Page 1
INSTRUCTIONS-PARTS
LIST
308–619
This
manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
120 VAC, 15 AMP
ULTRA
AIRLESS P
3000
psi (210 bar
Model 231–373, Series A
Complete
gun, RAC IV DripLess
and SwitchT
sprayer on Upright cart with hose,
ip
PLUS+
AINT SPRA
, 21 MPa) Maximum Working Pressure
T
ip Guard
1000
YER
First
choice when
quality counts.
Supersedes Rev. A
PCN B; unreleased
Rev. D
Rev. C
U.S. PATENT NO. 4,323,741; 4,397,610
PA
TENTED 1983, CANADA
AND OTHER PATENTS PENDING
GRACO INC. P.O. BOX 1441
MINNEAPOLIS, MN
http://www.graco.com
COPYRIGHT
Graco
Inc. is registered to I.S. EN ISO 9001
1996, GRACO INC.
MODEL
231–373
55440–1441
Page 2
Table
of Contents
Introduction 2.
Warnings 4
Setup 7
Startup 9
Shutdown
Flushing 12
Troubleshooting 13
Spin Test 18.
General
Motor
Brush Replacement
Power
On/Off
Pressure
Bearing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Care
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Information
Supply Cord Replacement
Switch Replacement
Control Replacement
Housing & Connecting Rod Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
11.
19.
20.
21.
22.
23.
25.
Introduction
Drive
Housing Replacement
Motor
Replacement
Displacement
Parts
Drawing – Sprayer
Parts
List – Sprayer
Parts
Drawing and List – Displacement Pump
Parts
Drawing – Pressure Control
Parts
List – Pressure Control
Wiring
Diagram
Accessories 39
Technical
Dimensions 39
Graco
Phone Number
The
Graco W
Pump Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
arranty And Disclaimers
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . .
26.
28.
30.
34.
35.
36.
37.
37.
38.
39.
40.
40.
ULTRA
Your
other
come
PLUS+
new sprayer functions and operates dif
airless paint sprayers. This section will help you be
familiar with the sprayer before operating it.
1000
BASIC COMPONENTS
Pressure Control
The
pressure control includes
sprayer, a pressure adjusting control knob and a freeze
resistant pressure sensing device. The function of the
pressure
sprayer maintains constant fluid pressure at the pump
outlet.
Pressure
The pressure drain valve provides pressure relief of the
sprayer.
and allows normal sprayer operation. In the downward
position, the pressure drain valve relieves the pressure
the system. The pressure drain valve will also open au
in
tomatically in the case of a control overpressure failure.
control is to control the
Drain V
In the forward position, the drain valve is closed
alve
an ON/OFF switch for the
motor speed so that the
Motor
The
DC motor has sealed bearings and replaceable
tor brushes. It drives the displacement pump at the rate
needed
pressure. W orking together , the pressure control and
motor
pressure
sounds like an automobile starter cranking. When the
pump
til
self off. However, there will still be power to the sprayer
and it will stay pressurized and ready to use until you
manually
to supply suf
cause the pump to cycle whenever there
demand.
is not cycling, the motor may hum intermittently un
the fluid pressure stabilizes, then the motor will shut
shut it of
ficient paint volume
When the pump is cycling, the motor
f and relieve pressure.
at the selected
ferently than
mo
is fluid or
it
Because the motor is DC, it is less sensitive to low voltage or voltage fluctuations than an AC motor, and a 12
or larger extension cord of up to 300 ft. (90 m) can
gauge
be
used without performance loss.
Drive Assembly
The
sealed drive assembly
motor
to the displacement pump.
transfers power from the DC
Displacement Pump
The
positive displacement, volume-balanced pump pro
equal fluid delivery on both the up
vides
strokes. The pump has a wet-cup which, when filled with
Graco Throat Seal Liquid, helps prevent damage to the
packings and piston rod.
throat
and down pump
Fluid Filter
The
fluid filter strains the paint to help avoid clogs in
hose
and spray tip. The filter includes a reusable element
and
has a pressure drain valve for manually relieving fluid
-
pressure.
Hoses
The
grounded, nylon spray hoses have spring guards on
both
ends. The 50 ft. (15.2 m) hose has a 1/4 in. ID. The
3 ft.
-
(0.9 m), 3/16
movement. The nylon hose material acts
dampener to absorb pressure fluctuations.
in. ID hose provides more flexible gun
as a pulsation
Spray Gun & RAC IV DripLess Tip Guard
Graco high pressure spray guns have a safety latch
prevents accidental
which
See T in Fig. 1. The gun provided with the sprayer also
-
-
a filter for final paint straining. The Reverse-A-Clean
has
IV SwitchTip uses high pressure fluid to remove clogs
the
from
Reverse-A-Clean IV DripLess tip guard is a safety feature
spray tip without removing it from the gun. The
which helps reduce the risk of fluid injection injury
triggering when it is engaged.
-
the
.
Page 3
T
A
B
C
D
S
0137
Fig. 1
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
J
K
Motor
Pressure Adjusting Knob
ON/OFF Switch
Drive Assembly
Fluid Filter
Secondary Fluid Outlet
Pail Hanger
Displacement Pump
50 ft (15 m) Main Hose
RAC IV T
ip Guard
Contractor Gun
RAC IV Switch T
ip
3 ft (0.9 m) Hose
Primary Fluid Outlet
Pressure Drain V
alve
Pressure Control
Spray Gun Safety Latch
M
E
F
G
H
R
P
N
L
04239
DC motor
, 120 V
ac, 15A, 1 phase
Controls fluid outlet pressure
Power switch that controls 120 V
T
ransfers power from DC motor to the displacement pump
ac main power to sprayer
Final filter of fluid between source and spray gun
Second spray gun operation is connected here
Container for fluid to be sprayed may be hung here
T
ransfers fluid to be sprayed from source through spray gun
1/4 in. ID, grounded, nylon hose with spring guards on both ends
Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
High pressure spray gun with gun safety latch
RAC switch tip uses high pressure fluid to remove clogs from spray
tip without removing tip from spray gun
3/16 in. ID, grounded, nylon hose used between 50 ft hose and
spray gun to allow more flexibility when spraying
Single spray gun operation is connected here
Relieves fluid outlet pressure when open
Controls motor speed to maintain fluid outlet pressure at displace
ment pump outlet. W
orks with pressure adjusting knob.
-
Gun safety latch inhibits accidental triggering of spray gun
Page 4
Symbols
Warning Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNINGWARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment
This equipment is for professional use only
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
misuse can cause the equipment to rupture or malfunction and result in serious injury
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
.
.
.
Check equipment daily
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
T
echnical Data
warnings.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
section of all equipment manuals. Read the fluid and solvent manufacturer
. Repair or replace worn or damaged parts immediately
on page 39 for the maximum working pressure of this equipment.
.
F).
’s
-
4
308-619
Page 5
WARNINGWARNING
INJECTION HAZARD
Spray
from the gun, leaks or ruptured components can inject fluid into your body and cause ex
tremely serious injury
can also cause serious injury
Fluid injected into the skin is a serious injury
injury
. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun dif
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
, including the need for amputation. Fluid splashed in the eyes or on the skin
.
. The injury may look like just a cut, but it is a serious
.
, glove or rag.
fuser operation weekly
. Refer to the gun manual.
-
Follow the
checking or servicing the equipment.
T
ighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily
not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
Pressure Relief Procedure
on page 13 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
TOXIC FLUID HAZARD
Hazardous
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container
state and national guidelines.
Always wear protective eyewear
and solvent manufacturer
fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
. Dispose of hazardous fluid according to all local,
, gloves, clothing and respirator as recommended by the fluid
.
. Do
308-619
5
Page 6
WARNING
WARNING
FIRE AND EXPLOSION HAZARD
Improper
result in a fire or explosion and serious injury
grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
.
If there is any static sparking or you feel an electric shock while using this equipment,
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or of
Do not operate a gasoline engine in the spray area.
f any light switch in the spray area while operating or if fumes are present.
MOVING PARTS HAZARD
Moving
parts, such as the air motor piston, can pinch or amputate your fingers.
stop
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the
NOTE: This
your sprayer
equipment from starting unexpectedly
is an example of the DANGER label on
. This label is available in other
.
languages, free of charge. See page 39 to order
FIRE
AND
EXPLOSION HAZARD
Spray
painting, flushing or cleaning equipment with flammable liquids in
confined
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses,
Avoid
open
connecting
off.
Failure
areas can result in fire or explosion.
containers and objects being sprayed.
all ignition sources such as static electricity from
flames such as pilot lights, hot objects such as cigarettes, arcs
or disconnecting power cords or turning light switches on
to follow this warning can result in death or serious injury
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
plastic drop cloths,
from
and
.
Pressure Relief Procedure
on page 13 to prevent the
.
SKIN INJECTION
HAZARD
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
ing 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 T
Failure to follow this warning can result in amputation or serious
injury.
reatment”.
void accidental trigger
-
Page 7
Setup
WARNING
To reduce the risk of serious injury from static
sparking, injection, or over pressurization and
rupture
cally conductive, the gun must have a tip guard, and
each
Maximum Working Pressure.
of the hose or gun, all hoses must be electri
part must be rated for at least 3000 psi (210 bar)
CAUTION
T
o avoid damaging the pressure control, which may
result in poor equipment performance and component
damage, follow these precautions:
1. Always use grounded, flexible spray hose at
least
50 ft. (15 m) long.
