Graco ULTRA 500 Instructions-parts List Manual
INSTRUCTIONS–P
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
220/240 VAC
ULTRA 500
ARTS LIST
307–889
Rev
K
Supercedes Rev J, never released,
and Rev H
AIRLESS P
195
bar (2750 psi) Maximum Working Pressure
Model 231–079, Series D
Complete
gun, RAC IV DripLess
and SwitchT
sprayer on Upright cart with hose,
ip
AINT SPRA
T
ip Guard
YER
GRACO INC. P.O. BOX 1441
COPYRIGHT
MINNEAPOLIS, MN
1995, GRACO INC.
55440–1441
Table
of Contents
Warnings 2.
Setup 6
Startup 8
Shutdown
Flushing 11
Troubleshooting 12
Spin Test 16.
General
Motor
Power
On/Off
Pressure
Filter
Drive
Replacement 24.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Care
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Information
Brush Replacement
Supply Cord Replacement
Switch Replacement
Control Replacement
Board Replacement
Housing, Connecting Rod, and Crankshaft
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10.
18.
19.
20.
21.
22.
23.
Symbols
Warning Symbol
Motor
Replacement
Displacement
Parts
Drawing – Upright Sprayer
Parts
List – Upright Sprayer
Parts
Drawing and List – Displacement Pump
Parts
Drawing – Pressure Control
Parts
List – Pressure Control
Wiring
Diagram
Accessories 35
Technical
Dimensions 36
Graco
Phone Numbers
The
Graco W
Pump Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
arranty and Disclaimers
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26.
28.
31.
32.
33.
34.
34.
35.
36.
36.
36.
Caution Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
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.
CAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
.
stop
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.
WARNING
WARNING
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 Graco T
tance at 1–800–543–0339.
Do not alter or modify this equipment.
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
nical Data
ings.
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.
misuse can cause the equipment to rupture or malfunction and result in serious injury
.
echnical Assis
. Repair or replace worn or damaged parts immediately
on page 36 for the maximum working pressure of this equipment.
section of all equipment manuals. Read the fluid and solvent manufacturer’s warn
.
.
-
Tech-
-
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.
W
ear hearing protection when operating this equipment.
F).
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
.
MOVING PARTS HAZARD
Moving
parts, such as the air motor piston, can pinch or amputate your fingers.
-
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the
equipment from starting unexpectedly
Pressure Relief Procedure
.
on page 12 to prevent the
WARNING
WARNING
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
Pressure Relief Procedure
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.
NOTE: This
is an example of the DANGER label on your sprayer
free of charge. See page 35 to order
FIRE
.
AND
EXPLOSION HAZARD
Spray
painting,
in confined areas can result in fire or explosion.
uids
Use outdoors or in extremely well ventilated areas. Ground equip
hoses, containers and objects being sprayed.
ment,
Avoid
all ignition sources such as
cloths,
open flames
arcs from
rettes,
light switches on and off.
ing
Failure
to follow this warning can result in death or serious injury
flushing or cleaning equipment with flammable liq
static electricity from plastic drop
such as pilot lights, hot objects such as ciga
connecting or disconnecting power cords or turn
on page 12 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
. Do
. This label is available in other languages,
SKIN INJECTION
HAZARD
Liquids
-
-
-
-
.
can be injected into the body by high
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
of gun by always setting safety latch when not spraying.
gering
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical
Failure to follow this warning can result in amputation or serious
injury.
T
reatment”.
pressure airless spray
void accidental trig
-
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
4
307-889
Major Components
T
K
M
0137A
A
B
C
D
E
H
S
R
P
J
N
L
Fig. 1
A Motor DC motor
B
C
D
E
H
J
K
L
M
Pressure Adjusting Knob
ON/OFF Switch
Drive Assembly
Fluid Filter
Displacement Pump
50 ft (15 m) Main Hose
RAC IV T
ip Guard
Contractor Gun
RAC IV Switch T
ip
Controls fluid outlet pressure
Power switch that controls 220/240 V
T
ransfers power from DC motor to the displacement pump
Final filter of fluid between source and spray gun
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 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
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
R
S
Primary Fluid Outlet
Pressure Drain V
alve
Pressure Control
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 oulet. W
T
Spray Gun Safety Latch
Gun safety latch inhibits accidental triggering of spray gun
05253
, 220/240 Vac, 50 Hz, 7A, 1 phase
ac main power to sprayer
-
orks with pressure adjusting knob.
