Graco ULTRA 500 Instructions-parts List Manual

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INSTRUCTIONS–P

This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE

220/240 VAC

ULTRA 500

ARTS LIST

307–889

Rev

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . .

26.

28.

31.

32.

33.

34.

35.

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

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 82C (180F) or below –40C (–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

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

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.

reatment”.

pressure airless spray

void accidental trig

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

307-889

Major Components

0137A

Fig. 1

A Motor DC motor

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

Controls fluid outlet pressure

Power switch that controls 220/240 V

ransfers power from DC motor to the displacement pump

Final filter of fluid between source and spray gun

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

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

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

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

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

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

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

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.

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

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.

to remove the oil left in to protect

Flushing

according to the manufacturer

. Strain the paint through a fine

’s

307-889

Setup

PRESSURE ADJUSTING KNOB

ACKING NUT/ WET–CUP

FILL 1/3 FULL WITH TSL

Fig.

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

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:

Flush the sprayer if this is a first-time startup. See page 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.

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

If more coverage is needed, use a larger tip rather

than increasing the pressure.

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

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

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.

Prime the pump

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.

ON/OFF

GUN SAFETY LA SHOWN DISENGAGED

SWITCH

TCH

01020A

PRESSURE

ADJUSTING

KNOB

OUTLET

NIPPLE

DRAIN

HOSE

Fig.

PRESSURE DRAIN VALV E







Cleaning a Clogged Tip

Startup

Return the

the handle to the original position, disengage

gun safety latch, and resume spraying.

WARNING

FLUID

INJECTION HAZARD

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

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

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.

GUN

SAFETY LATCH SHOWN ENGAGED

0137A





Shutdown

WARNING

FLUID

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

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

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

Clean

er 11 or refer to manual 307–273, supplied, for the cleaning

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

CAUTION

TIGHTEN

Fig.

FILL BEARING HOUSING

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.

307-889

never leave water or any

Fig.

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

Water or waterbased paint

Oil-based paint – new color

ater-based paint

Prepare for storage

ater-based paint

– new color

Oil-based paint

Prepare for storage

Mineral spirits

none none

Mineral spiritsWarm soapy

water

Mineral spirits

arm soapy

none none

Clean water

water

arm soapy

Clean water

water

arm soapy

Clean water

water

Clean water

none

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

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.

Follow the illustrated on page 12. Engage the gun safety latch.

2. T

urn the pressure adjusting knob fully counter

clockwise to zero pressure.

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.

Put the suction tube into a grounded metal pail with 1/2 gallon of compatible solvent.

Pressure Relief Procedure

Do not run the pump dry for more than 30 seconds to avoid damaging the pump packings!

Follow the illustrated

Pressure Relief Procedure

on page 12. Engage the gun safety latch.

Unscrew the filter bowl and reinstall the clean screen. Install the bowl and hand tighten.

Remove the suction tube and screen and clean them separately

FILTER

BOWL

SCREEN

FIL

TER

SUPPORT

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

Fig.

307-889

ALVE

05256

Troubleshooting

Pressure Relief Procedure

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

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

Disengage

gun ger

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

the gun to relieve pressure.

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

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

3. Check for motor damage. Remove drive

1. Check pressure control safety circuit. 2. Turn pressure control ON/OFF switch to

Troubleshooting

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

(20). It must be completely pushed into connecting be

32.

housing tate

manual.

(19)

and/or pressure control tube. Using

motor by hand. See page 16.

displacement pump

rod (9)

firmly in groove

assembly (6). See page 24. T

fan by hand.

procedures before disassembling the sprayer

the minimum setting

, carefully try to rotate fan at back

connecting rod pin

and retaining spring (21) must

of connecting rod. See Fig.

ry to ro

WHA

T T

When check is not OK refer to this column

The

1. Slowly

. Re

2. Relieve

2. Push

3. Replace motor (2) if fan won’t turn. See

O DO

increase the pressure setting to see

the motor starts.

tip, or fluid filter instruction manual for cleaning.

Thaw. Plug in sprayer and turn on. Slowly increase pressure setting to see if motor starts.

retainer.

page

OFF ty continues to trip, see ELECTRICAL SHORT

pressure, refer to the separate gun,

If it doesn’t, see NOTE 1, below

pin into

26.

to RESET

place and secure with spring

. If the pressure control safe

on page 16.

05257

2. Check

3. Check

4. Check sprayer power supply cord (314) for

5. Check

NOTE

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 28 (

307-889

electrical supply with volt meter should

read 200–250 V

extension cord fordamage. Check

cord continuity with a volt meter

tension

damage

motor brush leads, terminals and brush length. Brush length should be 1/2” (12 mm) minimum.

AC.

such as broken insulation or wires.

See page 19.

. If paint hardened (dried) in the sprayer

Displacement Pump

. Meter

) or 22 (

2. Reset building circuit breaker; replace building

Replace extension cord.

