Graco 231–373, 231–410, 231–411, ULTRA PLUS+ 1000 Instructions-parts List Manual

LIST
308–619
This
manual contains important warnings and information. READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
120 VAC, 15 AMP
ULTRA AIRLESS P
3000
psi (210 bar
Model 231–373, Series A
Complete gun, RAC IV DripLess and SwitchT
sprayer on Upright cart with hose,
ip
PLUS+
AINT SPRA
, 21 MPa) Maximum Working Pressure
T
ip Guard
1000
YER
First
choice when
quality counts.
Supersedes Rev. A PCN B; unreleased
Rev. D
Rev. C
U.S. PATENT NO. 4,323,741; 4,397,610 PA
TENTED 1983, CANADA
AND OTHER PATENTS PENDING

GRACO INC. P.O. BOX 1441
MINNEAPOLIS, MN
http://www.graco.com
COPYRIGHT
Graco
Inc. is registered to I.S. EN ISO 9001
1996, GRACO INC.
MODEL
231–373
55440–1441
Table
of Contents
Introduction 2.
Warnings 4
Setup 7
Startup 9 Shutdown
Flushing 12
Troubleshooting 13
Spin Test 18.
General
Motor
Brush Replacement
Power
On/Off
Pressure
Bearing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Care
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Information
Supply Cord Replacement
Switch Replacement
Control Replacement
Housing & Connecting Rod Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
11.
19.
20.
21.
22.
23.
25.
Introduction
Drive
Housing Replacement
Motor
Replacement
Displacement
Parts
Drawing – Sprayer
Parts
List – Sprayer
Parts
Drawing and List – Displacement Pump
Parts
Drawing – Pressure Control
Parts
List – Pressure Control
Wiring
Diagram
Accessories 39
Technical
Dimensions 39
Graco
Phone Number
The
Graco W
Pump Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
arranty And Disclaimers
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . .
26.
28.
30.
34.
35.
36.
37.
37.
38.
39.
40.
40.
ULTRA
Your other come
PLUS+
new sprayer functions and operates dif
airless paint sprayers. This section will help you be
familiar with the sprayer before operating it.
1000
BASIC COMPONENTS
Pressure Control
The
pressure control includes sprayer, a pressure adjusting control knob and a freeze resistant pressure sensing device. The function of the pressure sprayer maintains constant fluid pressure at the pump outlet.
Pressure
The pressure drain valve provides pressure relief of the sprayer. and allows normal sprayer operation. In the downward position, the pressure drain valve relieves the pressure
the system. The pressure drain valve will also open au
in tomatically in the case of a control overpressure failure.
control is to control the
Drain V
In the forward position, the drain valve is closed
alve
an ON/OFF switch for the
motor speed so that the
Motor
The
DC motor has sealed bearings and replaceable tor brushes. It drives the displacement pump at the rate needed pressure. W orking together , the pressure control and motor pressure sounds like an automobile starter cranking. When the pump til self off. However, there will still be power to the sprayer and it will stay pressurized and ready to use until you manually
to supply suf
cause the pump to cycle whenever there
demand.
is not cycling, the motor may hum intermittently un
the fluid pressure stabilizes, then the motor will shut
shut it of