2. Never
3. Never
4. Always
use a wire braid hose as it is too rigid to act
as
a pulsation dampener
install any shutof
and
the main hose. See Fig. 2.
use the main filter outlet for one gun op
eration.
Never plug this outlet.
.
f device
between the filter
NOTE:
1. Fill the packing nut/wet-cup
-
-
2. Connect the gun, 3 ft. hose and 50 ft. hose.
3. Two gun hookup
4.
See Fig. 2 while doing the setup.
1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
Screw the assembly onto the outlet nipple. Don’t
use thread sealant and don’t install the spray tip
yet!
. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 50 ft. long
(minimum) main hose. For more flexible gun
movement, install a 3/16. ID, 3 ft. hose between
the main hose and the gun.
Check the Electrical Service.
Two gun hookup. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 50 ft. long
(minimum) main hose. For more flexible gun movement,
install a 3/16 in. ID, 3 ft. hose between the main
hose
and the gun.
a.
Electrical requirements: 120 V AC, 60 Hz, 15
Amp (minimum).
b. Use
b. Do not remove the grounding prong of the
c. Extension
a grounded
20 ft. (6 m) from the spray area.
supply
cord and do not use an adapter
grounding type. (Long lengths reduce sprayer
performance.)
electrical outlet located at least
power
.
cord specifications: 15 Amps, 3 wires,
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Read the warning sec
tion
FIRE OR EXPLOSION HAZARD
page 6 for more detailed grounding
instructions.
on
5. Plug
6. Flush the pump
7.
-
in the sprayer. Turn the ON/OFF switch
OFF
. Plug the cord into a grounded electrical
outlet.
to remove the oil left in to protect
pump parts after factory testing. See
on page 12.
Prepare the paint
recommendations. Remove any paint skin. Stir the
paint thoroughly
nylon mesh bag (available at most paint dealers)
to remove particles that could clog the filter or
spray tip. This is an important step for trouble-free
paint spraying.
according to the manufacturer
. Strain the paint through a fine
Flushing
308-619
’s
7
Page 8
Setup
PRESSURE ADJUSTING KNOB
P
ACKING NUT/ WET–CUP
FILL 1/3 FULL WITH TSL
Fig.
2
PRESSURE
DRAIN
VALV E
1/4 npsm(m) FLUID OUTLET NIPPLE
DO NOT INST
ALL ANY SHUT
DEVICE HERE
OFF
ON/OFF
SWITCH
Page 9
Startup
Use this procedure each time you start the sprayer to
help
ensure the sprayer
start
it safely
.
is ready to operate and that you
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
,
-
ever you are instructed to relieve pressure.
NOTE:
Flush the sprayer if this is a first-time startup.
See page 12.
NOTE:
See Fig. 4 except where noted.
1. Put the suction tube into the paint container.
2. Turn the pressure adjusting knob fully coun-
terclockwise to zero pressure.
3.
Plug in the sprayer
.
CAUTION
c. Release
5. Check all fluid connections for leaks
the trigger. Engage the gun safety latch.
. Relieve
the fluid pressure before tightening connections.
6. Install the spray tip and tip guard.
Engage the
gun safety latch. See Fig. 3. Install the spray tip
according to the instructions supplied with it.
7. Adjust the spray pattern.
a. Increase the pressure just until spray from the
gun is completely atomized. Use the lowest
pressure
needed to
get the desired results. This
reduces overspray and fogging, decreases tip
wear
and extends the life of the sprayer
b.
If more coverage is needed, use a larger tip
rather
than increasing the pressure.
c.
Test the spray pattern. T o adjust the pattern,
engage
nut.
the gun safety latch, loosen the
Position the tip guard horizontally for a hori
zontal pattern or vertically for a vertical pattern.
Then
tighten the retaining nut.
GUN
SAFETY
LA
TCH SHOWN
ENGAGED
.
retaining
-
Do not run the pump without fluid in it for more than
30 seconds to avoid damage to the displacement
pump
packings.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
4.
Prime the pump
a.
Open
the pressure drain valve (handle in down
ward position). If you did not install a secondary
hose, be sure the nipple is tightly plugged with
the cap provided. T urn the ON/OFF switch to
ON. Slowly turn the pressure adjusting knob
clockwise until the sprayer starts. When fluid
comes
dle
in forward position).
b. Disengage the gun safety latch. See Fig. 3.
Following the warning, above, trigger the gun
until all air is forced out of the system and the
paint
flows freely from the gun.
.
from the drain hose, close
the valve (han
Fig.
3
ON/OFF
GUN SAFETY LA
SHOWN DISENGAGED
SWITCH
TCH
0137
PRESSURE ADJUSTING KNOB
-
-
OUTLET NIPPLE
Fig.
4
DRAIN HOSE
PRESSURE
DRAIN
VALV E
04243
Page 10
Startup
Cleaning a Clogged Tip
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
ever you are instructed to relieve pressure.
1. Clean the front of the tip frequently during the day’s
operation. First, relieve pressure.
2. If the spray tip does clog, release the gun trigger
gage the gun safety latch, and rotate the RAC IV
handle
180. See Fig. 5.
3.
Disengage the gun safety latch and trigger the gun
into a waste container. Engage the gun safety latch
again.
,
-
, en
4. Return
the handle to the original position, disengage
the
gun safety latch, and resume spraying.
5. If the tip is still clogged, engage the gun safety latch,
shut
of
f and unplug the sprayer
sure
drain valve to relieve pressure. Clean the spray
, and open the pres-
tip as shown in manual 307–848, supplied with the
RAC
IV
.
TIP GUARD HANDLE
SHOWN IN SPRA
TURN HANDLE 180
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
YING
POSITION
,
GUN
LA
ENGAGED
-
Fig.
5
SAFETY
TCH SHOWN
Page 11
Shutdown
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
1.
Check
pressure.
to help prevent fluid buildup on the piston rod and
premature
the packing nut/wet-cup daily. First relieve
Keep the wet-cup
wear of packings.
warning on page 13 when
Pressure Relief
1/3 full of TSL at all times
and Care
6.
Coil
the hose and hang it on the
storing
it, even for overnight, to help protect the hose
from
kinking, abrasion, coupling damage, etc.
,
-
PACKING
NUT/
WET–CUP
hose rack
when
Tighten
Over
ing wear. Use a round punch or brass rod and light
hammer
2.
Clean
er
12 or refer to manual 307–273, supplied, for the
cleaning
3.
Lubricate the bearing housing after every 100
hours of operation. First relieve pressure. Remove
the front cover. Fill the bearing housing cavity with
SAE
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray
5. Flush
fill
sion
the packing nut just enough to stop leakage.
tightening causes binding and excessive pack
to adjust the nut. Refer to Fig. 6.
the fluid filter often
is stored. Follow the Flushing Guidelines on
procedure.
10 non-detergent oil. See Fig. 7.
tip.
the sprayer at the end of each work day
it with mineral spirits to help prevent pump corro
and freezing. See page 12.
and whenever the spray
page
and
CAUTION
-
TIGHTEN
-
Fig.
6
FILL BEARING HOUSING
CA
VITY WITH SAE
NON-DETERGENT OIL
AFTER EVER
HOURS OF OPERATION
FRONT
COVER
-
Y 100
To
prevent pump corrosion,
type
of paint in the sprayer when it is not in use. Pump
water
or paint out with mineral spirits.
never leave water or any
Fig.
7
Page 12
Flushing
NOTE:
Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be
sprayed, or to store the sprayer
. Use this chart to determine the required flushing order for the fluid you are
using, and then follow the procedure below for flushing.
*Use this category for flushing a brand new sprayer and flushing after storage.
System has
this fluid in it:
Next fluid to be
sprayed.
Flushing order:
Flush 1 Flush 2 Flush 3
*Oil-based
solvent or paint
Oil-based
solvent or paint
Oil-based
solvent or paint
Water or waterbased paint
Water or waterbased paint
Water or waterbased paint
Oil-based paint –
new color
W
ater-based paint
Prepare for
storage
W
ater-based paint
– new color
Oil-based paint
Prepare for
storage
Mineral spirits
none none
Mineral spiritsWarm soapy
water
Mineral spirits
W
arm soapy
none none
Clean water
water
W
arm soapy
Clean water
water
W
arm soapy
Clean water
water
Clean water
none
Mineral spirits
Mineral spirits
Before you spray or store
sprayer:
Prime with oil-based paint
Prime with water-based
paint
Relieve pressure,
Leave drain valve open
Prime with water
Prime with oil
Relieve pressure,
Leave drain valve open
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
1.
Follow the illustrated
on page 13. Engage the gun safety latch.
2. T
urn the pressure adjusting knob fully counter
clockwise to zero pressure.
3.
Remove the spray tip from the gun. Remove the
filter bowl and screen; see manual 307–273. Clean
the screen separately and install the bowl without
the screen to flush it. See Fig. 8.
4.
Put the suction tube into a grounded metal pail
with 1/2 gallon of compatible solvent.
Pressure Relief Procedure
6.
Do not run the pump dry for more than 30 seconds
to avoid damaging the pump packings!
7.
Follow the illustrated
Pressure Relief Procedure
on page 13. Engage the gun safety latch.
8.
Unscrew the filter bowl and reinstall the clean
screen. Install the bowl and hand tighten.