Replace

Tighten terminal screws; replace brushes. See

to low temperatures, by placing it in a warm

Pressure Control).

fuse. T

page 19.

ry another outlet.

power supply cord. See page 20.

, the pump packings and/or

MOTOR WON’T OPERATE (Continued)

TYPE

OF PROBLEM

Follow Pressure Relief Proce

dure

from hose. Remove pressure control.

page 13. Remove gun

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 brush length which should be 12 mm (1/2

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 19.

in.) minimum. See page 19.

on top of brush. See page 19.

See page 19.

to check. See page 19.

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 19.

brushes. See page 19.

brush. See page 19.

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 26.

to leads. Be

are straight and

brushes

verti

Refer to the wiring diagram on page 35 to identify test points (TP).

7. Check

8. Check

9. 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

16.

tuting page

22.

and ON/Off switch TP3.Connect a jumper from TP4 to TP8. Plug in sprayer . Meter should Remove

TP1 female (neutral) and TP2 female and connect volt meter to these leads. Plug in sprayer. Meter should read 200 to 250 V AC. Unplug sprayer

and TP4 and connect volt meter to TP3 and TP4 terminal on the ON/OFF switch. Plug in sprayer and turn ON. Meter should read 200

250 V

to connect

volt meter to TP1 female and TP6 female.

in sprayer and turn on. Meter should read

Plug 200

to 250 V

Reconnect TP1, TP2, TP3, TP4, TP5, and TP6 connectors.

armature for shorts using arma

or perform spin test. See

pressure control board (301) by substi

with a good pressure control board. See

filter board. Connect volt meter to TP7

ON/OFF switch (307). Disconnect TP3

AC. T TP3.

to 250 V

jumper

. Reconnect TP2.

urn of

AC. T

AC. Unplug sprayer

f and

unplug sprayer

urn off and unplug sprayer

. Re

Replace motor

8. Replace with new pressure control board

9. Temporary

1. Replace

3. Allow

4. Replace damaged terminals and recon-

See page 22.

(301).

board?)

Replace ON/OFF switch. See page 21.

motor to heating. If switch remains cools, check continuity between TP4 female and TP5 female with ohmmeter . If open,

replace motor

nect securely.

. See page 26.

bypass to check (Replace

power supply cord. See page 20.

cool. Correct cause of over

open after motor

filter

307-889

LOW OUTPUT

TYPE

OF PROBLEM

Low

Output

WHAT TO CHECK

If check is OK, go to next check

Check for worn spray tip. 1. Follow Pressure Relief Procedure W

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 at least 1.5 mm longer

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.

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 200–250 V

than 100m (300 ft).

for loose motor brush leads and termi

See page 19.

12 mm (1/2 in.) minimum. See page 19.

. Prime with paint. T

pressure, turn of

AC.

(12 AWG) wire and no

See page 26.

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.

Service pump. See pages 28–30.

3. Reset building circuit breaker; replace building another

4. Replace with a correct, grounded extension

5. Be and firmly connected to female terminals. Replace any loose terminal or damaged wiring.

6. Tighten if

Replace brushes. See page 19.

fuse. Repair electrical outlet or try outlet.

cord.

sure male terminal blades are centered

Securely reconnect terminals.

terminal screws. Replace

leads are damaged. See page 19.

arn-

brushes

8. Check

9. Check motor brushes for binding in brush

10.Check

11. Check

12.Check

for broken and misaligned motor brush springs. Rolled portion of spring must rest squarely

holders.

bar

tuting page

armature See

on top of brush.

See page 19.

stall

(2500 psi) minimum.

pressure. Gauge should read 170

pressure control board (301) by substi

with a good pressure control board. See

22.

motor armature for shorts by using an

tester (growler) or perform spin

page 16.

test.

8. Replace spring if broken. Realign spring brush. See page 19.

with

9. Clean brush holders, remove carbon dust small cleaning brush.

with with

slot in brush holder to assure free

cal

brush movement.

10.Replace with new pressure control board

11. Replace with new pressure control board

12.

See page 22.

(301).

See page 22.

(301).

Replace motor

. See page 26.

Align brush lead

verti

307-889

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

Check paint supply

Check for clogged intake strainer

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 28.

ings.

displacement pump

(20).

See page 30.

connecting rod assembly (68) for dam

See page 24.

age.

sprayer and turn on briefly to check. Turn off and

unplug sprayer

. 1.

. 2.

. See page 28.

connecting rod pin

drive housing rotates; plug in

. See page 24.

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 28. Strain paint before using to remove particles that could clog the pump.

5. Replace check or nicks and replace if necessary. Tighten the

Replace pin if missing. Be sure retainer spring necting

Replace connecting rod assembly . See page

Check and replace if necessary

use thread sealant or sealing tape

and seats for nicks; replace if neces

packings. See pages 28–33.

piston valve seat

packing nut/wet-cup.

(42)

is fully in groove all around con

rod. See page 30.