ficient paint volume
When the pump is cycling, the motor
f and relieve pressure.
at the selected
ferently than
mo
is fluid or
it
Because the motor is DC, it is less sensitive to low volt­age or voltage fluctuations than an AC motor, and a 12
or larger extension cord of up to 300 ft. (90 m) can
gauge
­be
used without performance loss.
Drive Assembly
The
sealed drive assembly
motor
to the displacement pump.
transfers power from the DC
Displacement Pump
The
positive displacement, volume-balanced pump pro
equal fluid delivery on both the up
vides strokes. The pump has a wet-cup which, when filled with Graco Throat Seal Liquid, helps prevent damage to the
packings and piston rod.
throat
and down pump
Fluid Filter
The
fluid filter strains the paint to help avoid clogs in
hose
and spray tip. The filter includes a reusable element
and
has a pressure drain valve for manually relieving fluid
-
pressure.
Hoses
The
grounded, nylon spray hoses have spring guards on
both
ends. The 50 ft. (15.2 m) hose has a 1/4 in. ID. The
3 ft.
-
(0.9 m), 3/16 movement. The nylon hose material acts dampener to absorb pressure fluctuations.
in. ID hose provides more flexible gun
as a pulsation
Spray Gun & RAC IV DripLess Tip Guard
Graco high pressure spray guns have a safety latch
prevents accidental
which See T in Fig. 1. The gun provided with the sprayer also
-
-
a filter for final paint straining. The Reverse-A-Clean
has IV SwitchTip uses high pressure fluid to remove clogs
the
from Reverse-A-Clean IV DripLess tip guard is a safety fea­ture
spray tip without removing it from the gun. The
which helps reduce the risk of fluid injection injury
triggering when it is engaged.
-
the
.
T
A
B
C
D
S
0137
Fig. 1
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
J
K
Motor
Pressure Adjusting Knob
ON/OFF Switch
Drive Assembly
Fluid Filter
Secondary Fluid Outlet
Pail Hanger
Displacement Pump
50 ft (15 m) Main Hose
RAC IV T
ip Guard
Contractor Gun
RAC IV Switch T
ip
3 ft (0.9 m) Hose
Primary Fluid Outlet
Pressure Drain V
alve
Pressure Control
Spray Gun Safety Latch
M
E
F
G
H
R
P
N
L
04239
DC motor
, 120 V
ac, 15A, 1 phase
Controls fluid outlet pressure
Power switch that controls 120 V
T
ransfers power from DC motor to the displacement pump
ac main power to sprayer
Final filter of fluid between source and spray gun
Second spray gun operation is connected here
Container for fluid to be sprayed may be hung here
T
ransfers fluid to be sprayed from source through spray gun
1/4 in. ID, grounded, nylon hose with spring guards on both ends
Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
High pressure spray gun with gun safety latch
RAC switch tip uses high pressure fluid to remove clogs from spray tip without removing tip from spray gun
3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun to allow more flexibility when spraying
Single spray gun operation is connected here
Relieves fluid outlet pressure when open
Controls motor speed to maintain fluid outlet pressure at displace ment pump outlet. W
orks with pressure adjusting knob.
-
Gun safety latch inhibits accidental triggering of spray gun

Symbols
Warning Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNINGWARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment
This equipment is for professional use only
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
misuse can cause the equipment to rupture or malfunction and result in serious injury
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
.
.
.
Check equipment daily
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the Technical Data
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
T
echnical Data
warnings.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex pose Graco hoses to temperatures above 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.
section of all equipment manuals. Read the fluid and solvent manufacturer
. Repair or replace worn or damaged parts immediately
on page 39 for the maximum working pressure of this equipment.
.
F).
’s
-
4
308-619
WARNINGWARNING
INJECTION HAZARD
Spray
from the gun, leaks or ruptured components can inject fluid into your body and cause ex tremely serious injury can also cause serious injury
Fluid injected into the skin is a serious injury injury
. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun dif
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
, including the need for amputation. Fluid splashed in the eyes or on the skin
.
. The injury may look like just a cut, but it is a serious
.
, glove or rag.
fuser operation weekly
. Refer to the gun manual.
-
Follow the checking or servicing the equipment.
T
ighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.
Pressure Relief Procedure
on page 13 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
TOXIC FLUID HAZARD
Hazardous skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container state and national guidelines.
Always wear protective eyewear and solvent manufacturer
fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
. Dispose of hazardous fluid according to all local,
, gloves, clothing and respirator as recommended by the fluid
.
. Do
308-619
5
WARNING
WARNING
FIRE AND EXPLOSION HAZARD
Improper result in a fire or explosion and serious injury
grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
.
If there is any static sparking or you feel an electric shock while using this equipment,
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or of
Do not operate a gasoline engine in the spray area.
f any light switch in the spray area while operating or if fumes are present.
MOVING PARTS HAZARD
Moving
parts, such as the air motor piston, can pinch or amputate your fingers.
stop
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the
NOTE: This
your sprayer
equipment from starting unexpectedly
is an example of the DANGER label on
. This label is available in other
.
languages, free of charge. See page 39 to order
FIRE
AND
EXPLOSION HAZARD
Spray
painting, flushing or cleaning equipment with flammable liquids in
confined
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses,
Avoid open connecting off.
Failure
areas can result in fire or explosion.
containers and objects being sprayed.
all ignition sources such as static electricity from
flames such as pilot lights, hot objects such as cigarettes, arcs
or disconnecting power cords or turning light switches on
to follow this warning can result in death or serious injury
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
plastic drop cloths,
from
and
.
Pressure Relief Procedure
on page 13 to prevent the
.
SKIN INJECTION
HAZARD
Liquids
can be injected into the body by high pressure airless spray or
leaks
– especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the body
. Drain all pressure before removing parts.A
ing of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate “Surgical T
Failure to follow this warning can result in amputation or serious injury.
reatment”.
void accidental trigger
-