9.
Remove the suction tube and screen and clean
them separately
.
-
FILTER
SCREEN
FIL
TER
SUPPORT
BOWL
5.
Start the sprayer
still in the sprayer
. See page 9. T
o save the fluid
, trigger the gun into another
container until the next fluid appears, then trigger
the gun back into the fluid you are pumping. Circu
late the flushing fluid a couple of minutes to thor
oughly clean the system.
PRESSURE
DRAIN
V
ALVE
-
-
Fig.
8
Page 13
Troubleshooting
Pressure Relief Procedure
To
reduce the risk of serious bodily injury
splashing fluid or solvent in the eyes or on the skin,
jection,
or injury from moving parts or electric shock, always
this procedure whenever you shut of f the sprayer , when
checking
stalling,
stop
1.
2.
3.
or servicing any part of the spray system, when in
cleaning or changing
spraying.
Engage the gun safety latch.
Turn the ON/OFF switch to OFF.
Unplug the power supply cord.
spray tips, and whenever you
, including fluid in
follow
4.
Disengage
-
-
gun
ger
the gun to relieve pressure.
5.
Engage the gun safety latch.
6. Open the pressure drain valve, having a container
ready
you
the gun safety latch. Hold a metal part of the
firmly to the side of a
to catch the drainage. Leave the valve open until
are ready to spray again.
grounded metal pail, and trig
If you suspect that the spray tip or hose is completely
clogged,
lowing
retaining
then
or that pressure
the steps above,
nut or hose coupling to relieve pressure gradually
loosen completely
has not been fully relieved after fol
VER
Y SLOWL
. Now clear the tip or hose.
Y loosen the tip guard
-
-
,
1,5 2 4
Perform
all
Troubleshooting
MOTOR WON’T OPERATE
TYPE
OF PROBLEM
Basic
Fluid Pressure Problems
Basic
Mechanical Problems
Basic Electrical Problems
WHAT TO CHECK
If check is OK, go to next check
1. Check
2. Check
1.
2. Check
3. Check for motor damage. Remove drive
1. Check pressure control safety circuit. 2. Turn pressure control ON/OFF switch to
3
procedures before disassembling the sprayer
the pressure control knob setting.
motor
will not run if it is at
(fully counterclockwise).
for a clogged spray tip or fluid filter
fer to the separate gun, tip, or fluid filter instruction
Check for frozen or hardened paint in the
pump
a screwdriver
of
(43). It must be completely pushed into connecting
be
32.
housing assembly (67). See page 26. T ry to
rotate
manual.
(76)
and/or pressure control tube. Using
motor by hand. See page 18.
firmly in groove
, carefully try to rotate fan at back
displacement pump
rod (68) and retaining spring (42) must
fan by hand.
the minimum setting
connecting rod pin
of connecting rod. See Fig.
The
. Re
6
.
WHA
T T
When check is not OK refer to this column
1. Slowly
-
2. Relieve
1.
2. Push
3. Replace motor (73) if fan won’t turn. See
O DO
increase the pressure setting to see
if
the motor starts.
pressure, refer to the separate gun,
tip, or fluid filter instruction manual for
cleaning.
Thaw. Plug in sprayer and turn on. Slowly
increase pressure setting to see if motor
If it doesn’t, see NOTE 1, below
starts.
pin into
retainer.
28.
page
to RESET
OFF
ty continues to trip, see ELECTRICAL
SHORT
place and secure with spring
. If the pressure control safe
on page 17.
.
-
2. Check
3. Check
4. Check sprayer power supply cord (314) for
5. Check
NOTE
1:
area.
pressure
Thaw the sprayer if water or water-based paint has frozen in it, due to exposure
Do not
try to start the sprayer until it has thawed completely
control must be replaced. See page 30 (
electrical supply with volt meter
should
read 105–125 V
extension cord for
cord continuity with a volt meter
tension
damage
length.
See
such as broken insulation or wires.
motor brush leads, terminals and brush
Brush length should be 1/2”
page 20.
Displacement Pump
AC.
damage. Check ex
. If paint hardened (dried) in the sprayer
. Meter
.
minimum.
) or 23 (
Pressure Control).
2. Reset building circuit breaker; replace
-
3.
4.
5.
to low temperatures, by placing it in a warm
fuse. T
building
Replace extension cord.
Replace
Tighten terminal screws; replace brushes.
page 20.
See
ry another outlet.
power supply cord. See page 21.
, the pump packings and/or
308-619
13
Page 14
MOTOR WON’T OPERATE (Continued)
TYPE
OF PROBLEM
Follow Pressure Relief
Procedure on
page 13.
Remove gun from hose.
Remove pressure control.
WHAT TO CHECK
If check is OK, go to next check
1.Check leads from motor to be sure they are
securely
2. Check
and
3. Check
mum.
NOTE: The brushes do not wear at the same
rate on both sides of the motor . Check both
brushes.
4. Check for broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely
5. Check motor brushes for binding in brush
holders.
6. Check motor armature commutator for burn
spots, gouges and extreme roughness. Remove motor cover and brush inspection
plates
fastened and properly mated.
for loose motor brush lead connections
terminals. See page 20.
brush length which should be 1/2” mini
See page 20.
on top of brush. See page 20.
See page 20.
to check. See page 20.
WHA
T T
O DO
When check is not OK refer to this column
1. Replace
sure
firmly
Clean circuit board male terminals. Replace loose or damaged terminals. Securely
2. Tighten
if
-
3. Replace
4. Replace spring if broken. Realign spring
with
5. Clean
small cleaning brush. Align brush leads
with
cal
6. Remove
face
loose terminals; crimp
male terminal blades
connected to mating part.
reconnect leads.
terminal screws. Replace
leads are damaged. See page 20.
brushes. See page 20.
brush. See page 20.
brush holders. Remove carbon with
slot in brush holder to assure free
brush movement.
motor
commutator
and have motor shop resur
if possible. See page 28.
to leads. Be
are straight and
brushes
verti
-
-
Refer to the wiring diagram
on page 38 to identify test
points (TP).
7. Check
8. Check
1. Check power supply cord (314). Disconnect
2. Check
3. Check motor terminal cutoff switch. Connect
4. Check all terminals for damage or loose fit.
motor
tester (growler)
ture
page
18.
tuting
page
23.
TP1 female (neutral) and TP2 female and
connect volt meter to these leads. Plug in
sprayer. Meter should read 105 to 125 V AC.
Unplug sprayer
and
connect volt meter to TP1 female and TP3
male
terminal on the ON/OFF switch. Plug in
sprayer and turn ON. Meter should read 105
to
125 V
connect
volt meter to TP1 female and TP4 female.
in sprayer and turn on. Meter should read
Plug
105
to 125 V
Reconnect
armature for shorts using arma
or perform spin test. See
pressure control board (301) by substi
with a good pressure control board. See
. Reconnect TP2.
ON/OFF switch (307). Disconnect TP3
AC. T
urn of
f and
TP3.
AC. T
TP1, TP4, and TP5 connectors.
unplug sprayer
urn off and unplug sprayer
. Re
-
7.
Replace motor
-
8. Replace with new pressure control board
1. Replace
2.
-
3. Allow
.
4. Replace damaged terminals and recon-
See page 23.
(301).
Replace ON/OFF switch. See page 22.
motor to
heating. If switch remains
cools, check continuity between TP4 female and TP5 female with ohmmeter . If
replace motor
open,
nect securely.
. See page 28.
power supply cord. See page 21.
cool. Correct cause of over
open after motor
.
-
14
308-619
Page 15
LOW OUTPUT
TYPE
OF PROBLEM
Low
Output
WHAT TO CHECK
If check is OK, go to next check
1.
Check for worn spray tip. 1. Follow Pressure Relief Procedure W
2.
Check
to
stroke when gun trigger is released. Plug in
and
gun momentarily, then release and engage
safety
plug sprayer.
3. Check
should
4. Check extension cord size and length; must
be
300 ft.
5.
Check +, –, M+ and M– leads from motor to
pressure control circuit board (B1) for damaged or loose wires or connectors. Inspect
wiring insulation and terminals for signs of
overheating.
6.
Check
nals.
7. Check for worn motor brushes which should
be
see that pump does not continue to
turn on sprayer
latch. Relieve
electrical supply with volt meter
read 105–125 V
at least 12 gauge wire and no longer than
for loose motor brush leads and termi
See page 20.
1/2” minimum. See page 20.
. Prime with paint. T
pressure, turn of
AC.
See page 28.
rigger
f and un
. Meter
WHA
T T
O DO
When check is not OK refer to this column
then replace tip. See your separate gun
ing
or tip manual.
2.
Service pump. See pages 30–33.
-
3. Reset building circuit breaker; replace
4. Replace with a correct, grounded exten-
5. Be
-
6. Tighten
7.
fuse. Repair electrical outlet or try
building
another
outlet.
cord.
sion
sure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or damaged
wiring.
Securely reconnect terminals.
terminal screws. Replace
if
leads are damaged. See page 20.
Replace brushes. See page 20.
arn-
brushes
8. Check
9. Check motor brushes for binding in brush
10.Check stall pressure. 10.Replace with new pressure control board
11. Check
12.Check
for broken and misaligned motor brush
springs. Rolled portion of spring must rest
squarely
holders.
tuting
page
armature
See
on top of brush.