24.

drive housing assembly for damage

for hardened paint

. See page 24.

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

Check maximum working pressure.

Check

pressure control board (301) by substi

with a good pressure control board. See

tuting page

22.

Check LOW OUTPUT section, page 14.

WHA

T T

O DO

When check is not OK refer to this column

Reconnect securely

Replace (301).

with a new pressure control

See page 22.

with a new pressure control

See page 22.

. See Fig. 33.

board

307-889

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

CAUTION

Any short in any part of the motor

power circuit will cause the control circuit to inhibit sprayer operation. Correctly diagnose before checking and replacing

and

repair all shorts

control board.

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 32

sprayer

3. Determine ized,

WHAT TO CHECK

If check is OK, go to next check

1. Check tion, Also check wires between pressure control and motor which are encased in conduit (1). See

2. Check for missing inspection plate gasket (see page 26), bent terminal forks or other metal to metal contact points which could cause

3. Check motor armature for shorts. Use an armature tester (growler) or perform spin test. See

is not located in direct sun.

if sprayer was turned on,

but

not operating for long periods of time.

all

electrical wiring for damaged insula

and all terminals for loose

page 26.

a short.

page 16. Inspect windings for burns.

C (90F)

pressur

fit or damage.

and

WHA

T T

When check is not OK refer to this column

1. Decrease pressure setting or increase tip

3 Turn

WHA

When check is not OK refer to this column

1. Repair or replace any damaged wiring or

O DO

size.

Move

sprayer to shaded, cooler area if

sible.

f sprayer whenever you stop spray

for a while and relieve fluid pressure.

ing

T T

O DO

terminals.

Correct faulty conditions.

Replace motor

Securely reconnect all wires.

. See page 26.

pos

Building as soon as sprayer is plugged into outlet and sprayer is NOT turned

Sprayer erates

circuit breaker opens

on.

quits

after sprayer op

for 5 to 10 minutes.

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 12.

ON/OFF switch

sure the sprayer is unplugged!

from switch. Check

wires ter.

The

reading should be infinity with the ON/

OFF switch OFF

pressure

should

tightening tightens packings on rod, restricts pump

control. See page 22.

Basic Electrical Problems on page 12.

electrical supply with volt meter

read 200 to 250 V

action, and damages packings.

(307) See page 21.

, and zero with

Spin

See page 22.

Disconnect

switch with ohmme

the switch ON.

AC.

est

. Meter

4. Replace (301).

1. Perform necessary procedures.

2. Replace

Replace damaged parts. See page 22.

1. Perform necessary procedures.

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 22.

ON/OFF switch. See page 21.

See page 28.

board

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

307-889

WARNING

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

warning on page 12 when

ever you are instructed to relieve pressure.

Pressure Relief

checking armature, motor winding and brush electri

For

continuity

cal

Setup

Relieve

24.

Remove the motor shield (1), the fan cover (F) and the inspection

Remove the pressure control/cover(301). Disconnect the cover

pressure.

Remove the drive housing. See page

covers (J). See Fig. 9.

– and + leads from the motor to the pressure

terminals M–, and M+. See Fig. 10.

control/

Armature Short Circuit Test

Relieve pressure. Quickly turn the motor fan by hand. If

are no shorts, the motor will

there lutions before coming to a complete stop. If the motor

not spin freely

does

must be replaced. See page 26.

tor

, the armature is shorted and the mo

coast two or three revo

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

turning resistance, check the fol

broken brush springs, brush leads, motor leads;

brush terminal screws, motor lead terminals;

Repair parts as needed. See page 19.

there is still uneven or no turning resistance, replace the

See page 26.

worn

Fig. 9

Fig. 10

05210

301

M–

–

M+

04790

307-889

General

Repair Information

CAUTION

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

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

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.

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 12 – 16, 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.

Reinstall the motor shield before regular op eration

aged. The cover directs cooling air around the mo tor 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.

307-889

Motor

Brush Replacement

NOTE: Replace the brushes when they have worn to

less than 12 mm (1/2 in). Note that the brushes wear dif ferently on each side of the motor , so check them both. Brush Repair Kit 222–157 is available. A new spring clip, P/N 1 10–816 may be

purchased separately

WARNING

INJECTION HAZARD

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: Read the GENERAL REP AIR INFORMATION

page 18 before doing this procedure.

Relieve pressure.

Remove the motor shield (1). Remove the inspec tion covers (J) and gaskets on each side of the motor

. See Fig. 1

Inspect the commutator for excessive pitting, burn

ing or gouging. A black color on the commutator 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.

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

Fig. 11

Push in the spring clip to release its hooks from the brush holder

. Pull out the spring clip. See Fig.

12.

SPRING

HOOK

BRUSH

SPRING P/N 1

Fig. 12

4. Loosen brush lead away

the brush lead terminal screw

, leaving the motor lead terminal in

. Pull the

place. Remove brush and spring. See Fig. 14.

