Owner`s manual

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OWNER’S MANUAL

820–047

Rev D

Supersedes C and PCN D

U.S.

TENT NO. 4,323,741, 4,397,610

PATENTED 1983, CANADA

AND OTHER PATENTS PENDING

, Portable, Electric

ULTIMATE NOVA1000 AIRLESS

AINT SPRAYER

3000

psi (210 bar) MAXIMUM WORKING PRESSURE

Model 820–045, Series C

Basic

sprayer on Upright cart without

hose or gun

The SHERWIN-WILLIAMS COMPANY, CLEVELAND, OHIO 44115

This manual contains Important Warnings

and

Instructions. Read the manual and

keep

for reference.

Liquids

can be injected into the body by high

pressure airless spray

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 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

reatment”.

Failure to follow this warning can result in amputation or serious

injury.

FIRE

AND

EXPLOSION HAZARD

SKIN INJECTION

HAZARD

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

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

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

Summary of content (44 pages)

PAGE 1
OWNER’S MANUAL 820–047 Rev D Supersedes C and PCN D This manual contains Important Warnings and Instructions. Read the manual and keep it for reference. U.S. PATENT NO. 4,323,741, 4,397,610 PATENTED 1983, CANADA AND OTHER PATENTS PENDING 1 HP, Portable, Electric ULTIMATE NOVA 1000 AIRLESS PAINT SPRAYER 3000 psi (210 bar) MAXIMUM WORKING PRESSURE Model 820–045, Series C Basic sprayer on Upright cart without hose or gun NOTE: This is an example of the DANGER label on your sprayer.
PAGE 2
TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AVERTISSEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADVERTENCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Startup . . . . . . . . . . .
PAGE 3
TRIGGER SAFETY SHOWN ENGAGED MOTOR PRESSURE ADJUSTING KNOB DRIVE ASSEMBLY SECONDARY HOSE OUTLET CIRCUIT BREAKER BUTTON ON/OFF SWITCH PRESSURE CONTROL PAIL HANGER FLUID OUTLET DISPLACEMENT PUMP PRESSURE DRAIN VALVE Fig 3–1 820–047 3
PAGE 4
SAFETY WARNINGS HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS Read and understand all instruction manuals before operating equipment. FLUID INJECTION HAZARD General Safety This equipment generates very high fluid pressure. Spray from 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.
PAGE 5
HOSE SAFETY 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 4 before checking or servicing any part of the sprayer, to prevent it from starting accidentally.
PAGE 6
AVERTISSEMENT La pulvérisation à haute pression peut causer des 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 generales de sécurité Verrou de sécurité Cet appareil produit un fluide à très haute pression.
PAGE 7
RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIEL Consignes générales de sécurité Pression Toute utilisation anormale de l’appareil de 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 incompatibles et l’utilisation de pièces usées ou abîmées peut causer des dégâts à l’appareil ou des ruptures de pièces et entraîner une injection de liquide ou d’autrès blessures sérieuses, un incendie,
PAGE 8
ADVERTENCIA EL ROCIADO a ALTA PRESIÓN PUEDE CAUSAR GRAVES LESIONES. SOLO PARA USO PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA. Lea y entienda todo el manual de instrucciónes antes de manejar el equipo. PELIGRO DE INYECCIÓN DE FLUIDO Seguridad general Aparatos de seguridad de la pistola pulverizadora Este equipo genera un fluido a una presión muy alta.
PAGE 9
PELIGRO POR MAL USO DEL EQUIPO Seguridad general Presión del sistema Cualquier mal uso del equipo pulverizador o los accesorios, tal como sobre presurización, modificación de piezás, uso de matériales y productos quimicos incompatibles, o utilización de piezás dañadas o desgastadas, puede hacen que se rompan y causen la inyección de fluido u otras lesiones corporales graves, incendio, explosión o dañon a la propiedad.
PAGE 10
SETUP 1. Prepare the paint. Remove any skin that may have formed. Stir the paint thoroughly. Strain the paint through a fine nylon mesh bag to remove particles that could clog the filter, if used, or the spray tip. WARNING Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious bodily injury and property damage. See the warning section FIRE OR EXPLOSION HAZARD on page 5 for more detailed grounding instructions.
PAGE 11
OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying. 6.
PAGE 12
SHUTDOWN AND CARE NOTE: The Pressure Relief Procedure is given on page 11. 5. For very short shutoff periods, leave the suction tube in the paint, relieve pressure, and clean the spray tip. 1. Keep the packing nut/wet–cup 1/3 full of TSL at all times to help prevent fluid buildup on the piston rod and premature wear of packings. Relieve pressure before adding TSL. 6. Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing. See page 13.
PAGE 13