See page 20.
pressure control board (301) by substi
with a good pressure control board. See
23.
motor armature for shorts by using an
tester (growler) or perform spin
page 18.
8. Replace spring if broken. Realign spring
brush. See page 20.
with
9. Clean brush holders, remove carbon dust
small cleaning brush.
with
with
slot in brush holder to assure free
cal
brush movement.
See page 23.
(301).
-
11. Replace with new pressure control board
12.
test.
See page 23.
(301).
Replace motor
. See page 28.
Align brush lead
verti
-
308-619
15
Page 16
NO OUTPUT
TYPE
OF PROBLEM
Motor runs and pump strokes
Motor runs but pump does not
stroke
WHAT TO CHECK
If check is OK, go to next check
1.
Check paint supply
2.
Check for clogged intake strainer
3.
Check for loose suction tube or fittings.
4. Check
5. Check for leaking around throat packing nut
1. Check
2. Check
3. Be sure crank in
to see if intake valve ball and piston ball
are
seating properly
which may indicate worn or damaged pack-
See page 30.
ings.
displacement pump
(43).
See page 32.
connecting rod assembly (68) for dam
See page 25.
age.
sprayer and turn on briefly to check. Turn off
and
unplug sprayer
. 1.
. 2.
. See page 30.
connecting rod pin
drive housing rotates; plug in
. See page 26.
WHA
T T
O DO
When check is not OK refer to this column
Refill and reprime pump.
Remove and clean, then reinstall.
3. Tighten;
on threads if necessary.
4. Remove intake valve and clean. Check
balls
sary. See page 30. Strain paint before using to remove particles that could clog the
pump.
5. Replace
check
or nicks and replace if necessary. Tighten
the
1.
Replace pin if missing. Be sure retainer
spring
necting
-
2.
Replace connecting rod assembly . See
page
3.
Check
and replace if necessary
use thread sealant or sealing tape
and seats for nicks; replace if neces
packings. See pages 30–33.
piston valve seat
packing nut/wet-cup.
(42)
is fully in groove all around con
rod. See page 32.
25.
drive housing assembly for damage
for hardened paint
. See page 26.
-
Also
-
EXCESSIVE
TYPE
OF PROBLEM
Spray pattern variations.
PRESSURE FLUCTUA
TIONS
WHAT TO CHECK
If check is OK, go to next check
1. Be sure leads to pressure control circuit board
(B1)
are firmly connected. Be sure all male ter
minals blades are centered and firmly con-
to female terminals. See Fig. 33.
nected
2.
Check maximum working pressure.
3.
Check
pressure control board (301) by substi
with a good pressure control board. See
tuting
page
23.
4.
Check LOW OUTPUT section, page 15.
-
-
WHA
T T
O DO
When check is not OK refer to this column
1.
Reconnect securely
2.
3.
Replace
(301).
Replace
(301).
with a new pressure control
See page 23.
with a new pressure control
See page 23.
. See Fig. 33.
board
board
Page 17
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE
OF PROBLEM
Motor is hot and runs intermittently.
ELECTRICAL
TYPE
OF PROBLEM
Building circuit breaker opens
as soon as sprayer switch is
on.
turned
SHORT
WHAT TO CHECK
If check is OK, go to next check
1. Determine if sprayer was operated at high
pressure with small tips, which causes low
RPM and excessive heat build up.
motor
2. Be sure ambient temperature where sprayer
is located is no more than 90
not located in direct sun.
is
3. Determine
ized,
WHAT TO CHECK
if sprayer was turned on,
but
not operating for long periods of time.
F and sprayer
pressur
If check is OK, go to next check
1. Check
2. Check for missing inspection plate gasket
3. Check motor armature for shorts. Use an ar-
all
electrical wiring for damaged insula
and all terminals for loose
tion,
Also check wires between pressure control
and motor which are encased in conduit (1).
page 28.
See
(see page 28), bent terminal forks or other
metal to metal contact points which could
a short.
cause
mature tester (growler) or perform spin test.
page 18. Inspect windings for burns.
See
fit or damage.
WHA
T T
O DO
When check is not OK refer to this column
1. Decrease pressure setting or increase tip
size.
2.
Move
sprayer to shaded, cooler area if
sible.
-
3 Turn
WHA
of
f sprayer whenever you stop spray
for a while and relieve fluid pressure.
ing
T T
O DO
When check is not OK refer to this column
-
1. Repair or replace any damaged wiring or
terminals.
2.
Correct faulty conditions.
3.
Replace motor
Securely reconnect all wires.
. See page 28.
pos
-
-
Sprayer
erates
quits
for 5 to 10 minutes.
after sprayer op
4. Check
1. Check
2. Check
3. Check for damaged or pinched wires in the
-
1. Check
2. Check
3. Check tightness of pump packing nut. Over-
pressure control board (301) by substi
with a good control board.
tuting
Basic Electrical Problems on page 13.
ON/OFF switch
(307) See page 22.
sure the sprayer is unplugged!
wires
from switch. Check
The
reading should be infinity with the ON/
ter.
OFF switch OFF
pressure
Basic Electrical Problems on page 13.
electrical supply with volt meter
should
read 105 to 125 V
tightening tightens packings on rod, restricts
action, and damages packings.
pump
, and zero with
control. See page 23.
See page 23.
Disconnect
switch with ohmme
the switch ON.
AC.
Be
. Meter
-
4. Replace
(301).
1. Perform necessary procedures.
2. Replace
-
3.
Replace damaged parts. See page 23.
1. Perform necessary procedures.
2.
If voltage is too high, do not operate
sprayer until corrected.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings, if
necessary.
with a new pressure control
See page 23.
ON/OFF switch. See page 22.
See page 30.
board
308-619
17
Page 18
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury
.
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
warning on page 13 when
Pressure Relief
Spin
,
-
T
est
lutions before coming to a complete stop. If the motor
not spin freely
does
must be replaced. See page 28.
tor
59
, the armature is shorted and the mo
F
-
For
checking armature, motor winding and brush electri
continuity
cal
.
Setup
Relieve
26.
Remove
inspection
Remove the pressure control/cover(301). Disconnect
the
cover
pressure.
the
covers (J). See Fig. 9.
– and + leads from the motor to the pressure
terminals M–, and M+. See Fig. 10.
Remove the drive housing. See page
motor shield (59), the fan cover (F) and the
control/
Armature Short Circuit Test
Relieve pressure. Quickly turn the motor fan by hand. If
are no shorts, the motor will
there
coast two or three revo
301
Fig. 9
-
J
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Relieve
gether with a test lead. T urn the motor fan by hand at
about
If
lowing:
loose
brushes.
If
-
motor.
pressure. Connect the two black motor leads to
two revolutions per second.
there is uneven or no
broken brush springs, brush leads, motor leads;
brush terminal screws, motor lead terminals;
Repair parts as needed. See page 20.
there is still uneven or no turning resistance, replace the
See page 28.
turning resistance, check the fol
01224A
-
-
worn
Fig. 10
M–
–
M+
+
04790
Page 19
General
Repair Information
CAUTION
To
reduce the risk of a pressure control malfunction:
Always use needle nose pliers to disconnect a
Never pull on the wire, pull on the connec
wire.
tor.
Mate wire connectors properly. Be sure the flat
of the insulated male
blade
in the wrap-around blade of the female connector.
Route wires carefully to avoid interference with
other connections of the pressure control. Be
the
sure
the wires are not pinched between the cover
and
the control box.
Tool List
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet
Adjustable wrench
Adjustable, open-end
wrench
T
orque wrench
connector is centered
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
WARNING
ELECTRIC SHOCK HAZARD
T
o reduce the risk of serious injury
-
your fingers or a tool while inspecting the repair
Shut of
complete the inspection. Reinstall all covers, gas
kets, screws and washers before operating the
sprayer.
3.
If the sprayer does not operate properly
the repair procedure again to verify that everything
was done correctly. If necessary, see the
T
roubleshooting Guide, pages 13 – 17, to help
identify other possible problems and solutions.
cluding electric shock, DO NOT touch
any moving parts or electrical parts with
f the sprayer and unplug it as soon as you
, in
-
.
-
, review
CAUTION
Do not run the sprayer dry for more than 30 sec
onds to avoid damaging the pump packings.
4.
Reinstall the motor shield before regular op
eration
aged. The cover directs cooling air around the
motor to help prevent overheating. It can also help
reduce the risk of burns, fire or explosion; see the
WARNING,
of the sprayer and replace it if it is dam
below
.
-
-
-
1. Keep
2. T
all screws, nuts, washers, gaskets, and
electrical fittings
dures. These parts are not normally provided with
replacement assemblies.
est your repair before regular operation
sprayer to be sure the problem is corrected.
removed during repair proce
-
of the
WARNING
FIRE AND EXPLOSION HAZARD
During operation, the motor and drive
housing become very hot and could
burn your skin if touched. Flammable
materials spilled on the hot, bare motor could
cause a fire or explosion. Always have the motor
shield in place during regular operation to reduce
the risk of burns, fire or explosion.
Page 20
Motor
Brush Replacement
NOTE: Replace the brushes when they have worn to
less
than 1/2 in. Note
ferently
on each side of the motor
that the brushes wear dif
, so check them
both. Brush Repair Kit 220–853 is available. A
new
spring clip, P/N 1
10–816 may be purchased
separately.
WARNING
INJECTION
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
page 19 before doing this procedure.
on
1.