CLIP

10–816

05210

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

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

307-889

11. Test the brushes.

Remove the pump connecting rod pin.

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.

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 sec

onds while checking the brushes to avoid damag ing 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

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

NOTE:

Read the GENERAL REP on page 18 before doing this procedure.

Relieve pressure.

Remove the pressure control board/cover (301).

Disconnect the power supply cord (314), both leads from the ON/OFF switch (307), and the green wire to the grounding screw (317).

Loosen the strain relief bushing (315) and remove the power supply cord (314).

Install the new power supply cord in the reverse order.

HAZARD

Pressure Relief

warning on page 12 when

AIR INFORMA

TION

307

317

301

315

Install the proper plug on the other end of the pow er supply cord. Follow all local codes to select the proper plug.

Fig. 15





314

04791

On/Off

Switch Replacement (Fig. 16)

WARNING

FLUID

INJECTION HAZARD

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 18 before doing this procedure.

Relieve pressure.

Remove the pressure control board/cover (301).

Disconnect the two wires from the ON/OFF switch (307). See Fig. 15.

Using a 5/8 in. socket wrench, remove the nut and rubber boot (309). Remove the switch guard (308). See Fig. 16.

Remove the ON/OFF switch (307).

warning on page 12 when

Pressure Relief

Powder the inside of the rubber boot (309) with talcum powder boot.

Install the nut and rubber boot and tighten.

10.

Reconnect all wires.

, then shake the excess out of the

309

308

Install the new switch so the internal tab of the pressure control housing (D) engages with the ver tical groove in the threads of the switch.

Install the switch guard (308), aligning the internal tab with the groove in the threads.

307

Fig. 16

04795

307-889

Pressure

Control Replacement

WARNING

FLUID

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

Relieve pressure.

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 12 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

Remove the four mounting screws and washers (302, 303, 304) from the pressure control board/ cover (301). See Fig. 18.

Carefully remove the pressure control board/cover (301) so as not to stress the cables.

Remove the potentiometer cable (310) from the pressure control board/cover (301).

Disconnect the pressure control board/cover black/ white M+ and black M– leads from the motor + and– leads.

Disconnect the red motor leads from the TS leads on the pressure control board/cover (301).

Disconnect the brown power lead (L1) from the filter board.

Disconnect the blue lead (L2) from the filter board.

10.

Loosen the ground terminal screw (317) and dis connect the ground lead (C).

11.

Pull of

f the pressure control board/cover

Fig. 17

TO GUN

FILTER/DRAIN

ASSEMBL

VALV E

TO PUMP

301

05258





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. Carefully route the wires away from the filter board. Attach the pressure control board/cover (301) using the four mounting screws and washers (302, 303, 304),

304

Fig. 18

303

302

304

310

317

04790

Filter

WARNING

FLUID

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

Relieve pressure.

Perform the cedure steps 2 through 1

Pressure Control Replacement

warning on page 12 when

Board Replacement

Remove the three screws holding the filter board in

3. place and remove the filter board.

Pressure Relief

pro-

Reassemble in the reverse order; replace filter board, 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. Care fully route the wires away from the filter board. At tach the pressure control board/cover (301) using the four mounting screws and washers (302, 303,

304),





Drive

Housing, Connecting Rod, and

Crankshaft Replacement (Fig. 20)

WARNING

FLUID

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

warning on page 12 when

Pressure Relief

Remove the screws (12), spacers (15), screws (16) and the motor shield (1).

Remove the two screws (58) and lockwashers (7) holding the motor to the drive housing.

Lightly tap the lower rear of the drive housing (6) with a plastic mallet to loosen it from the front of the motor

. Then pull the drive housing straight of

NOTE: Read the GENERAL REP AIR INFORMATION

page 18 before doing this procedure.

NOTE:

noted.

NOTE:

get the crank (57) in its lowest position. If the crank must be lowered manually of the fan with a screwdriver

3. T

See Fig. 20 for Steps 1 to 15 unless otherwise

Stop the sprayer at the bottom of its stroke to

, carefully rotate the blades

Remove the displacement pump. See page 28.

Remove the connecting rod (9). Inspect it for wear or damage. Replace the rod, if necessary

urn the displacement rod so the pin hole faces straight back. Insert a hex key wrench through the hole and unscrew the screw (8) located in the back of the drive housing. See Fig. 19.

8,7

Inspect the drive housing (6) for excessive wear and replace parts as needed.

Pull the crankshaft (57) out. Inspect it for wear or damage and replace it, if necessary thrust bearings (57a and 57b) are in the proper place on crankshaft.

10.

Evenly lubricate the inside of the bronze bearing in the drive housing with high quality motor oil. Liber ally pack the roller bearing and gears with bearing grease.

11.

Carefully align the drive housing and front of the motor with the locating pins. Push the drive hous ing onto the motor mallet.

12.

Reinstall the motor shield (1), screws (16) and screws (12) and spacers (15).

