O'Brien FULTRONIC 1000, Owner'S Manual

Page 1: ...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 o...

Page 2: ...risk of fluid injection 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 holding the...

Page 3: ...eck the electrical resistance of your fluid hoses at least once a week If your hose does not have a tag on it which specifies the maximum electrical resis tance contact the hose supplier or manufactur...

Page 4: ...ccidentellement Diffuseur Le diffuseur du pistolet sert diviser le jet et r duire les ris ques d injection accidentelle quand l ajutage n est pas en pla ce V rifier le fonctionnement du diffuseur r gu...

Page 5: ...ans mise la terre ou avec une mise la terre incorrecte peut entra ner des risques pour votre sys t me Lisez aussi LES RISQUES D INCENDIE OU D EX PLOSION RISQUES D INCENDIE OU D EXPLOSION De l lectrici...

Page 6: ...stola inoperante El no hacerlo puede llevar al disparo imprevisto de la pistola Difusor El difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyecci n cuando no est instalada...

Page 7: ...uesta a tierra o con la puesta a tierra en malas condiciones Leer tambi n la informaci n sobre RIESGO DE INCENDIO O EXPLOSION m s arriba PELIGRO DE INCENDIO O EXPLOSION El flujo a alta velocidad del f...

Page 8: ...and main spray hose DO NOT use thread sealant on the hose and gun connections DO NOT install the spray tip until the system is primed 2 Fill the packing nut wet cup 1 3 full with Throat Seal Liquid s...

Page 9: ...unded metal pail and trigger the gun to relieve pressure 5 Engage the gun safety latch 6 Open the pressure drain valve having a container ready to catch the drainage Leave the pressure drain valve ope...

Page 10: ...ON and slowly increase the pres sure until the sprayer starts Keep the gun triggered until all air is forced out of the system and the paint flows freely from the gun Release the trigger and engage th...

Page 11: ...relieve pressure Loosen the tip guard re taining nut slowly to relieve any additional pressure and then remove the spray tip to clean it See the instructions supplied with your spray tip for cleaning...

Page 12: ...screen see manu al 307 273 Clean the screen Install the bowl only to flush it Close the pressure drain valve See Fig 12 1 Fig 12 1 PRESSURE DRAIN VALVE SCREEN SUPPORT FILTER BOWL 3 Pour one half gallo...

Page 13: ...e pattern depends on the fan pattern of the tip you choose Do not try to increase coverage by increasing the fluid pressure Use the lowest pressure needed for good results This prolongs the life of yo...

Page 14: ...n manual for tip cleaning Basic Mechanical Problems 1 Check for frozen or hardened paint in the pump 29 and or pressure control tube Us ing a screwdriver carefully try to rotate fan at back of motor b...

Page 15: ...ituting with a good bridge or performing bridge test See page 21 CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature will immediately burn out a good b...

Page 16: ...ctors 10 Replace damaged terminals and recon nect securely 11 Check circuit board 79 by substituting with a good board See page 26 11 Replace circuit board See page 26 Condition C Red lamps on Clear l...

Page 17: ...308 and leads and termi nals to motor Inspect wiring insulation and terminals for signs of overheating See page 27 7 Be sure male terminal blades are centered and firmly connected to female terminals...

Page 18: ...ge 39 6 2 Check connecting rod assembly 68 for dam age See page 30 2 Replace connecting rod assembly See page 30 3 Be sure crank in drive housing rotates plug in sprayer and turn on briefly to check T...

Page 19: ...ubstituting with a good bridge or by performing bridge test See page 21 CAUTION Do not check bridge until arma ture is determined to be good A bad armature will immediately burn out a good bridge 4 Re...

Page 20: ...rt Circuit Test Quickly turn the motor fan by hand If there are no shorts the motor will coast two or three revolutions before coming to a complete stop If the motor does not spin freely the armature...

Page 21: ...he continuity Fig 21 1 AC1 AC2 G2 G1 In Tests 1 2 and 3 there should be NO continuity In Tests 4 5 and 6 connect the and meter wires as in dicated check continuity then switch the meter wire con necti...

Page 22: ...tion be sure to properly mate connectors and never pull on a wire to disconnect it Pulling on a wire could loosen the connector from the wire CAUTION 7 Route wires carefully in the pressure control as...

