Owner’s manual 308–209 rev a fultronic 1000 airless paint sprayer 1 gpm, electric model 235–040, series a 3000 psi (210 bar) maximum working pressure table of contents warnings 2 . . . . . . . . . . . . . . . . . . . . . Setup 8 . . . . . . . . . . . . . . . . . . . . . . . . Startup 10 . . . . . . ...
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 this equipment generates very high fluid pressure. Spray from the gun, leaks or ru...
3 moving parts hazard moving parts can pinch or amputate your fingers or other body parts. Keep clear of moving parts when starting or operating the sprayer. Follow the pressure relief procedure on page 2 before checking or servicing any part of the spray- er, to prevent it from starting accidentall...
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 g...
5 risques en cas de mauvaise utilisation du material consignes générales de sécurité toute utilisation anormale de l’appareil du pulvérisation ou des accessoires comme, par exemple, la mise sous une pression excessive, les modifications de pièces, l’utilisation de produits chimiques et de matières i...
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 este equipo general un fluido a una presión...
7 peligro por mal uso del equipo seguridad general cualquier mal uso del equipo pulverizador o los accesorios, tal como sobre presurización, modificación de piezas, uso de materiales y productos químicos incompatibles, o utilización de piezas dañadas o desgastadas, puede hacen que se rompan y causen...
8 setup to reduce the risk of serious bodily injury caused by static sparking, fluid injection or over–pressurization and rupture of the hose or gun: 1. Ground the sprayer and all objects being sprayed. Read fire or explosion hazard on page 3. 2. Do not operate the spray gun without a tip guard in p...
9 setup operation pressure relief procedure to reduce the risk of serious bodily injury, fluid injection, splashing in the eyes or on the skin, injury from moving parts or electric shock, fol- low this procedure whenever you shut off the sprayer, check or service any part of the spray system, instal...
10 operation pump on/off switch pressure control knob pressure drain valve fig 10–1 ccw to lower pressure circuit breaker strainer suction tube 1. Prime the sprayer with paint. A. Close the pressure drain valve. B. Don’t install the spray tip yet! C. Put the suction tube into the paint. D. Turn the ...
11 operation 3. Adjusting the spray pattern (see fig 11–1.) a. Increase the pressure just until spray from the gun is completely atomized. To avoid excessive overspray and fogging, to decrease tip wear and to extend the life of the sprayer, use the lowest pressure needed for good atomization. B. If ...
12 flushing guidelines when to flush never leave water in the sprayer if there is the slightest chance it could freeze. Flush out the water with mineral spirits. If water freezes in the pressure control tube, it prevents the sprayer from being started and causes seri- ous damage to the pressure cont...
13 application methods hold the gun perpendicular to the surface. Keep the gun at an even 12 to 14 in. (300–356 mm) from the surface you are spraying. See fig 13–1. Begin moving the gun horizontally at a steady rate. Start the spray stroke off the target surface and pull the trigger as the gun is mo...
14 troubleshooting guide warning pressure relief procedure to reduce the risk of serious bodily injury, including fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, al- ways follow this procedure whenever you shut off the sprayer, when...
15 type of problem what to check if check is ok, go to next check what to do when check is not ok refer to this column 1 . Check leads from bridge (308) to motor to be sure they are securely fastened and properly mated. 1. Replace loose terminals; crimp to leads. Be sure male terminal blades are str...
308-209 16 motor won’t operate . Type of problem what to check if check is ok, go to next check what to do when check is not ok refer to this column condition b (continued) both lamps off 6. Check motor thermal cutout switch. Connect volt meter to tp6 female and tp9 female. Plug in sprayer and turn ...
17 low output type of problem what to check if check is ok, go to next check what to do 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. See your separate gun or tip manual. 2. Check to see that pump doe...
18 no output type of problem what to check if check is ok, go to next check what to do when check is not ok refer to this column motor runs and pump strokes 1. Check paint supply. 1. Refill and reprime pump. 2. Check for clogged intake strainer. 2. Remove and clean, then reinstall. 3. Check for loos...
19 motor is hot and runs intermittently type of problem what to check if check is ok, go to next check what to do when check is not ok refer to this column 1. Determine if sprayer was operated at high pressure with small tips, which causes low motor rpm and excessive heat build up. 1. Decrease press...
20 spin test before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Warning for checking armature, motor winding and b...
21 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. Perform all tests in the chart. If the bridge fails...
General repair information pressure relief procedure to reduce the risk of serious bodily injury, including fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when checkin...
23 motor brush replacement note: replace the brushes when they have worn to less than 1/2 in. Refer to step 1, fig 23–3. Note that the brushes wear differently on each side of the motor, so check them both. Brush repair kit 220–853 is available. Before doing this procedure, follow the pressure relie...
24 power supply cord replacement before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Warning refer to fig 24–1. 1. ...
25 bridge rectifier replacement before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Warning note: the most common c...
26 circuit board replacement before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Warning refer to fig 26–1 and 26–2...