Relieve pressure.
2.
Remove the motor shield (59). Remove the in
spection covers (J) and gaskets (K) on each side
of the motor
. See Fig. 1
HAZARD
,
Pressure Relief
warning on page 13 when
1.
-
-
5.
Inspect the commutator for excessive pitting,
-
burning or gouging. A black color on the commuta
tor is normal. Have the commutator resurfaced by
a qualified motor repair shop if the brushes seem
to wear too fast.
CAUTION
When installing the brushes, follow all steps care
fully to avoid damaging the parts.
6.
Install a new brush so the lead is in the long slot of
the holder
. See Fig. 13.
BRUSH HOLDER
SLOT
SHORT
LONG SLOT
BRUSH
SPRING
CLIP
-
59
F
Fig. 11
3.
Push in the spring clip to release its hooks from
the brush holder
. Pull out the spring clip. See Fig.
J
12.
SPRING
Fig. 12
4. Loosen
brush lead away
the brush lead terminal screw
, leaving the motor lead terminal in
place. Remove the brush and spring. See Fig. 14.
HOOK
BRUSH
SPRING
10–816
P/N 1
. Pull the
01224A
CLIP
01227
NOTE: SPRING MUST COIL
IN THIS DIRECTION
Fig. 13
7. Slide
the terminal under the terminal screw washer
and tighten the screw. Be sure the motor lead is
still connected at the screw
SPRING
BRUSH
Fig. 14
8. Place
9.
the spring on the brush as shown in Fig. 13.
Install the spring clip and push it down to hook the
. See Fig. 14.
SPRING CLIP
BRUSH
TERMINAL SCREW
MOT
OR LEAD
TERMINAL
short slots in the housing. See Fig. 13.
10.
Repeat for the other side.
01227
LEAD
01227
Page 21
11. Test the brushes.
Remove the pump connecting rod pin.
a.
b.
With the sprayer OFF
trol knob fully counterclockwise to minimum
pressure. Plug in the sprayer
c. T
urn the sprayer ON. Slowly increase the
pressure until the motor is at full speed.
d.
Inspect the brush and commutator contact
area for excessive arcing. Arcs should not
“trail” or circle around the commutator surface.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury
, turn the pressure con
.
.
CAUTION
Do not run the sprayer dry for more than 30
-
seconds while checking the brushes to avoid
damaging the displacement pump packings.
12.
Install the brush inspection covers and gaskets.
13.
Break in the brushes.
least one hour with no load. Install the connecting
rod pin.
Operate the sprayer for at
Power
Supply Cord Replacement (Fig. 15)
WARNING
INJECTION
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
page 19 before doing this procedure.
on
1.
Relieve pressure.
2.
Remove the pressure control board/cover (301).
3.
Disconnect the power supply cord (314)
black lead from the ON/OFF switch (307),
the white wire going to the circuit board (301), and
the green wire to the grounding screw (317).
4.
Loosen the strain relief bushing (315) and remove
the power supply cord (314).
HAZARD
,
Pressure Relief
warning on page 13 when
-
307
317
301
5.
Install the new power supply cord in the reverse
order.
Fig. 15
315
314
04791
Page 22
On/Off
Switch Replacement (Fig. 16)
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
page 19 before doing this procedure.
on
1.
Relieve pressure.
2.
Remove the pressure control board/cover (301).
3.
Disconnect the two wires from the ON/OFF switch
(307). See Fig. 15.
4.
Using a 5/8 in. socket wrench, remove the nut and
rubber boot (309). Remove the switch guard (308).
See Fig. 16.
5.
Remove the ON/OFF switch (307).
warning on page 13 when
Pressure Relief
,
-
8.
Powder the inside of the rubber boot (309) with
talcum powder
boot.
Install the nut and rubber boot and tighten.
9.
10.
Reconnect all wires.
, then shake the excess out of the
309
308
D
6.
Install the new switch so the internal tab of the
pressure control housing (D) engages with the
vertical groove in the threads of the switch.
7.
Install the switch guard (308), aligning the internal
tab with the groove in the threads.
Fig. 16
307
04795
Page 23
Pressure
Control Replacement
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
1.
Relieve pressure.
2.
Disconnect the filter/drain valve assembly and the
pump supply hose at the pressure control while
holding the pressure control fitting (A) firmly
the
CAUTION
warning on page 13 when
, below
. See Fig. 17.
Pressure Relief
,
CAUTION
Do not allow the fittings (A) to turn when removing
or connecting the hose and filter/drain assembly
Do not over tighten the screws when attaching the
pressure control board/cover
over tightening the screws may shift the calibration
of the pressure control.
. T
urning the fittings or
-
. See
.
3.
Remove the four mounting screws and washers
(302, 303, 304) from the pressure control board/
cover (301). See Fig. 18.
4.
Carefully remove the pressure control board/cover
(301) so as not to stress the cables.
5.
Remove the potentiometer cable (310) from the
pressure control board/cover (301).
6.
Disconnect the pressure control board/cover
black/white M+ and black M– leads from the motor
+ and– leads.
7.
Disconnect the red motor leads from the TS termi
nals on the pressure control board/cover (301).
8.
Disconnect the black power lead (L1) from the
ON/OFF switch.
9.
Disconnect the white power lead (L2) from the
power cord (314) to the pressure control
board/cover (301).
10.
Loosen the ground terminal screw (317) and
disconnect the ground lead (C).
11.
Pull of
f the pressure control board/cover
.
-
Fig. 17
TO GUN
A
FILTER/DRAIN
VE ASSEMBL
VAL
301
Y
T
O PUMP
A
Page 24
Pressure
Control Replacement
WARNING
Do not attempt to adjust or calibrate the pressure
control.
If the pressure control is faulty, replace it.
301
12.
Reassemble in the reverse order; attach ground
wire (C), power leads (L1 and L2), the red leads to
the TS terminals on the circuit board (B1), the M+
and M– leads, and the potentiometer cable to the
connector on B1. Attach the pressure control
board/cover (301) using the four mounting screws
and washers (302, 303, 304),
304
Fig. 18
303
302
304
310
TS
L2
L1
B1
C
317
Page 25
Bearing
Housing and Connecting Rod
Replacement (Fig. 19)
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
on
page 19 before doing this procedure.
NOTE: Stop
Relieve pressure.
1.
2.
Remove the front cover (49). Unclip the drain hose
(36) from the pump. Hold a wrench on the pump
intake valve (223) and unscrew the pump suction
tube. Disconnect the pump hose (70).
3.
Push up the retaining spring (42). Push the pin
(43) out the rear.
Loosen the locknut (47). Unscrew the displace
4.
ment pump (76).
the sprayer at the bottom of its stroke to get
the crank (E) in its lowest position.T o lower the
crank
manually
fan
with a screwdriver
warning on page 13 when
, carefully rotate the blades of the
Pressure Relief
.
,
-
-
11.
Align the connecting rod (68) with the crank (E)
and the drive housing locating pins (G) with the
bearing housing (69) holes. Push the bearing
housing onto the drive housing or tap it into place
with a plastic mallet.
CAUTION
DO NOT use the bearing housing screws (25) to try
to
align or seat the bearing housing; the bearing and
drive
housing will not align properly and will result
premature
Install the screws and lockwashers (25,23). T
12.
en the screws evenly to 175 in-lb (19 N.m).
13.
Install the pump. See page 32.
14.
Install the remaining parts. See Fig. 19
BEARING GREASE
175 in-lb (19 N.m)
bearing wear
P
ACK WITH
OIL
25,23
TORQUE TO
.
.
67
C
68
B
E
in
ight-
G
5.
Remove the four screws and lockwashers (25,23).
6.
Lightly tap the lower rear of the bearing housing
(69) with a plastic mallet to loosen it from the drive
housing (67). Pull the bearing housing and the
connecting rod assembly (68) straight off the drive
housing.
Remove the pail bracket assembly (F) and install it
7.
on the new bearing housing.
8.
Inspect the crank (E) for excessive wear and
replace parts as needed. Evenly lubricate the
inside of the bronze bearing (B) with high quality
motor oil. Liberally pack the roller bearing (C) with
bearing grease.
9.
Assemble the connecting rod (68) and bearing
housing (69).
10.
Clean the mating surfaces of the bearing and drive
housings (69,67).
49
F
Fig. 19
42
43
47
76
223
69
40
70
99
Page 26
Drive
Housing Replacement (Fig. 20)
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
warning on page 13 when
Pressure Relief
CAUTION
4.
Lightly tap the lower rear of the bearing housing
(69) with a plastic mallet to loosen it from the drive
housing (67). Pull the assembled bearing housing
,
-
and connecting rod straight of
5.
Remove the two drive housing screws (26) and
lockwashers (20).
6.
Remove the two lower screws (13) and lockwash
ers (20) and then the two upper screws (16) and
lockwashers (20) from the front of the motor (73).
f the drive housing.
-
DO NOT drop the gear cluster (51) when removing
drive housing (67). The gear cluster
the
in the motor front end bell or the drive housing.
gaged
DO
NOT lose the thrust balls (9) located at each end
of
the gear cluster (51) or drop them between gears.
The balls, which are heavily covered with grease,
usually stay in the shaft recesses, but could be dislodged. If caught between gears and not removed,
the balls will seriously damage the drive housing. If
balls are not in place, the bearings will wear pre
the
maturely.