Page 23: ...the holder so the lead is in the long slot of the holder Slide the terminal under the ter minal screw washer Ensure the motor lead is still con nected at the screw Refer to Fig 23 4 7 Place the sprin...

Page 24: ...electric shock Unplug the sprayer WARNING Refer to Fig 24 2 except where noted 1 Remove the pressure control cover 2 Use a needle nose pliers to disconnect the upper ter minal wire from the microswitc...

Page 25: ...d male connector is centered in the wrap around blade of the female connector when the connections are made Improper connections may cause the sprayer to malfunction Route all wires carefully to avoid...

Page 26: ...y close attention to where connections are made Refer to Fig 26 2 4 Pull out the black plastic tipped pin 34 Push the bottom of the circuit board toward the wall of the con trol and carefully slide th...

Page 27: ...etain it Refer to page 26 6 Remove the conduit 13f 7 Remove the three screws 28 and lockwashers 39 and nuts 40 located below the pressure control Re move the pressure control 8 Remove the screws 16 ho...

Page 28: ...se Part No 214 915 1 Follow the Pressure Relief Procedure Warning on page 22 2 Refer to the above list of tools and equipment needed Remove the plug 62a from the top of the fluid filter and install th...

Page 29: ...0 bar 17 Turn the pressure control knob to the minimum set ting Release the gun safety latch and trigger the gun into a grounded waste container until pressure is re lieved Engage the gun safety latch...

Page 30: ...rive housings 9 Align the connecting rod with the crank A and care fully align the locating pins in the drive housing with the holes in the bearing housing 8 Push the bearing housing onto the drive ho...

Page 31: ...ive housing 8 It is easily damaged if dropped The gear may stay engaged in either the front end bell or the drive housing DO NOT lose the thrust balls 8a 13h located at each end of the gear cluster 51...

Page 32: ...ter 51 to fall when re moving the drive housing 8 It is easily damaged if dropped The cluster may stay engaged in either the front end bell or the drive housing DO NOT lose the thrust balls 8a 13h loc...

Page 33: ...RAM 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 BLUE...

Page 34: ...ing nut 216 and plug 205 Refer to Fig 35 3 4 Use a plastic mallet to tap the piston rod 224 down then pull the rod out through the bottom of the cylinder 5 Remove the throat packings 207 213 and gland...

Page 35: ...a wrench to CAREFULLY tighten the nut 211 onto the piston rod to 19 ft lbs 25 N m Refer to Fig 35 2 Use two wrenches to maintain the alignment men tioned in Step 7 above Fig 35 2 224 211 TORQUE NUT O...

Page 36: ...and the outlet nipple 67 is straight back Push the retaining spring 65 into the groove all the way around the connecting rod Tighten the locknut 31 very tight about 70 ft lb 97 N m with a 2 in open e...

Page 37: ...213 178 965 V PACKING plastic 3 214 181 338 WASHER backup 1 215 178 969 GLAND female 1 216 179 809 NUT packing 1 218 185 213 SLEEVE cylinder 1 219 185 211 CYLINDER 1 220 185 214 GUIDE ball 1 221 178...

Page 38: ...lacement see parts on page 37 1 30 155 665 UNION adapter 3 8 npsm swivel x 3 8 npt m 1 REF NO PART NO DESCRIPTION QTY 31 178 941 NUT hex 1 5 8 unef 2B x 2 18 OD 0 25 thick 1 32 108 982 CONNECTOR tube...

Page 39: ...ER 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 LABEL...

Page 40: ...319 107 260 TERMINAL female 1 320 107 266 TERMINAL female 1 321 103 885 TERMINAL male 1 322 103 886 TERMINAL female 3 323 107 265 TERMINAL female 1 324 107 263 TERMINAL female 1 325 102 799 TERMINAL...

Page 41: ...18 405 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 32...

Page 42: ...bar Max Working Pressure FLUID FILTER KIT 223 857 Includes a fluid filter and all necessary mounting hardware REVERSE A CLEANt IV DriplesstTIP GUARD 220 422 Uses fluid pressure from the gun to remove...

Page 43: ...ize 1 4 npsm from fluid filter Wetted Parts Displacement Pump Carbon steel Polyurethane Polyethylene DelrinR Leather Filter Aluminum Carbon steel Stainless Steel NOTE DelrinR is a registered trademark...

Page 44: ...an authorized Graco distributor for verification of the claim If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the o...