, or tap it into place with a plastic

. Be sure the

CAUTION

DO NOT use the drive housing screws (8) to try to align or seat the housing to the motor; doing so will not ensure proper alignment, but will cause prema-

bearing wear

ture

Fig. 19

4. Remove (7) from the top front of the drive housing (6).

the other two screws (8) and lockwashers

307-889

Step

See procedure

01579

3 for

13.

Install the screws (8) and lockwashers (7) on the bearing housing and tighten evenly

14.

See Installing the Pump on page 30.

15.

Reinstall the front cover and screws (1 connect the suction tube (14) and pump outlet hose (23).

1,13). Re

Drive

Housing, Connecting Rod,

and Crankshaft Replacement

cavity with SAE non-detergent motor oil

Fill

57b

Fig.

57a

05259

307-889

Motor

Replacement (Fig. 21 and 22)

WARNING

FLUID

INJECTION HAZARD

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 18 before doing this procedure.

Relieve pressure.

Remove the motor shield (1).

Remove the pressure control board/cover (301). Disconnect the four motor leads. See figure 21.

Loosen the conduit connector nut on the conduit connector (318) at the pressure control.

Swing the conduit (41) away from the conduit con nector (318).

Remove the conduit seal (31) from around the conduit elbow coming into the pressure control. Pull the motor leads through the elbow time.

warning on page 12 when

Pressure Relief

, one at a

12.

Remove the two screws (58) and lockwashers (7) from the motor (2).

ap the drive housing (6) with a plastic mallet to

13. T loosen it from the front of the motor (2), and then pull the drive housing straight of

CAUTION

DO NOT drop the gear cluster (26) when removing

drive housing (6). The

the

in the motor front end bell or the drive housing.

gaged

NOT lose the thrust balls (24) located at each end

the gear cluster (26) 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.

supporting the motor (2) to keep the sprayer from tipping, remove the four motor mounting screws (4). Lift of

Install the new motor (2).

gear cluster may stay en

f the motor

CAUTION

Always pull the motor leads one at a time to avoid loosening the terminals, which could result in a bad connection

Loosen the connector nut on the connector elbow (39) at the motor and pull the conduit (41) away from the motor one at a time.

Unscrew the connector elbow (39) from the motor.

Pull the wires through the elbow

10.

Remove the front cover (1

11.

Remove the two drive housing capscrews (8) and lock washers (7).

and poor sprayer performance.

. Pull the leads through the conduit,

, one at a time.

1).

16.

Liberally apply bearing grease to the gear cluster (26). 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 (24) are in place.

17.

Place the bronze-colored washer (57a) and then the silver-colored washer (57b) on the shaft pro truding from the big gear in the drive housing (6).

18.

Align the gears and push the drive housing (6) straight onto the front of the motor (2) and locating pins.

Continue reassembling the sprayer

19. motion on the conduit (41) when feeding wires through it. Install the conduit seal (31) 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

307-889

Motor

Replacement

DETAIL

Shows position of conduit seal (31) in conduit connector

(318)

Fig.

LIBERALLY

APPL

POWER CORD

Y GREASE

M+

57b

M–

MOTOR

–

04772

318

01232

Fig. 22

57b

318

301

05260





Displacement

Pump Repair (Fig. 23 – 32)

WARNING

FLUID

INJECTION HAZARD

o reduce the risk of serious injury

follow the illustrated

Procedure

ever you are instructed to relieve pressure.

warning on page 12 when

Pressure Relief

223

Disassembling the pump.

1. Unscrew parts. See Fig. 25.

Fig. 25

Remove the plug (205). Unscrew the packing nut (216). See Fig. 26.

3. T

ap the piston rod (224) down and pull it out the

bottom of the cylinder (219). See Fig. 26.

Remove the throat packings. See Fig. 26.

the intake valve (223) and remove all

220

221*

*204

*202

223

02396

Fig. 23

Fig. 24

Removing the pump.

1. Flush

the pump. Relieve pressure.

Remove the front cover (1

Unscrew the suction tube (14) from the pump, holding a wrench on the pump intake valve (223) to keep the pump from loosening. See Fig. 23

Disconnect the pump outlet hose (23). See Fig. 23

Use a screwdriver to push aside the retaining spring (21) at the top of the pump. Push the pin (20) out the rear

. See Fig. 24.

1). See Fig. 23

05261

01579

205 216

*209

*213

*208

Fig. 26

Clamp the piston rod (224) in a vise. Loosen the nut (21 the piston packings. See Fig 27.

224

211

1). Unscrew the piston valve (222). Remove

207*

224

02397

222

Push the retaining spring (21) up. Push the pin (20) out the rear.





Fig. 27

02398

Displacement

Pump Repair

WARNING

reduce the risk of serious bodily injury from pump rupture, If distributor

use

only

tool

224–786 to remove the sleeve.

the sleeve is stuck, send the cylinder to your Graco

for removal.