NOTE: Read the GENERAL REP AIR INFORMATION
on
page 19 before doing this procedure.
1.
Relieve pressure.
2.
Remove the front cover (49) and the motor shield
(59). Unclip the drain hose (36) from the pump.
3.
Remove the four bearing housing screws (25) and
lockwashers (23).
may stay en
-
-
7. T
ap the drive housing (67) with a plastic mallet to
loosen it from the front of the motor (73), and then
pull the drive housing straight of
8.
Liberally apply bearing grease to the gear cluster
(51). The gear area should have approximately 4
total ounces of grease. Grease is supplied with
the drive housing replacement kit. Be sure the
thrust balls (9) are in place.
9.
Place the bronze-colored washer (67b) THEN the
silver-colored washer (67a) on the shaft protruding
from the big gear in the drive housing (67).
10.
Align the gears and push the new drive housing
straight onto the front of the motor and locating
pins.
Continue reassembling the sprayer
11.
f.
.
Page 27
Drive
Housing Replacement
34
16
20
25,23
TORQUE TO
175 in-lb (19 N.m)
49
LIBERALLY
69
APPL
67
Y GREASE
67b
99
9
59
67a
51
13
20
9
20
26
Fig.
20
03752
Page 28
Motor
Replacement (Fig. 21 and 22)
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
warning on page 13 when
Pressure Relief
12.
Remove the two lower screws (13) and lockwash
ers (20) and then the two upper screws (16) and
lockwashers (20) from the front of the motor (73).
,
-
13. T
ap the drive housing (67) with a plastic mallet to
loosen it from the front of the motor (73), and then
pull the drive housing straight of
f.
-
NOTE: Read the GENERAL REP AIR INFORMATION
on
page 19 before doing this procedure.
1.
Relieve pressure.
2.
Remove the motor shield (59).
3.
Remove the pressure control board/cover (301).
Disconnect the four motor leads. See figure 21.
4.
Loosen the conduit connector nut on the conduit
connector (318) at the pressure control.
5.
Swing the conduit (1) away from the conduit
connector (318).
6.
Remove the conduit seal (29) from around the
conduit elbow coming into the pressure control.
Pull the motor leads through the elbow
time.
, one at a
CAUTION
Always pull the motor leads one at a time to avoid
loosening the terminals, which could result in a bad
connection
and poor sprayer performance.
CAUTION
DO NOT drop the gear cluster (51) when removing
drive housing (67). The gear cluster
the
in the motor front end bell or the drive housing.
gaged
DO
NOT lose the thrust balls (9) located at each end
of
the gear cluster (51) or drop them between gears.
The balls, which are heavily covered with grease,
usually stay in the shaft recesses, but could be dislodged. If caught between gears and not removed,
the balls will seriously damage the drive housing. If
balls are not in place, the bearings will wear pre
the
maturely.
14. While
15.
16.
supporting the motor (73) to keep the
sprayer from tipping, remove the four motor
mounting screws (8). Lift of
Install the new motor (73).
Liberally apply bearing grease to the gear cluster
(51). The gear area should have approximately 4
total ounces of grease, Grease is supplied with
the drive housing replacement kit. Be sure the
thrust balls (9) are in place.
f the motor
may stay en
.
-
-
7.
Loosen the connector nut on the connector elbow
(31) at the motor and pull the conduit (1) away
from the motor
one at a time.
8.
Unscrew the connector elbow (31) from the
motor.
9.
Pull the wires through the elbow
10.
Remove the front cover (49).
11.
Remove the two drive housing screws (26).
. Pull the leads through the conduit,
, one at a time.
17.
Place the bronze-colored washer (67b) and then
the silver-colored washer (67a) on the shaft pro
truding from the big gear in the drive housing (67).
18.
Align the gears and push the drive housing (67)
straight onto the front of the motor (73) and locat
ing pins.
19.
Continue reassembling the sprayer
motion on the conduit (1) when feeding wires
through it. Install the conduit seal (29) around the
wires in the conduit elbow (318) at the pressure
control to keep contaminants from entering the
motor conduit. See the Detail in Fig. 22.
. Use a turning
-
-
Page 29
B1
Motor
Replacement
DETAIL
Shows
position of
conduit seal (29) in
conduit connector
(345)
Fig.
21
LIBERALL
POWER CORD
Y APPL
Y GREASE
67
67b
51
M+
M–
67a
+
MOTOR
9
73
29
318
–
01232
04772
34
59
16
20
31
69
49
Fig. 22
26
99
20
40
8
9
11
70
10
70
301
318
1
13
20
04245
Page 30
Displacement
Pump Repair (Fig. 23, 24, 25
and 26)
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
NOTE: Read the GENERAL REP AIR INFORMATION
page 19 before doing this procedure.
on
205
216
224
219
Fig. 23
warning on page 13 when
Pressure Relief
220
221*
204*
202*
223
,
-
INTAKE
VALV E
A
B
218
219
Fig. 26
NOTE: Use Packing Repair Kit 222–588. An asterisk
following a reference number, i.e., (210*), indicate
that the part included in the kit. For the best
results,
old
NOTE: Clean
pump.
use all the new parts in the kit even if the
ones still look good.
and inspect parts after disassembling
Replace worn or damaged parts.
Disassembling the Pump
1. See
2.
3.
page 32 to remove the pump.
Unscrew the intake valve (223) from the cylinder
(219). Remove all parts. See Fig. 23.
If no further service is needed, reassemble the
intake valve. Be sure you use a new o-ring (202*).
the
*209
*213
THROAT
PACKINGS
*208
Fig. 24
224
*225
211
Fig. 25
*206
207*
210*
212*
215*
203*
214*
222
219
PISTON
ASSEMBLY
4.
Remove the packing nut (216) and plug (205). See
Fig. 23.
5.
Use a plastic mallet to tap the piston rod (224)
down, then pull the rod out through the bottom of
the cylinder (219). See Fig. 23.
6.
Remove the throat packings and glands. See Fig.
24.
7.
Clamp the flats of the piston rod in a vise. Loosen
the retaining nut (21
(222) from the rod. Remove all parts from the
piston valve (222). See. Fig 25.
8.
Remove and clean the sleeve (218). Use ONL
the special sleeve removal tool, P/N 222–586.
1). Unscrew the piston valve
WARNING
Always use the special sleeve removal tool to remove the sleeve. Other removal methods could
the pump to rupture, resulting in serious bodily
cause
injury. If the sleeve cannot be removed easily using
tool, return the sleeve and cylinder to your Graco
the
distributor
9.
Screw the large nut (B) of the tool into the top of
the cylinder (19). Screw down the rod (A) to push
the sleeve out. Remove the tool. See Fig. 26
for removal.
Y
.
Page 31
Displacement
Reassembling the Pump
NOTE: Alternate
in Fig. 27. The lips of the throat “V” packings
must
ings must face up. The lips of the U–cup seal
(203*)
the
NOTE:
1.
Soak leather packings in oil before using them.
Check the outside of the piston rod (224) and the
inside of the sleeve (218) for scoring or scratches.
If these parts are damaged, new packings will not
seal properly
2.
Stack the backup washer (214), seal (203*),
female gland (215*), alternate packings
(212*,206*), and then male gland (210*) onto the
piston valve (222). See Fig. 25.
leather and plastic packings as shown
face down. The lips of the piston “V” pack
face down. Incorrect installation damages
packings and results in pump leaking.
. Replace these parts if needed.
Pump Repair
-
TORQUE TO
10.5 in-lb (1.2 N.m)
to seat the packing,
and then back of
tighten finger tight.
POLY
*212
LIPS F
ACE UP
Fig. 27
f and
211
*210
222
224
225*
APPLY ONE DROP
OF SEALANT T
THESE THREADS
206*
LIPS F
O
LEATHER
ACE UP
215*
203*
LIPS F
ACE DOWN
214*
0029
3. T
ighten the packing retaining nut (21
1) against the
piston valve (222) to 10.5 in-lb (1.24 N.m).
Note the alignment
packing retainer nut (21
of the piston (222) to the
1). Maintain this alignment
through Steps 5, 6 and 7.
4.
Place the ball (225) on the piston valve (222). See
Fig. 27.
CAUTION
Step 5 is critical. Follow the procedure carefully to
damaging the packings by overtightening.
avoid
5.
Apply one drop of adhesive, supplied, to the piston
valve threads. Then hand tighten the valve assem
bly into the piston rod just until the nut (21
tacts the rod. See Fig. 27.
1) con
6. Place
7.
the flats at the top of the rod in a vise.
Use a wrench to
(21
1) onto the piston rod to 19 ft-lbs (25 N.m). See
CAREFULLY
tighten the nut
Fig. 28.
Use two wrenches to maintain the alignment
mentioned in Step 7, above.
224
211
TORQUE
AGAINST ROD T
19 ft–lb (27 N.m)
DO NOT ALLOW NUT
(211) TO MOVE
INSTALLING
NUT
WHEN
PIST
ONTO ROD
ON
O
01238
Fig. 28
8. Stack
the male gland (208*), alternate packings
(213*,207*), and female gland (9) into the top of
the cylinder (219). See Fig. 29.
-
-
9.
Install the packing nut (216) and plug (205), but
leave loose for now
. See Fig. 29.
Page 32
Displacement
Pump Repair
10. Coat
the piston rod and packings with oil. Carefully
slide the assembly
INT
O THE T
OP OF THE
SLEEVE.