27 pressure control replacement before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Warning refer to fig 27–1 excep...
28 pressure control adjustment this procedure sets the sprayer to3000 psi (210 bar) maximum working pressure and sets the overpressurization switch (microswitch) to approxi- mately 3600 psi (242 bar). Perform this procedure whenever the pressure control assembly is removed and reinstalled or replace...
29 pressure control adjustment maximum working pressure adjustment 13. Turn the sprayer off . Disengage the gun safety latch. Trigger the gun into a grounded waste container until pressure is relieved. Engage the gun safety latch. 14. Use the 3/8 in. Nut driver to turn the pressure adjust- ment nut ...
30 bearing housing & connecting rod replacement before doing this procedure, follow the pressure relief procedure warning on page 22 to reduce the risk of a fluid injection injury , splashing in the eyes or in the skin, injury from moving parts or elec- tric shock. Unplug the sprayer! Warning fig 30...
31 drive housing replacement before doing this procedure, follow the pressure relief procedure warning on page 22 to reduce the risk of a fluid injection injury , splashing in the eyes or in the skin, injury from moving parts or elec- tric shock. Unplug the sprayer! Warning refer to fig 31–1. 1. Rem...
32 motor replacement before doing this procedure, follow the pressure relief procedure warning on page 22 to reduce the risk of a fluid injection injury , splashing in the eyes or in the skin, injury from moving parts or elec- tric shock. Unplug the sprayer! Warning refer to fig 33–1 unless otherwis...
33 fig 33–1 detail shows position of conduit seal (21) in conduit connector (345) 21 345 wiring diagram 10 9 55 24 48 47 8a 8b 51 13h 8c 9 23 49 66 a 9 58 liberally apply grease 8 2 69 1 5 note: pressure con- trol does not have to be removed for this procedure. 38 59 40 39 b ac1 ac2 g1 g2 _ + white ...
34 displacement pump repair warning before doing this procedure, follow the pressure relief procedure warning 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. Unplug the sprayer! Note: packing repair kit 222...
35 displacement pump repair 3. Tighten the packing retaining nut (211) onto the piston valve (222) to 19 ft–lb (27 n.M). Note the alignment of the piston (222) to the packing retainer nut (21 1). Maintain this alignment through steps 5, 6 and 7. 4. Place the ball (225) on the piston valve (222). Ref...
36 displacement pump repair cylinder piston assembly sleeve tapered end fig 36-1 12. Slide the sleeve/piston rod assembly int o the bottom of the cylinder . This is to prevent packing damage during reassembly . Refer to fig 36–1. 13. Screw down the cylinder locknut (31) until it is finger tight at t...
37 parts drawing & list – displacement pump model 222–580, series a sleeved displacement pump includes items 202 to 225 ref no. Part no. Description qty 202 110–165* packing, o–ring, r 2 203 107–093* seal, u–cup, polyurethane 1 204 105–445* ball; sst 1 205 179–810 plug 1 206 178–939* v–packing, leat...
38 parts list fultronic 1000 sprayer model 235–040, series a includes items listed below ref no. Part no. Description qty 1 110–883 capscrew; mach; cross recess pnh; 8–32 unc–2a x 0.75” 4 2 186–378 handle, lift 1 3 110–847 bushing, snap 1 4 110–037 screw,mach; cross recess pan hd; 10–24 unc x 0.38” ...
39 parts drawing 1 69 2 55 fultronic 1000 sprayer model 235–040, series a 75 id label danger label danger label 77 this side 76 other side id label 15 23 13 38 59 13a 13f 20 42 81 44 24 40 9 58 3 26 67 31 29 12 37 63 65 27 37 36 57 41 45 25 5 56 68 66 9 10 49 9 35 47 48 16 70 4 18 64 ref 26 82 id la...
40 parts drawing & list – pressure control pressure control assembly 220–455 includes all items listed below, except the terminals. The terminals are included with the circuit board (item 79). The terminals listed in this parts list are shown on the wir- ing diagram on page 41. Part numbers for item...
41 wiring diagram circuit board 218–405, 5 wires ac1 ac2 g1 g2 _ + white blue yellow red green black white thermal switch ground wire black power supply cord motor 336 ref 14,34 13b 323 320 302 317 318 316 324 306 303 309 312 321 (13g) 322 337 308 323 323 314 319 13c 13b.
42 accessories must be purchased sep arately french 185–955 spanish 185–962 german 186–042 greek 186–046 korean 186–050 english 185–954 apply other language in this area on other side of shroud danger labels the english language danger label shown on page 1 is also on your sprayer. If you have paint...
43 technical data power requirements 120 vac, 60hz, . . . . . . . . . . . . . . . . . . . . 1 phase, 15 amp minimum working pressure range 0–3000 psi (0 – 210 bar) . . . . . . . . . Cycles/gallon (liter) 200 (53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum delivery 0.85 gpm (3.2 ...
44 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...