Remove the sleeve (218) whenever your service

the pump. Use special tool, Part No. 224–786 only

Screw the nut (H) into the cylinder (219). Screw

down the rod (J) to push the sleeve out. See Fig.

28.

219

218

Apply

sealant to these threads

Fig. 29

4. Note the alignment ton nut (21 Steps 5, 6 and 7.

Apply repair kit, to the piston threads. Place the ball (225*) on the piston. Hand tighten the piston into the rod (224) just until the nut (21 rod. See Fig. 29. Place the flats of the rod in a vise.

6. T

ighten the nut (21 Use two wrenches to maintain the alignment as mentioned in Step 4.

one drop of

of the piston (222) to the pis

1) and maintain this alignment through

ONE

drop of adhesive, supplied with the

1) contacts the

1) onto the rod (224) to 25 N.m.

224

225*

211

222

0029

Fig. 28

Assembling the pump.

NOTE: For

and use all the kit parts. Parts included in the kit are marked with an asterisk, (202*), in the text and draw ings.

NOTE:

inside of the cylinder with oil.

NOTE:

shown in Fig. 31. Be sure the lips of the v–packings face the direction shown. Incorrect installation dam ages the packings and results in pump leakage.

Check 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

Stack the piston packings onto the piston (222) as

2. shown in Fig. 31.

3. T N.m.

the best results, use repair kit 222–587,

Soak the packings in oil, and coat the rod and

Alternate leather and plastic packings as

ighten the piston nut (21

1) onto the piston to 0.7

0028

Stack the throat packings into the top of the cylin der (219). Install the packing nut (216) loosely Fig. 31.

Install the new o–ring (202*) on top of the sleeve (216). Insert the piston rod (224) assembly into the

top of the sleeve.

the

bottom of the cylinder

end of the sleeve is the bottom. See Fig. 30.

end

Tapered

Fig. 30

9. Assemble packing (202*). T Fig. 31.

and install the intake valve. Use a

Slide the sleeve assembly into

. Note that the tapered

219

224

202*

218

ighten the valve to 64 N.m. See

. See

0030

new





Displacement

Lips

of throat v–packings must face up

Lips of piston v–packings must face down

Lips of U–cup packing must face down

Leather

Poly

orque to 64 N.m

224

Pump Repair

Installing the pump

to 95 N.m

Torque

Face of bearing housing

205

216

*209

*207

*208

219

*202

*210

*206

*215

*214

*221

220

*202

Fig.

1. Screw

213*

the pump 3/4 of the way into the bearing housing (6). Hold the pin (20) up to the pin hole in the connecting rod (9) and continue screwing in the pump until the pin slides easily into the hole.

01579

See Fig. 32.

225*

218

Align the top threads of the pump cylinder flush with the face of the bearing housing and so the outlet nipple (22) is straight back. See Fig. 32.

211

212*

203*

Be sure the retaining spring (21) is firmly in the groove of the connecting rod, all the way around, to

prevent to

Fig. 32.

from working loose due to vibration. Refer

WARNING

222

the pin works loose, parts could break of

f due to the

force of the pumping action. These parts could be

through the air and result in serious bodily

sprayer damage or property damage.

ighten the

204*

223

projected injury,

Push the retaining spring (21) into the groove of the connecting rod, all the way around. T locknut (56) very tight – 95 N.m, to prevent it loos ening and damaging the threads of the bearing housing. See Fig. 32.

Fig.





0085

Assemble the remaining parts.

Parts

– Upright Sprayer

Model 231–079, Series C

Danger

or W

Identification Label

On outside of cover

On inside of cover

See page 34

arning Label

57a

57b

16 88

Ref

12 39

Ref 33

318

Ref

307-889

02340

Parts

– Upright Sprayer

Model

231–079, Series C

Ultra 500, 230 V

olt

Includes items 1 to 92

Ref. No. Part No. Description Qty.

2 222–052 MOTOR, ELECTRIC, 1/2 HP

4 110–963 SCREW 6 223–100 DRIVE HOUSING

6a 110–293 . GREASE 1 7 105–510 LOCKW 8 107–445 CAPSCREW 9 218–359 CONNECTING ROD 1 10 100–040 11 181–611 COVER, drive housing 1 12 108–709 SCREW

13 107–209 SCREW 14 185–417 TUBE, suction 1 15 108–663 SPACER 2 16 108–865 SCREW 19

20 21 22

24 100–069 26 218–364 GEAR REDUCER 1 27 28 108–691 PLUG, plastic 2 29 206–994 THROAT SEAL LIQUID,

30 31 33 222–555 FRAME, sprayer 1 38 39 108–460 CONNECT 40 PRESSURE CONTROL

41 065–312 CONDUIT

42 106–062 44 101–242 45 104–811 HUBCAP 2 49 107–264 TERMINAL 52 107–267 TERMINAL, 53 214–570 FILTER,

181–612

222–584 DISPLACEMENT PUMP

176–818 176–817 162–453

235–574

 185–952 LABEL, DANGER 1

181–609 107–447

 185–954* LABEL, DANGER 1

SHIELD, MOTOR,

includes one of item 24

includes items 24, 49 and 52

, hex head, no. 5/16–18 x .25”