NOTE: The
11.
Place a new o-ring (202*) firmly in the cylinder
tapered end of the sleeve is the bottom of
See
Fig. 30.
groove. See Fig. 29
205
216
*209
47
*207
LEATHER
LIPS MUST
FACE DOWN
*208
it.
213*
POLY
LIPS MUST
FACE
DOWN
219
218
PISTON
ASSEMBLY
Fig.
30
12. Slide
the sleeve/piston rod assembly
BOTT
OM OF THE CYLINDER
packing damage during reassembly
13.
Screw down the cylinder locknut (47) until it is
finger tight at the bottom of the external cylinder
threads.
14.
Place the flats of the intake valve (223) in a vise.
Install a new o-ring (202*). Screw the pump cylin
der into the valve. T
orque to 67 ft-lb (90 N.m). See
Fig. 29.
TAPERED
INT
. This is to prevent
. See Fig. 30.
END
0030
O THE
-
*202
219
218
*210
*206
LEATHER
LIPS MUST
F
ACE UP
*203
U–CUP SEAL
LIPS MUST
FACE DOWN
*202
212*
POLY
MUST
LIPS
F
ACE UP
215*
214*
211
TORQUE TO:
67 ft-lb
(90 N.m)
15.
Install the pump.
Fig. 29
01197
Page 33
Displacement
REMOVING AND INSTALLING PUMP
Remove the pump
1.
Flush the pump. Relieve pressure. Stop the pump
with the piston rod (224) in its lowest position or
carefully rotate the blades of the fan with a screw
driver to lower the rod.
2.
While holding the pump intake valve (223) steady
with a wrench, unscrew the suction tube (71).
3.
Disconnect the hose (70).
4.
Push the retaining spring (42) up. Push out the pin
(43).
5.
Loosen the locknut (47) and unscrew the pump
from the bearing housing (69).
(Fig. 31).
Pump Repair
3.
Push the retaining spring (42) into the groove all
the way around the connecting rod.
4. T
ighten the locknut (47) very tight–about 70 ft-lb
(97 N.m)–with a 2 in. open–end wrench and a light
-
hammer.
WARNING
Be sure the retaining spring (42) is firmly in the
groove of the connecting rod, all the way around, to
it
prevent
to
Fig. 32.
If
the pin works loose, parts could break of
force of the pumping action. These parts could be
projected
injury,
from working loose due to vibration. Refer
through the air and result in serious bodily
sprayer damage or property damage.
CAUTION
f due to the
69
42
224
43
47
Fig. 31
216
70
40
223
71
Install the pump ( Fig. 32).
1.
Screw the displacement pump 3/4 of the way into
the bearing housing (69).
2.
Hold the pin (43) up to the pin hole in the connect
ing rod assembly (68) and continue screwing in the
pump until the pin slides easily into the hole. Back
of
f the pump until the top threads of the pump
cylinder are flush with the face of the bearing
housing and the outlet nipple (40) is straight back.
03749
If the locknut (47) loosens during operation, the
threads
Be
5. T
FACE
BEARING
HOUSING
-
Fig. 32
of the bearing
sure to tighten the locknut firmly
ighten the packing nut (216) just enough to stop
leakage, but no tighter
1/3 full with Graco TSL (65).
68
OF
216
housing (69) will be damaged.
.
. Fill the wet-cup/packing nut
43
42
69
47 T
ORQUE TO
70 ft–lb
(95 N.m)
03750
Page 34
Parts
Ultra
PLUS+
Model 231–373, Series A
Includes
Complete Sprayer
25
49
58
LABEL
61
24
1000 Sprayers
items 1 – 102
67
68
69
23
42
47
43
Drawing – Sprayer
LABEL
41*
LABEL
57
LABEL
56
11
34
10
9
40
67b
32
70
51
26
67a
12
20
9
73
17*
LABEL
73D*LABEL
16
20
8
78
20
13
77
59
34
83
44
34
27
REF
77
31
62
48
52
8
37
35
REF
78
76
36
71
102
53
100
101
34
308-619
38
72
66b
65
40
45
50
33
66
66a
Ref 36
80
74
39
21
14
63
64
1
SEE PARTS ON P
19
Ref
AGE 37
70
Page 35
Parts
List – Sprayer
Ultra
PLUS+
1000 Sprayers
Model 231–373, Series A
Includes
Complete Sprayer
REF
NO. PART NO. DESCRIPTION QTY
1 065–312 CONDUIT
8 110–963 SCREW,
9
100–069
10
11 100–214
12 186–494 CLIP,
13 100–643 SCREW
14 101–242 RING,
16
19 104–811 HUBCAP 2
20 105–510
21 106–062 WHEEL,
23 106–115 LOCKWASHER,
24 107–209 SCREW,
25 107–210 CAPSCREW,
26 107–218
27 100–020 WASHER 2
29 107–447 SEAL,
31 108–460
32 112–746 NUT,
33 108–691
34 108–865
35 109–032 SCREW,
36 190–091 HOSE,
37 110–243 RING,
38 181–102 CLIP
39 109–046
40 162–453 NIPPLE,
41 185–952* LABEL,
42 176–817 SPRING,
43
44 110–240 SPEED NUT 2
45
47 178–941 NUT,
48 111–590 BUTTON,
49
50 100–840 ADAPTER, elbow,
51 179–961 GEAR REDUCER 1
52 183–350 WASHER 2
53
56 290–032
57 290–031 LABEL,
58 290–030 LABEL,
59 237–095 SHIELD,
61 186–277 HANGER,
items 1 – 102
s
pecify
5/16–18 x 3/4
100–188
100–644
176–818 PIN, straight,
178–034*
179–899
187–147
BALL,
NUT
LOCKWASHER,
SCREW,
LOCKWASHER, spring,
CAPSCREW
CONNECTOR, conduit,
PLUG, tubing
SCREW,
ADAPTER,
1
1/16–16 UN thread
TAG,
COVER, housing 1
STRAINER 1
LABEL,
includes
,
electrical
length when ordering
serrated
flange, hex hd,
0.7 ft
”
steel, 1/4” dia.
,
heavy
hex, 5/16–18 unc–2a
spring, 5/16”
large
,
socket
retaining 2
conduit
hex 2
head, 1/4–20 x 1”
socket head, 1/4–20 x 0.75”
semi–pneumatic 2
filh, no. 8–32 x1”
sch, 3/8–16 x 1–1/2”
,
sch,
,
see
pan head, no. 8 x 3/8”
pnhd, 10–32 x 1/4”
1/4”
spring, 3/8”
1/4–20 x 2.75”
page 29
45
1
drain
retaining 2
,
small 1
female, ORS 3/8–18 npt(f)
1/4
npt(m) x 1/4 npsm
DANGER,
retaining
W
ARNING 1
hex
English
hdls, 0.3125” dia x 1.023”
snap
1/4–18 npt (m x f)
ID,
motor cover
ID,
motor cover
ID,
front cover
motor
items 34, 41, 56, 57
pail
, left
, right
10
REF
NO. PART NO. DESCRIPTION QTY
62 192–027 SLEEVE 2
63 290–024 LABEL,
4
64
290–023
LABEL, ID, control, bottom
ID, control, top
65 206–994 THROAT SEAL LIQUID, 8
66 214–570 FLUID
2
4
4
1
66a 100–040 .PLUG 1
2
66b 162–453 NIPPLE,
FIL
Includes
see manual 307–273 for parts
TER 1
66a and 66b
1/4
npt(m) x 1/4 npsm
67 218–032 DRIVE HOUSING 1
2
67a 178–967 .WASHER,
67b 107–089 .WASHER,
6
68
4
4
218–034
69
218–035 BEARING HOUSING 1
70 223–766 HOSE,
4
2
71 185–386 TUBE,
2
72 220–285 CAP,
73 222–388**
2
4
73a 107–267 .TERMINAL,
1
73b 107–504 .TERMINAL,
73c
103–885
73d 185–951* .LABEL,
74 237–677
1
76 222–580
2
77 222–554 HANDLE,
1
78 222–555 FRAME,
1
1
80 111–225 CONNECTOR,
includes
replaceable items 67a and 67b
silver–colored 1
bronze–colored 1
CONNECTING ROD 1
cpld 1/4 npsm (f), 29” (715 mm),
spring guards both ends
MOTOR, ELECTRIC 1
includes
(which are shown on page 38
and one of item 9
grounded,
suction
for
secondary outlet
replaceable items 73a to 73d
.TERMINAL,
VALVE,
DISPLACEMENT PUMP
see
DANGER,
pressure drain
page 36 for parts
sprayer
nylon,1/4” ID
female 2
female
wire, female, snap–on
English
cart
tube, 90
1
83 185–384 BRACKET 2
100 238–361 HOSE,
1
2
101 238–358 HOSE,
1
grounded, nylon, 1/4” ID,
cpld 1/4 npsm(f), 50 ft (15 m)
spring guards both ends
cpld 1/4 npsm(f), 3 ft (.9 m),
grounded,
spring guards both ends
nylon, 3/16” ID,
102 220–955 SPRAY GUN
see
manual 307–614 for parts
1
1
*Extra
Danger and W
arning tags and labels available free.
1
1
**Motor Brush Repair Kit 220–853 is available.
Order separately
.
