 10 OPERATION ON/OFF SWITCH CIRCUIT BREAKER SUCTION TUBE STRAINER PRESSURE CONTROL KNOB CCW TO LOWER PRESSURE PUMP PRESSURE DRAIN VALVE Fig 10–1 1. Prime the sprayer with paint. NOTE: If the pump is hard to prime, open the valve. When fluid comes from the valve, close it.

  • Page 11: Maintenance

    OPERATION 3. Adjusting the spray pattern (See Fig 11–1.) WARNING To reduce the risk of serious bodily injury a. Increase the pressure just until spray from from injection, use extreme caution when the gun is completely atomized. To avoid cleaning or changing spray tips. If the spray excessive overspray and fogging, to tip clogs while spraying, engage the gun decrease tip wear and to extend the life of...

  • Page 12: Startup

    FLUSHING GUIDELINES When To Flush 3. Changing from water-base to oil-base paint. Flush with warm, soapy water, and then CAUTION flush with mineral spirits. NEVER leave water in the sprayer if there is 4. Changing from oil-base to water-base the slightest chance it could freeze. Flush out paint.

  • Page 13: Application Techniques

    APPLICATION METHODS Hold the gun perpendicular to the surface. Keep The best way to control the rate of coverage is the gun at an even 12 to 14 in. (300–356 mm) with the gun tip size. A small tip orifice applies less from the surface you are spraying.

  • Page 14: Troubleshooting Guide

    TROUBLESHOOTING GUIDE WARNING Pressure Relief Procedure 4. Disengage the gun safety latch. Hold a metal part To reduce the risk of serious bodily injury, including fluid of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. injection, injury from splashing fluid or solvent in the 5.
  • Page 15 MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1 . Check leads from bridge (308) to motor to be 1.
  • Page 16 MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Condition B (continued) 6. Check motor thermal cutout switch. Connect 6. Allow motor to cool. Correct cause of over- volt meter to TP6 female and TP9 female.
  • Page 17 LOW OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warn- ing then replace tip.

  • Page 18: Excessive Pressure Fluctuations

    NO OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Motor runs and pump strokes 1. Check paint supply. 1. Refill and reprime pump. 2.

  • Page 19: Electrical Short

    MOTOR IS HOT AND RUNS INTERMITTENTLY TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1. Determine if sprayer was operated at high 1.

  • Page 20: Spin Test

    SPIN TEST WARNING Before doing this procedure, follow the Pressure Relief Procedure W arning on page 22 to reduce the risk of a fluid injection injury , splashing in the eyes or on the skin, injury from moving parts, or electric shock.

  • Page 21: Repair

    BRIDGE TEST Remove the bridge from the pressure control box and per- form this test to determine if the bridge is functional. Refer to BRIDGE RECTIFIER REPLACEMENT, page 25. Use a continuity tester , such as multi–meter set on the X1 ohms scale.

  • Page 22: General Repair Information

    GENERAL REPAIR INFORMATION WARNING 7. Route wires carefully in the pressure control assem- bly, guiding them through the legs of the U–shaped Pressure Relief Procedure bourdon tube. This is to avoid interfering with the To reduce the risk of serious bodily injury, including bourdon tube, which moves as the pressure setting fluid injection, injury from splashing fluid or solvent changes, and to avoid pinching the wires between the...

  • Page 23: Motor Brush Replacement

    MOTOR BRUSH REPLACEMENT NOTE: Replace the brushes when they have worn to less SPRING than 1/2 in. Refer to STEP 1, Fig 23–3. Note that HOOK the brushes wear differently on each side of the motor, so check them both. Brush Repair BRUSH 220–853 is available.

  • Page 24: Power Supply Cord Replacement

    POWER SUPPLY CORD REPLACEMENT WARNING Before doing this procedure, follow the Pressure Relief Procedure W arning on page 22 to reduce the risk of a fluid injection injury , splashing in the eyes or on the skin, injury from moving parts, or electric shock.

  • Page 25: Bridge Rectifier Replacement

    BRIDGE RECTIFIER REPLACEMENT WARNING 5. Install the front screw (331), lockwasher (333) and nut (332). Make sure the bridge is flush with the side of the Before doing this procedure, follow the Pressure box and tighten the screws securely. Relief Procedure W arning on page 22 to reduce the risk of a fluid injection injury , splashing in the CAUTION eyes or on the skin, injury from moving parts, or...

  • Page 26: Circuit Board Replacement

    CIRCUIT BOARD REPLACEMENT WARNING 6. Reconnect all wires. Refer to the wiring diagram in Fig 26–2. Ease the pin (34) into the retainer. Before doing this procedure, follow the Pressure Relief Procedure W arning on page 22 to reduce É É É É Ç Ç Ç Ç É É É É É É É É the risk of a fluid injection injury , splashing in the PRESSURE CONTROL KNOB...

  • Page 27: Pressure Control Replacement

    PRESSURE CONTROL REPLACEMENT 6. Remove the conduit (13f). WARNING Before doing this procedure, follow the Pressure 7. Remove the three screws (28) and lockwashers (39) Relief Procedure W arning on page 22 to reduce and nuts (40) located below the pressure control. Re- the risk of a fluid injection injury , splashing in the move the pressure control.