FLUSHING GUIDELINES 5. Storage. When To Flush 1. New Sprayer. This sprayer was factory tested in lightweight oil which was left in to protect pump parts. Before using water–base paint, flush with mineral spirits, and then soapy water, and then clean water. Before using oil–base paint, flush with mineral spirits. 2. Changing Colors. Flush with a compatible solvent such as mineral spirits or water. 3. Changing from water–base to oil–base paint. Flush with warm, soapy water, and then mineral spirits. 4.
PAGE 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, always follow this procedure whenever you shut off the sprayer, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying. 1. Engage the gun safety latch. 2. Turn the ON/OFF switch to OFF. 3.
PAGE 15
MOTOR WON’T OPERATE TYPE OF PROBLEM Diagnosing circuit board indicator lamps. The normal condition is red lamp on, clear lamp on when board is telling pump to run. Follow Pressure Relief Procedure Warning. Remove gun from hose. Remove pressure control cover. Check for faulty condition of circuit board lamps. Condition A Both lamps on; pump won’t operate and motor is not running WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK refer to this column 1.
PAGE 16
MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check Condition B (continued) 6. Check motor thermal cutout switch. Connect 6. Allow motor to cool. Correct cause of overheating. If switch remains open after motor volt meter to TP6 female and TP9 female. Plug in sprayer and turn on. Meter should read cools, check continuity between TP9 female and TP10 with ohmmeter. If open, re105 to 125 VAC. Turn off and unplug sprayer. place motor.
PAGE 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 Warning then replace tip. See your separate gun or tip manual. 2. Check to see that pump does not continue to 2. Service pump. See pages 35–37. stroke when gun trigger is released. Plug in and turn on sprayer. Prime with paint. Trigger gun momentarily, then release and engage safety latch.
PAGE 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 loose suction tube or fittings. 3. Tighten; use thread sealant or sealing tape on threads if necessary. 4. Check to see if intake valve ball and piston 4. Remove intake valve and clean.
PAGE 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 1. Decrease pressure setting or increase tip pressure with small tips, which causes low size. motor RPM and excessive heat build up. 2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible. is located is no more than 90_F and sprayer is not located in direct sun. 3.
PAGE 20
SPIN TEST 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! For checking armature, motor winding and brush electrical continuity. 14 Setup F Remove the drive housing. See page 31. Remove the pressure control cover. Remove the motor shield (14). Remove the fan cover (F) and the inspection covers (J). See Fig 20–1.
PAGE 21
BRIDGE TEST Remove the bridge from the pressure control box. Perform this test to determine if the bridge is functional. See 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 even one test, it must be replaced. Fig 21–1 shows the position of the wires on the bridge. Using the chart at the right, connect the meter wires as indicated by the black dots for each test, and then check the continuity.
PAGE 22
GENERAL REPAIR INFORMATION 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, always follow this procedure whenever you shut off the sprayer, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying. 1. 2. 3. 4. Engage the gun safety latch. Turn the ON/OFF switch to OFF.
PAGE 23
MOTOR BRUSH REPLACEMENT NOTE: Replace the brushes when they have worn to less than 1/2 in. See STEP 1, Fig 23–3. Note that the brushes wear differently on each side of the motor, so check them both. Brush Repair Kit 820–536 is available. HOOK SPRING BRUSH 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.
PAGE 24
POWER SUPPLY CORD REPLACEMENT 303 WARNING 308 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! See Fig 24–1. 1. Remove the pressure control cover. 2.
PAGE 25
BRIDGE RECTIFIER REPLACEMENT 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: The most common cause of bridge failure is a faulty motor. Check the motor before replacing the bridge to prevent damaging the new bridge. 4.
PAGE 26
CIRCUIT BOARD REPLACEMENT 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! 6. Reconnect all wires. Refer to the wiring diagram in Fig 26–2. Ease the pin (95) into the retainer. PRESSURE CONTROL KNOB CIRCUIT BOARD Refer to Fig 26–1 and 26–2. 95 1. Remove the pressure control cover. T 2.
PAGE 27
PRESSURE CONTROL REPLACEMENT 6. Remove the conduit (22). 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! 7. Remove the three screws (44) and lockwashers (40) and nuts (41) located below the pressure control. Remove the pressure control. 8.
PAGE 28
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) MAXIMUM WORKING PRESSURE and sets the overpressurization switch (microswitch) to approximately 3600 psi (242 bar).