1
OZ
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
308-619
35
Page 36
Parts
PTFE
Drawing & List – Displacement Pump
Model 222–580, Series A
Sleeved
Includes items 202 to 225
REF
NO. PART NO. DESCRIPTION QTY
202 108–526* P
203 107–093*
204 105–445* BALL, sst 1
205 179–810 PLUG 1
206 178–939* V–P
207 178–940* V–P
208 178–942*
209 178–943*
210 178–944*
211
212 178–964* V–PACKING, plastic 3
213 178–965* V–PACKING, plastic 3
214 181–338* WASHER, backup 1
215 178–969*
216
218
219 185–21
220
221 178–938*
222
223
224
225 105–444*
Displacement Pump
SEAL, u–cup, polyurethane
GLAND, male
GLAND, female
178–945
179–809
185–213
185–214
218–036
222–437
222–438
GLAND, male
NUT
GLAND, female
NUT
SLEEVE, cylinder 1
1
CYLINDER 1
GUIDE, ball 1
PIN, ball stop
VAL
VAL
ROD, piston 1
BALL
ACKING, o–ring,
ACKING, leather
ACKING, leather
, hex, retaining
, packing
VE, piston
VE, intake
205
224
216
209*
225*
2
1
211
210*
2
2
1
1
1
1
*207
213*
*206
212*
208*
1
1
219
215*
203*
214*
222
1
1
1
1
202*
220
221*
*Supplied
in repair kit 222–588.
Keep a repair kit on hand to reduce down time.
218
204*
202*
223
Page 37
Parts
Drawing – Pressure Control
304
303
302
304
301
305
320
308
307
319
315
317
306309
313
312
311
310
316
318
Parts List – Pressure Control
Basic Pressure Control for the ULTRA)
REF
NO. PART NO. DESCRIPTION QTY
301 239–042 BOARD, pressure control 1
302 107–251 SCREW
303 112–610 SCREW
304 100–020 WASHER, lock, #10 4
305 189–095 HOUSING, cast 1
306 290–034*
307 112–826
308 112–608 GUARD, locking 1
309 105–659 BOOT, switch 1
310 236–352 POTENTIOMETER, pressure 1
*
Extra
W
arning and Caution labels are available free.
LABEL, caution
SWITCH, toggle
adjustment
,panhead, 10–24 x 1”
,panhead, 10–24 x 2”
PLUS+
2
2
1
1
314
1000 Sprayers
REF
NO. PART NO. DESCRIPTION QTY
311 108–358
312 112–768 KNOB, control 1
313 185–565
314 239–050 CORD SET
315 108–295 BUSHING, strain relief 1
316 112–376 LOCKNUT 1
317 100–078 SCREW
318 108–460 CONNECT
319 189–286*
320 238–192 BOARD, filter 1
SEAL, shaft
LABEL, knob
, power
, hexhead, 8–24 x .375
OR, conduit
LABEL, warning
308-619
04791
1
1
1
1
1
1
37
Page 38
Wiring
PRESSURE CONTROL BOARD/COVER 239–042
Diagram
PRESSURE
TRANSDUCER
TP6
TP8
TP5
BLACK
M –
GREEN/YELLOW
GROUND
WIRE
CIRCUIT
BOARD
(B1)
BROWN
73b
POWER
POTENTIOMETER
TP4 (behind)
BLACK/WHITE
BLUE
GREEN/YELLOW
SUPPL
Y CORD
TP3
M +
BLACK
M –
73a
WINDINGS
ON/OFF SWITCH
TP1 (behind)
TP2
–
+
MOTOR
THERMAL SWITCH
BROWN (L1)
BLUE (L2)
TP7
FILTER
BOARD
BLUE(L2)
RED
Fig.
33
Page 39
Accessories
SUCTION
TUBE
KIT 208–259
55 gallon
(200 liter) size
Includes:
Ref Part
No. No. Name Qty
1 156–589 UNION 1
2 214–961
3 156–591 ELBOW 1
4 156–593 PACKING 1
5 100–220 THUMBSCREW
6 176–684 ADAPTER 1
7 156–592 TUBE 1
8 159–100 RETAINER 1
9 161–377 SCREEN 1
10 159–101 NUT 1
SUCTION TUBE KIT
HOSE, 3/4 ID, 6 ft
208–920
5 gallon (19 liter) size
Includes:
REF PART
NO. NO. NAME QTY
1 101–818 CLAMP 2
2 160–327 UNION,
3 170–705 ADAPTER 1
4 170–706
5 170–957
6 181–072 STRAINER 1
90
HOSE, 48”
TUBE,
SLEEVE
3
5
1
2
1
4
6
7
8
9
10
0162
NOTE: Be
222–586 Sleeve
REMOV
DANGER
AL TOOL
sure you
LABELS
order the correct tool for your pump.
Removal T
ool, for pump 222–580.
The English language DANGER label shown on
page
6 is also on your
who
do not read English, order one of the following
labels to apply to your sprayer
the
best placement of these labels for good
sprayer
. If you have painters
. The drawing shows
visibility
.
Order the labels directly from Graco, free of
1
5
charge. Toll Free: 1–800–328–0211
Apply
language here
other
French 185–955
Spanish 185–962
1
1
1
2
6
4
1
3
0161
German 186–042
Greek 186–046
Korean 186–050
04244
Technical
Power
Requirements
Motor 1HP DC.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise
Level
Sound power
Sound pressure
W
orking Pressure Range
Cycles/Gallon (liter) 200(53).
Maximum Delivery
Tip Size
Power Cord
Inlet
Outlet Paint Filter
Pump Inlet Size
Fluid
Wetted Parts:
NOTE: Delrin
.
. . . . . . . . . . . . . . . .
.
Paint Strainer
Outlet Size
Displacement Pump
Packing Material
Filter
. . . . . . . . . . . . . . . .
.
. . . . . . . . . .
. . . . . . . . . . . . . . . . . .
1
phase, 15A minimum or 3500W generator
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . .
0–3000 psi (0–210 bar
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . .
.
. . . . . . . . . .
.
. . . . . . . . . . . . . . .
.
60
mesh (250 micron) reusable SST screen
is a registered trademark of the DuPont Co.
one gun –0.031; two guns–0.019
Stainless
Stainless
.
. . . . . . .
. . . . . . . . .
Aluminum,
Data
measured
(with
latex at 2000 psi (138 bar)
14 A
WG, 3 wire, 8’6” (2.6 m)
16 mesh (1
Steel Screen, reusable
60 mesh (250 micron)
Steel Screen, reusable
3/4 npt(m) with 30 ID chamfer
1/4 npsm from fluid filter
Carbon steel, Polyurethane,
Leather
Carbon steel, Stainless Steel
, UHMW polyethylene
120 V
AC, 60Hz,.
98.3 dBa
per
ISO 3744
at 3.1 feet (1 m)
1.0 gpm (3.8 lpm)
89.8 dBa
, 0–21 MPa)
190 micron)
Delrin
Dimensions
W
eight (dry w/o packaging)
Height 28
Length 26
Width 22.5
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . .
95 lb (43 Kg)
in. (71
1 mm)
in. (660 mm)
in. (572 mm)
Page 40
Graco
Graco
warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material
any
replace
operated
This
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution
Graco
installation,
This
verification
equipment
in
transportation.
Graco’s
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years
date
GRACO
A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches,
in
In
hereunder,
breach
and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With
special extended or limited warranty published by Graco,
any part of the equipment determined by Graco to be defective. This warranty applies only
and maintained in accordance with Graco’
warranty does not cover
of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
equipment with structures, accessories, equipment or materials not supplied by Graco,
operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor
sole obligation and buyer’s sole remedy for any breach of warranty shall be as set
of sale.
MAKES NO W
hose, etc.), are subject to the warranty
making any claim for breach of these warranties.
no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying
or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
of warranty
, the negligence of Graco, or otherwise.
, and Graco shall not
ARRANTY
, AND
DISCLAIMS ALL IMPLIED W
s written recommendations.
be liable for general wear and tear
, if any
W
arranty
Graco will, for a period of twelve months from the date of sale, repair or
ARRANTIES OF MERCHANT
, of their manufacturer
the exception of
when the equipment is installed,
, or any malfunction, damage or wear caused by
or the improper design, manufacture,
, and
forth above. The buyer agrees that no other
sales,
injury to person or property
ABILITY AND FITNESS FOR
, MA
TERIALS OR COMPONENTS SOLD BUT
. Graco will provide purchaser with reasonable assistance
, or any
of
the
equipment
FOR
GRACO CANADA CUST
The
parties acknowledge that they have required that the present document,
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent
judiciaires
avoir convenu que la rédaction du présente document sera
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
OMERS
as well as all documents, notices and legal proceedings
en Anglais, ainsi que tous documents, avis et procédures
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty
Program”.
TO
PLACE AN ORDER
you:
1–800–367–0211 T
Graco
, contact your Graco distributor
oll Free.
Phone Number
, or call this number to identify the distributor closest to
All
written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Foreign Offices:
Sales Offices:
Belgium, Canada, England, Korea, France, Germany
GRACO INC. P.O. BOX 1441
PRINTED
40
308-619
IN U.S.A. 308–619 September 1996, Revised August 1997
Minneapolis, Detroit, Los Angeles
MINNEAPOLIS, MN
http://www.graco.com
, Hong Kong, Japan
55440–1441
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