  • Page 28: Pressure Control Adjustment

    PRESSURE CONTROL ADJUSTMENT WARNING USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT 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 to3000 psi (210 bar) NEVER try to increase the sprayer’s maximum work- MAXIMUM WORKING PRESSURE and sets the ing pressure of 3000 psi (210 bar ) by performing these...
  • Page 29 PRESSURE CONTROL ADJUSTMENT Maximum Working Pressure Adjustment 17. Turn the pressure control knob to the minimum set- ting. Release the gun safety latch and trigger the gun 13. Turn the sprayer OFF . Disengage the gun safety into a grounded waste container until pressure is re- latch.
  • Page 30 BEARING HOUSING & CONNECTING ROD REPLACEMENT WARNING 7. Assemble the connecting rod (68) and bearing hous- ing (8). Before doing this procedure, follow the Pressure Relief Procedure Warning on page 22 to reduce 8. Clean the mating surfaces of the bearing and drive the risk of a fluid injection injury , splashing in the housings.

  • Page 31: Drive Housing Replacement

    DRIVE HOUSING REPLACEMENT WARNING CAUTION Before doing this procedure, follow the Pressure DO NOT allow the gear cluster (51) to fall when re- Relief Procedure Warning on page 22 to reduce moving the drive housing (8). It is easily damaged the risk of a fluid injection injury , splashing in the if dropped.

  • Page 32: Motor Replacement

    MOTOR REPLACEMENT WARNING CAUTION Before doing this procedure, follow the Pressure DO NOT allow the gear cluster (51) to fall when re- Relief Procedure Warning on page 22 to reduce moving the drive housing (8). It is easily damaged the risk of a fluid injection injury , splashing in the if dropped.

  • Page 33: Wiring Diagram

    WIRING DIAGRAM DETAIL Shows position of conduit seal (21) in BLUE conduit connector WHITE (345) YELLOW BLACK MOTOR LEADS BLACK WHITE MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD LIBERALLY APPLY GREASE NOTE: Pressure Con- trol does not have to be removed for this procedure.

  • Page 34: Displacement Pump Repair

    DISPLACEMENT PUMP REPAIR WARNING 2. Clean and inspect the parts for wear or damage, re- placing parts as needed. Always use the new o–ring Before doing this procedure, follow the Pressure included in the Repair Kit. If no further service is need- Relief Procedure Warning on page 22 to reduce ed, reassemble the intake valve.
  • Page 35 DISPLACEMENT PUMP REPAIR 3. Tighten the packing retaining nut (211) onto the piston 10. Coat the piston rod and packings with oil. Carefully valve (222) to 19 ft–lb (27 N.m). slide the assembly INTO THE TOP OF THE SLEEVE. Note the alignment of the piston (222) to the packing NOTE: The tapered end of the sleeve is the bottom of it.
  • Page 36 DISPLACEMENT PUMP REPAIR WARNING Be sure the retaining spring (65) is firmly in the groove of the connecting rod, all the way around, to CYLINDER prevent it from working loose due to vibration. Refer to Fig 36–2. If the pin works loose, it or other parts could break off due to the force of the pumping action.

  • Page 37: Parts

    PARTS DRAWING & LIST – DISPLACEMENT PUMP Model 222–580, Series A Sleeved Displacement Pump Includes items 202 to 225 NO. PART NO. DESCRIPTION PTFE PTFE PTFE 110–165* PACKING, o–ring, 107–093* SEAL, u–cup, polyurethane 105–445* BALL; sst 179–810 PLUG 1 178–939* V–PACKING, leather 178–940* V–PACKING, leather...

  • Page 38: Parts List

    PARTS LIST FULTRONIC 1000 Sprayer PART NO. DESCRIPTION Model 235–040, Series A 178–941 NUT, hex; 1 5/8 unef–2B x 2.18 OD; Includes items listed below 0.25” thick 108–982 CONNECTOR, tube PART NO. DESCRIPTION 110–883 CAPSCREW; mach; cross recess pnh; 179–945 ADAPTER, elbow, special;...

  • Page 39: Parts Drawing

    PARTS DRAWING FULTRONIC 1000 Sprayer Model 235–040, Series A THIS SIDE OTHER SIDE ID LABEL DANGER LABEL ID LABEL DANGER LABEL ID LABEL, OUTSIDE ID LABEL, INSIDE Ref 26...
  • Page 40 PARTS DRAWING & LIST – PRESSURE CONTROL PRESSURE CONTROL ASSEMBLY 220–455 Includes all items listed below, except the terminals. Part numbers for items 7,13b,13c,13g,14,21,29,34,79 are shown in the drawings below and on page 41 are The terminals are included with the circuit board (item 79). given on page 38.
  • Page 41 WIRING DIAGRAM CIRCUIT BOARD 218–405, 5 WIRES BLUE WHITE (13g) YELLOW BLACK Ref 14,34 13b 323 BLACK WHITE MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD...

  • Page 42: Accessories

    ACCESSORIES MUST BE PURCHASED SEP ARATELY REVERSE-A-CLEAN Dripless TIP GUARD 220–422 Uses fluid pressure from the gun to remove clogs without removing the tip guard to spray tip. (As shown DANGER LABELS on guns, below .) Requires SwitchTip , purchased The English language DANGER label shown on separately.

  • Page 43: Technical Data

    TECHNICAL DATA DIMENSIONS Weight (dry w/o packaging) ....100 lb (45 Kg) Power Requirements ....120 VAC, 60Hz, Height .

  • Page 44: 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 workman- ship 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 on EM and GM sprayers or power train on EH &...

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235–040 a

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