Includes item 6a

ASHER, spring, 1/4”

, sch, 1/4–20 x 1.5”

PLUG, pipe, 1/4”

, pnh, T

8–32 unc–3a x 1”

, filh, no. 8–32 x 1”

, pan head, no. 8 x 3/8”

see page 33 for parts

PIN, straight, hdls SPRING, retaining NIPPLE, hex, 1/4 npsm x 1/4 npt, 1–3/16” 2 HOSE, grounded, nylon, 1/4” ID, 29” (736 m) long, spring guard both ends BALL, stainless steel, 1/4” dia.

8 oz. (0.27 liter) LABEL, identification SEAL, conduit

see parts list on page 34

specify length when ordering WHEEL, semi–pneumatic RING, retaining

fluid

see manual 307–273 for parts

ype I,

not shown

see page 26

OR, conduit, 45

, electrical,

see

page 35

female

see

 1

0.79 ft

page 35

54 237–677 PRESSURE DRAIN VALVE 1 55 181–610 56 176–762 NUT 57 218–242 CRANKSHAFT ASSEMBLY,

57a 180–131 . BEARING 1 57b 107–434 . BEARING 1 58 101–682 59 178–034 TAG, WARNING 1

60 100–509 61 220–955 SPRAY GUN, airless

1 7

62 214–701

64 100–214 LOCKW

65 100–188 NUT 66 110–243

67 111–590 BUTTON, snap 2 68 187–603 69 222–554 HANDLE, cart 1

70 187–190 STRAINER 1

71 181–607 78 109–046 81 185–365 HANGER, pail 1

83 183–350 WASHER, 0.9 ID x 1.25 OD 2 84 109–032 SCREW

1 1

85 185–384 BRACKET

86 110–240 NUT 87 103–846 CAPSCREW

88 100–020 LOCKW

90 178–341 CLIP

91 190–091 DRAIN TUBE 1 92 186–245 CLIP



1 1 2

2 2

223–541

Replacement

cards are available at no cost.

LABEL, identification

, hex, 1–1/2–18

includes items 57a and 57b

SCREW

PLUG, square head, 1/4 npt(m)

see 307–614 for parts

HOSE, grounded, nylon, 3/16” ID, 3 ft (0.9 m) long, spring guards both ends HOSE, grounded, nylon, 1/4” ID, 50 ft (15 m) long, spring guard both ends

RING, retaining

SLEEVE, handle

LABEL, identification UNION, adapter

10–24 x 1/4”

x 1/2”

Danger and W

, socket head, 1/4–20 x 0.62 ”

ASHER, spring, 5/16”

, heavy hex, 5/16–18 unc–2a

,swivel x 3/8 npt(m)

, pnh, type F

, shield mounting

, retaining, T

, sch, 10–24 unc–3a

ASHER, 0.194 ID x 0.334 OD

, large

, small

ype U 2

arning labels, tags and

1 1

1 4 4 2

1 1

4 2

2 4 1





Parts

PTFEPTFEPTFE

Model

222–584, Series A

Drawing & List – Displacement Pump

Includes items 202 to 225

Ref. No. Part No. Description Qty.

202* 108–954 P 203* 105–522 204* 105–445 BALL, sst 1 205 180–656 PLUG 1 206* 176–749 V–P 207* 176–755 V–P 208* 176–754 209* 176–757 210* 176–750 211 212* 176–882 V–PACKING, plastic 3 213* 176–997 V–PACKING, plastic 3 214* 180–161 WASHER, backup 1 215* 180–073 216 218 219 220 221* 183–555 222 223 224 225* 105–444

* These

176–751

176–758 183–571 183–562 183–559

218–197 221–098 183–563

parts are also included in Repair Kit

ACKING, o–ring,

SEAL, u–cup, polyurethane

ACKING, leather

ACKING, leather GLAND, male GLAND, female GLAND, male NUT

, hex, retaining

GLAND, female NUT

, packing SLEEVE, cylinder 1 CYLINDER 1 GUIDE, ball 1 PIN, ball stop VAL

VE, piston

VAL

VE, intake ROD, piston 1 BALL

222–587, which may be purchased separately

NOTE:

This pump uses sleeve removal tool 224–786.



205

216

2 1

*209

224

225*

2 2 1

*207

1 1 1

213*

211

210*

*208

*206

1 1

219

1 1 1

*202

212*

215*

203*

214*

222

220

221*

218

204*

202*

223

0089





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) 500 Sprayer

REF NO. PART NO. DESCRIPTION QTY

301 238–073 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* 307 111–826 308 107–255 GUARD, locking 1 309 105–659 BOOT, switch 1 310 236–352 POTENTIOMETER, pressure 1

Extra

arning and Caution lables are available free.