307-889
5
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 210 bar (3000 psi)
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, 0.9 m (3 ft) hose and 15.1 m
3.
4. Plug
See Fig. 2 while doing the setup.
1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
(50 ft) hose.
nipple. Don’t use thread sealant and don’t install
the spray tip yet!
Check the Electrical Service.
a.
Electrical requirements: 220/240 V AC, 50 Hz,
7A (minimum).
b. Use
6 m (20 ft) from the spray area.
b. Do not remove the grounding prong of the
supply
c. Extension cord specifications: 10A, 3-wire,
grounding type. (Long lengths reduce sprayer
performance.)
in the sprayer. Turn the ON/OFF switch
OFF
. Plug the cord into a grounded electrical out
let.
Screw the assembly onto the outlet
a grounded
cord and do not use an adapter
electrical outlet located at least
power
.
-
instructions.
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 2 for more detailed grounding
on
5. Flush the pump
pump parts after factory testing. See
on page 1
Prepare the paint
6.
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.
1.
to remove the oil left in to protect
Flushing
according to the manufacturer
. Strain the paint through a fine
’s
6
307-889
Setup
PRESSURE ADJUSTING KNOB
P
ACKING NUT/ WET–CUP
FILL 1/3 FULL WITH TSL
Fig.
2
ON/OFF
1/4 npsm(m) FLUID OUTLET NIPPLE
SWITCH
PRESSURE
DRAIN
VALV E
DO NOT INST
ALL ANY SHUT
DEVICE HERE
OFF
05254
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 12 when
Pressure Relief
ever you are instructed to relieve pressure.
NOTE:
NOTE:
Flush the sprayer if this is a first-time startup.
See page 1
1.
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
.
,
-
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
-
CAUTION
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). Turn the ON/OFF switch to ON.
Slowly turn the pressure adjusting knob clockwise until the sprayer starts. When fluid comes
from the drain hose, close the valve (handle in
forward
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.
.
position).
Fig.
3
ON/OFF
GUN SAFETY LA
SHOWN DISENGAGED
SWITCH
TCH
01020A
PRESSURE
ADJUSTING
KNOB
-
OUTLET
NIPPLE
DRAIN
HOSE
Fig.
4
PRESSURE
DRAIN
VALV E
Cleaning a Clogged Tip
Startup
4.
Return
the
the handle to the original position, disengage
gun safety latch, and resume spraying.
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 12 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
3.
Disengage the gun safety latch and trigger the gun
180. See Fig. 5.
into a waste container. Engage the gun safety latch
again.
,
-
, en
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
tip
as shown on the RAC IV package.
TIP GUARD HANDLE
SHOWN IN SPRA
TURN HANDLE 180
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
YING
POSITION
,
, and open the pres-
-
Fig.
5
GUN
SAFETY
LATCH
SHOWN
ENGAGED
0137A
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
the packing nut/wet-cup daily. First relieve
pressure.
to help prevent fluid buildup on the piston rod and
premature
Keep the wet-cup
wear of packings.
warning on page 12 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
11 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 1
and whenever the spray
page
and
1.
CAUTION
-
-
-
TIGHTEN
Fig.
6
FILL BEARING HOUSING
CA
VITY WITH SAE 10
NON-DETERGENT OIL
AFTER EVER
HOURS OF OPERATION
FRONT
COVER
05206
Y 100
prevent pump corrosion,
To
type
of paint in the sprayer when it is not in use. Pump
water
or paint out with mineral spirits.
10
307-889
never leave water or any
Fig.
7
05207
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 12. 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 12. 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
BOWL
SCREEN
FIL
TER
SUPPORT
5.
Start the sprayer
still in the sprayer
. See page 8. T
, 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.
o save the fluid
PRESSURE
DRAIN
V
-
-
Fig.
8
307-889
ALVE
05256
11
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