PAGE 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 adjustment nut (T) counterclockwise one full turn. 15. With the pressure control knob at the minimum setting, turn the sprayer ON. 16. Slowly turn the pressure control knob (B) clockwise to the maximum setting and hold it there.
PAGE 30
BEARING HOUSING & CONNECTING ROD REPLACEMENT 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 in the skin, injury from moving parts or electric shock. Unplug the sprayer! C PACKING WITH BEARING GREASE 31 9. Clean the mating surfaces of the bearing and drive housings. 10.
PAGE 31
DRIVE HOUSING REPLACEMENT WARNING CAUTION DO NOT allow the gear cluster (9) to fall when removing the drive housing (18). It is easily damaged if dropped. The gear may stay engaged in either the front end bell or the drive housing. 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 electric shock.
PAGE 32
MOTOR REPLACEMENT WARNING CAUTION 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 electric shock. Unplug the sprayer! DO NOT allow the gear cluster (51) to fall when removing the drive housing (18). It is easily damaged if dropped. The cluster may stay engaged in either the front end bell or the drive housing.
PAGE 33
WIRING DIAGRAM DETAIL BLUE WHITE YELLOW BLACK RED Shows position of conduit seal (5) in conduit connector (345) AC1 G1 AC2 G2 5 _ + 345 MOTOR LEADS WHITE BLACK MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD 14 21 63 R B LIBERALLY APPLY GREASE 10 9 30 18a 54 18 18b 49 63 27 33 36,84 10 40 41 22 E 47 46 43 345 FIg 33–1 820–047 33
PAGE 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. NOTE: Packing Repair Kit 222–588 is available. In the text and drawings, reference numbers with an asterisk, i.e., (210*), indicate the parts included in the repair kit. For the best results, use all the new parts in the kit, even if the old ones still look good.
PAGE 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 (211). Maintain this alignment through Steps 5, 6 and 7. 4. Place the ball (225) on the piston valve (222). Refer to Fig 35–1. CAUTION Step 5 is critical. Follow the procedure carefully to avoid damaging the packings by overtightening. 5. Apply one drop of adhesive, supplied, to the threads of the piston valve.
PAGE 36
DISPLACEMENT PUMP REPAIR CYLINDER SLEEVE PISTON ASSEMBLY TAPERED END Fig 36-1 12. Slide the sleeve/piston rod assembly INTO THE BOTTOM OF THE CYLINDER. This is to prevent packing damage during reassembly. Refer to Fig 36–1. 13. Screw down the cylinder locknut (38) until it is finger tight at the bottom of the external cylinder threads. WARNING Be sure the retaining spring (35) is firmly in the groove of the connecting rod, all the way around, to prevent it from working loose due to vibration.
PAGE 37
PARTS DRAWING & LIST – DISPLACEMENT PUMP Model 820–553, Series A Sleeved Displacement Pump Includes items 202 to 225 REF NO. 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 218 219 220 221 222 223 224 225 PART NO.
PAGE 38
PARTS DRAWING – SPRAYER Ultimate Nova 1000 Sprayer 99 Model 820–045, Series C Includes items 1–99 Basic Sprayer 2 85 ID LABEL DANGER LABEL – English 14 DANGER LABEL – English 102 21 63 1 32 29 51 63 18 10 18b 18a 9 10 83 89 54 6 Ref 99 96 4 ID LABEL 27 49 100 94 DANGER LABEL French 31 33 41 101 40 81 80 35 32 82 97 93 92 41 Ref 6 A 20 38 46 47 39 SEE PAGE 37 FOR PARTS 14 60 42 58 69 91 15 36 44 7 71 INSIDE LABEL 73 OUTSIDE LABEL 43 SEE PAGE 40 FOR PARTS 16 88 59
PAGE 39
PARTS LIST – SPRAYER Ultimate Nova 1000 Sprayer Model 820–045, Series C Includes items 1 – 102 Basic Sprayer REF REF NO. PART NO.
PAGE 40
PARTS DRAWING & LIST – PRESSURE CONTROL PRESSURE CONTROL 820–503 Includes all items listed below, except the terminals. The terminals are included with the circuit board (item 23). The terminals listed in this parts list are shown on the wiring diagram on page 41. Part numbers for items 1a, 1b, 1c, 5, 23, 87, 90, and 95 are shown in the drawings below and on page 41. Part numbers are given on page 39. REF REF NO. PART NO.
PAGE 41
WIRING DIAGRAM CIRCUIT BOARD 218–405 303 309 316 23 302 318 317 324 306 322 BLUE 312 337 321 (1c) WHITE YELLOW 1b BLACK RED 308 336 Ref 90,95 319 1a 323 320 AC1 G1 _ AC2 G2 + 323 1a BLACK WHITE 314 323 MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD 820–047 41
PAGE 42
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 liter/min) Power Cord . . . . . . . . . . .
PAGE 43
SERVICE INFORMATION A new warranty has been added to the manual. See the back cover for the text. Listed below are the parts for Sprayer Model 820–045 that have changed. The series level is now at C. Ref No. Status Part No.
PAGE 44
THE SHERWIN-WILLIAMS ULTIMATE NOVAR 1000 WARRANTY AND DISCLAIMERS The Sherwin-Williams Company warrants the Ultimate 1000 sprayer to be free from defects in material and workmanship on the date of sale to the original purchaser for use.