307-889

LABEL, caution SWITCH, toggle

adjustment

,panhead, 10–24 x 1” ,panhead, 10–24 x 2”

314

REF NO. PART NO. DESCRIPTION QTY

311 108–358 312 112–768 KNOB, control 1

313 185–565

314 237–822 CORD, power 1 315 105–746 BUSHING, strain relief 1 316 112–376 LOCKNUT 1

317 100–078 SCREW

318 108–460 CONNECT 319 189–286* 320 237–491 BOARD, filter 1

SEAL, shaft

LABEL, knob

, hexhead, 8–24 x .375

OR, conduit

LABEL, warning

04791

4 1 1

Wiring

Diagram

PRESSURE TRANSDUCER

TP6

TP8

TP5

BLACK

–

GREEN/YELLOW

GROUND

WIRE

CIRCUIT BOARD

(B1)

WIRING

BLUE

DIAGRAM

POTENTIOMETER

TP4 (behind)

TP3

BLACK/WHITE

M +

BLACK

M –

GREEN/YELLOW

ON/OFF SWITCH

–

MOTOR

TP1 (behind) TP2

BROWN (L1)

BLUE (L2)

TP7

FILTER BOARD

BLUE(L2)

RED

BROWN

SUPPL

Y CORD

Fig.

POWER

Accessories

Displacement

See parts on page 33. Repair instructions included.

19 Liter Suction T

Installation instructions included

Pump Repair

ube Kit 218–402

222–587

WINDINGS

THERMAL SWITCH

DANGER

LABELS

The English language DANGER label shown on page

4 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 charge. Toll Free: 1–800–328–0211

Apply

language here

other

French 185–955 Spanish 185–962 German 186–042 Greek 186–046 Korean 186–050

04772

05263

Motor Brush Kit

222–157

Repair instructions included with kit.

Spring Clip

110–816

Holds in motor brushes (not included with brush kit).

Sleeve Removal T

ool

224–786

Required for removing the displacement pump sleeve.

307-889

Technical

Power

Requirements

orking Pressure Range Cycles/liter 124 Maximum Power Inlet

Paint Strainer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery

Cord

. . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

Stainless

Data

230 V

AC, 50 Hz,

phase, 7 amp minimum

. . . . . . . . . . . . . .

No. 14 A

steel screen, reusable

0 – 195 bar

1.8 liter/min

WG, 3 wire, 2.6 m

190 micron

Outlet Paint Filter

Pump Inlet Size Fluid

Outlet Size

Wetted

NOTE: Delrin DuPont Company

Parts:

Displacement Pump

UHMW polyethylene, Delrin, Leather

Filter

Aluminum, Carbon steel, Stainless steel,

. . . . .

is a registered trademark of the

. . . . . . . . . . . . . . . . . . . . . .

Stainless

3/4 npt(m) with 20 ID chamfer

. . . . .

. . . . . . . . . .

. .

steel screen, reusable

1/4 npsm from fluid filter

Carbon steel, Polyurethane,

250 micron.

Dimensions

eight (dry w/o packaging) Height 711 mm. Length 660 mm. Width 572 mm.

WARRANTY

Graco the date warranty defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for forty-eight months from the date of sale and the electric motor (excluding brush replacement, which is routine maintenance) or pressure control assembly which will be repaired or replaced for twenty-four months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’

This warranty does not cover misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, instal lation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The

warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on

of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this

, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the Ultra equipment proven

Graco Warranty and Disclaimers

. . . . . . . . .

, and Graco shall not be liable for

40 Kg (approx.)

Manual

The Pressure Control Assembly 222–176 has been replaced with the freeze resistant Pressure Control, see

34.

page

, any malfunction, damage or wear caused by faulty installation,

Change Summary

s written recommendations.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), liabilities, including product liabilities, based on negligence or strict liability tial damages or loss is expressly excluded and denied. In no case shall Graco’ Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

including warranty of merchantability or warranty of fitness for a particular purpose,

. Every form of liability for direct, special or consequen

s liability exceed the amount of the purchase price.

, and disclaims all implied

Graco

PLACE AN ORDER

call this number to identify the distributor closest to you:

1–800–367–4023 Toll Free.

Foreign Offices:

GRACO INC. P.O. BOX 1441

307-889

, contact your Graco distributor

Belgium; Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan

Sales Offices:

PRINTED

IN U.S.A.

warranties of merchantability and fitness for a particular purpose,

, switches, hose, etc.) are subject to the warranty

Phone Numbers

FOR TECHNICAL ASSISTANCE,

information or assistance regarding the application of

equipment:

Graco

Atlanta, Chicago, Detroit, Los Angeles

MINNEAPOLIS, MN

307–889 November 1988 Revised June 1995

1–800–543–0339 T

55440–1441

and of any non–contractual

, if any

, of their manufacturer

service repair

oll Free

with

Graco ULTRA 500 Instructions-parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual