Graco 232131 User Manual
INSTRUCTIONS-PARTS LIST
308801
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
ELECTRIC, 120 VAC
ULTRA MAX 695
Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Models 232133 and 232131, Series A
Complete sprayer with hoses, gun, RAC IV DripLess
Tip Guard and SwitchTip
Model 232132 and 232130, Series A
Basic sprayer only
Rev. E
First choice when
quality counts.
Model 232133
Related Manuals
Displacement Pump 308815. . . . . . . . . . . . . . . . .
Fluid Filter 308249. . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Model 232131
7727A7728A
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 19. . . . . . . . . . . . . . . . . . . . .
Motor Test 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brushes 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Board 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Power Supply Cord 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 26. . . . . .
Pressure Transducer 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Seal 28. . . . . . . . . . . . . . . . . . . . . .
Suction Hose 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts 32. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phone Number 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
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 distributor.
Do not alter or modify this equipment. Use only genuine Graco parts.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 31 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
2 308801
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
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, glove or rag.
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 diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do 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.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
308801 3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing 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 off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Use only with a grounded outlet that matches the grounded plug of this equipment.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
NOTE: This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge. See page 31 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in
confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as cigarettes,
arcs from connecting or disconnecting power cords or turning light
switches on and off.
Failure to follow this warning can result in death or serious injury.
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.Avoid accidental triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious injury.
4 308801
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Component Function and Identification
03008
S
K
J
B
A
C
D
E
F
G
H
R
L
P
N
Fig. 1
M
A Motor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch Power switch that controls 120 VAC main power to sprayer
D Drive Assembly Transfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Fluid Outlet Main hose to spray gun is connected here
G Pail Hanger Container for fluid to be sprayed may be hung here
H Displacement Pump Transfers fluid to be sprayed from source through spray gun
J 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
K RAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury
L Contractor Gun High pressure spray gun with gun safety latch
M RAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip
without removing tip from spray gun
N 3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun
to allow more flexibility when spraying
P Pressure Drain Valve Relieves fluid outlet pressure when open; diverts fluid to drain line
R Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement
pump outlet. Works with pressure adjusting knob.
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
7727A
308801 5
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Working Pres-
sure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over–
pressurization and rupture of the hose or gun.
CAUTION
Setup
2. Fill packing nut (D). Fill packing nut full with
Graco Throat Seal Liquid (TSL) (64) supplied.
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 FIRE OR EX-
PLOSION HAZARD on page 4 and
Grounding, page 7.
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions:
Do not allow material to freeze in sprayer.
Use nylon spray hose at least 50 ft (15 m) long.
Do not use wire braid hose.
Do not install shutoff device between sprayer and
gun. See Fig. 2.
1. Connect hose (B) and gun (C) and screw it onto
outlet nipple (A). Don’t use thread sealant, and
don’t install spray tip yet!
1
Do not install any shutoff device here.
2
Fill full with TSL
3
Shown in closed, or spray position.
3. Plug in sprayer. Be sure ON/OFF switch (E) is
OFF. Plug cord into grounded outlet at least 20 ft
(6 m) away from spray area.
4. Flush pump to remove oil installed to protect
pump parts after factory testing. See page 12.
5. Prepare paint according to manufacturer’s recommendations. Remove any paint skin. Stir paint to
mix pigments. Strain paint through a fine nylon
mesh bag (available at most paint dealers) to
remove particles that could clog gun filter or spray
tip. This is an important step toward trouble-free
paint spraying.
continued on next page
Fig. 2
6 308801
1
A
E
C
3
D
2
B
Model 232133 Shown
7728A
Setup
Grounding
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire or
explosion that could cause serious injury or death.
1. This equipment requires a 120 Vac, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
Grounded
Outlets
Grounding Prong
Fig. 3
2. Do not alter the ground prong or use an adapter.
3. A 12 AWG, 3-wire, grounded 150 ft extension cord
may be used with this equipment.
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully
counterclockwise to obtain the minimum setting. Turn
the knob clockwise to increase pressure. See Fig. 6.
1
Engaged
1
Disengaged
2
Fig. 4
2
03008
NOTE: Long extension cords affect sprayer perfor-
mance.
How to use the gun safety latch
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 4.
WARNING
If the gun still sprays when the gun safety latch is
engaged, adjust the gun. See manual 307614,
supplied.
How to use the pressure drain valve
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over-pressure condition, it opens automatically to relieve fluid pressure. If this happens, stop
spraying immediately, shut off and unplug the sprayer.
Determine the cause of the problem and correct it
before operating the sprayer again. Refer also to the
Troubleshooting Guide, page 14. See Fig. 5.
Fig. 5
1
Rotate to increase (+)
or decrease (–)
pressure
Fig. 6
Closed, or
1
spray position
Open, or
2
drain position
–
1
1
2
7731A
+
7732A
308801 7
Setup
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
install or clean the spray tip.
1. Engage gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
The tip guard alerts you to the risk of injection and
helps prevent placing any part of the body close to the
spray tip. The tip guard also adjusts the vertical or
horizontal spray pattern. See page 10. The tip guard
holds a reversing spray tip. The tip is in the spraying
position when the tip handle points forward. See Fig. 7.
Clean front of tip frequently during day’s operation.
First, follow preceding Pressure Relief Procedure.
1 2
Tip handle shown in
1
spraying position.
Turn handle 180,
2
trigger gun to clear clog
Fig. 7
03008
4. Disengage gun safety latch. Hold a metal part of
gun against a grounded metal pail and trigger gun
into pail to relieve pressure.
5. Engage gun safety latch.
6. Open any fluid drain valves in system. Leave drain
valve open until you are ready to dispense again.
How to use the RAC IV tip guard
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
preceding Pressure Relief Procedure.
How to remove a tip clog
7. Release gun trigger. Engage safety latch. Rotate
RAC IV tip handle 180
8. Disengage safety latch. Trigger gun into a pail or
onto ground to remove clog.
9. Engage safety latch. Rotate tip handle to spraying
position.
10. If tip is still clogged, engage safety latch, shut off
and unplug sprayer, and open pressure drain valve
to relieve pressure. Clean spray tip as shown in
manual 308644, supplied.
. See Fig. 7.
8 308801
Startup
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely.
NOTE: If this is a first–time startup, flush the sprayer.
See page 12.
1. Open pressure drain valve (A). See Fig. 8.
2. Don’t install spray tip until pump is primed!
3. Put suction hose or tube (C) into paint. If you
are pumping from a 1 gallon (5 liter) pail, push
drain hose (D) down below top of pail to avoid
splashing paint when drain valve is opened.
Shown in closed, or spray position.
1
2
Open, or drain position
+
–
E
D
4. Turn pressure knob (E) to minimum setting.
5. Disengage gun safety latch. See Fig. 4.
CAUTION
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in it
for more than 30 seconds.
6. To prime pump, turn sprayer ON/OFF switch (F)
ON. Slowly increase pressure until sprayer starts.
When fluid comes from pressure drain valve, close
valve.
Fig. 8
C
B
F
1
A
2
Model 232133 Shown
7728A
308801 9
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing
when priming, be sure the spray tip is
not installed on the gun, and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
Startup
NOTE: Spray patterns will change as tips wear.
Change spray tip if adjusting pressure will not improve
spray pattern.
1
7. To prime hose, lower pressure to reduce splashing. Holding gun against pail, trigger gun and
slowly increase pressure until pump starts. Keep
gun triggered until all air is forced out of system
and fluid flows freely from gun. Release trigger and
engage gun safety latch.
8. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
9. Install spray tip. Engage gun safety latch first!
See manual 308644 for how to install tip.
10. Adjust spray pattern
a. Increase pressure just until spray from gun is
completely atomized. To avoid excessive
overspray and fogging, and to extend tip and
sprayer life, always use lowest pressure
needed to get desired results.
b. If more coverage is needed, use a larger tip
rather than increasing pressure.
c. Test spray pattern. To adjust direction of spray
pattern, engage gun safety latch and loosen
retaining nut (B). Position tip guard horizontally
for a horizontal pattern or vertically for a vertical pattern. Hold tip guard in place while tightening retaining nut. See Fig. 9.
1
2
Fig. 9
For a vertical
spray pattern
For a horizontal
spray pattern
B
2
03008
10 308801
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
6. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 12.
7. For very short shutoff periods, leave suction
hose in paint, relieve pressure, and clean spray tip.
1. Relieve pressure.
2. Check packing nut daily. Keep packing nut full of
TSL at all times to help prevent fluid buildup on
piston rod and premature wear of packings.
3. If pump begins to leak, loosen packing nut and
remove throat nut spacer (228). Tighten packing
nut just snug. Over tightening causes binding and
excessive packing wear. Use a round punch or
brass rod and light hammer to adjust nut. Refer to
Fig. 10. When leakage occurs again, repack pump.
4. Clean gun’s fluid filter often and whenever gun
is stored. Relieve pressure first. Refer to manual
307614.
5. Lubricate bearing housing after every 100 hours
of operation. Remove front cover. Apply several
drops of SAE 10 non-detergent oil in bearing
housing cavity (B). See Fig. 10.
CAUTION
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
8. Coil hose when storing it, even for overnight, to
help protect hose from kinking, abrasion, coupling
damage, etc.
Turn packing
1
nut clockwise to
tighten
B
1
228
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold weather,
never leave water or any type of paint in the sprayer
when it is not in use. Freezing can seriously damage
the sprayer or result in a loss of pressure or stalling.
Fig. 10
7734A
308801 11
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