Setup
WARNING
To reduce the risk of serious injury from static sparking, injection, or over pressurization and rupture cally conductive, the gun must have a tip guard, and each Maximum Working Pressure.
of the hose or gun, all hoses must be electri
part must be rated for at least 3000 psi (210 bar)
CAUTION
T
o avoid damaging the pressure control, which may result in poor equipment performance and compo­nent
damage, follow these precautions:
1. Always use grounded, flexible spray hose at
least
50 ft. (15 m) long.
2. Never
3. Never
4. Always
use a wire braid hose as it is too rigid to act
as
a pulsation dampener
install any shutof
and
the main hose. See Fig. 2.
use the main filter outlet for one gun op
eration.
Never plug this outlet.
.
f device
between the filter
NOTE:
1. Fill the packing nut/wet-cup
-
-
2. Connect the gun, 3 ft. hose and 50 ft. hose.
3. Two gun hookup
4.
See Fig. 2 while doing the setup.
1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
Screw the assembly onto the outlet nipple. Don’t use thread sealant and don’t install the spray tip yet!
. Unscrew the cap from the 1/4 npsm(m) secondary hose outlet. Connect a hose and gun to the outlet. Use a 1/4 in. ID, 50 ft. long (minimum) main hose. For more flexible gun movement, install a 3/16. ID, 3 ft. hose between the main hose and the gun.
Check the Electrical Service.
Two gun hookup. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose and gun to the outlet. Use a 1/4 in. ID, 50 ft. long (minimum) main hose. For more flexible gun move­ment,
install a 3/16 in. ID, 3 ft. hose between the main
hose
and the gun.
a.
Electrical requirements: 120 V AC, 60 Hz, 15 Amp (minimum).
b. Use
b. Do not remove the grounding prong of the
c. Extension
a grounded
20 ft. (6 m) from the spray area.
supply
cord and do not use an adapter
grounding type. (Long lengths reduce sprayer performance.)
electrical outlet located at least
power
.
cord specifications: 15 Amps, 3 wires,
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious injury and property damage. Read the warning sec tion
FIRE OR EXPLOSION HAZARD
page 6 for more detailed grounding
instructions.
on
5. Plug
6. Flush the pump
7.
-
in the sprayer. Turn the ON/OFF switch
OFF
. Plug the cord into a grounded electrical
outlet.
to remove the oil left in to protect pump parts after factory testing. See on page 12.
Prepare the paint
recommendations. Remove any paint skin. Stir the paint thoroughly nylon mesh bag (available at most paint dealers) to remove particles that could clog the filter or spray tip. This is an important step for trouble-free paint spraying.
according to the manufacturer
. Strain the paint through a fine
Flushing
308-619
’s
7
Setup
PRESSURE ADJUSTING KNOB
P
ACKING NUT/ WET–CUP
FILL 1/3 FULL WITH TSL
Fig.
2
PRESSURE DRAIN VALV E
1/4 npsm(m) FLUID OUTLET NIPPLE
DO NOT INST
ALL ANY SHUT
DEVICE HERE
OFF
ON/OFF
SWITCH


Startup
Use this procedure each time you start the sprayer to help
ensure the sprayer
start
it safely
.
is ready to operate and that you
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
,
-
ever you are instructed to relieve pressure.
NOTE:
Flush the sprayer if this is a first-time startup. See page 12.
NOTE:
See Fig. 4 except where noted.
1. Put the suction tube into the paint container.
2. Turn the pressure adjusting knob fully coun-
terclockwise to zero pressure.
3.
Plug in the sprayer
.
CAUTION
c. Release
5. Check all fluid connections for leaks
the trigger. Engage the gun safety latch.
. Relieve
the fluid pressure before tightening connections.
6. Install the spray tip and tip guard.
Engage the gun safety latch. See Fig. 3. Install the spray tip according to the instructions supplied with it.
7. Adjust the spray pattern.
a. Increase the pressure just until spray from the
gun is completely atomized. Use the lowest pressure
needed to
get the desired results. This reduces overspray and fogging, decreases tip wear
and extends the life of the sprayer
b.
If more coverage is needed, use a larger tip rather
than increasing the pressure.
c.
Test the spray pattern. T o adjust the pattern, engage nut.
the gun safety latch, loosen the
Position the tip guard horizontally for a hori zontal pattern or vertically for a vertical pattern. Then
tighten the retaining nut.
GUN
SAFETY
LA
TCH SHOWN
ENGAGED
.
retaining
-
Do not run the pump without fluid in it for more than 30 seconds to avoid damage to the displacement pump
packings.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and splashing when flushing, always remove the spray tip from the gun and hold a
metal part of the gun firmly to the side of a grounded metal pail.
4.
Prime the pump
a.
Open
the pressure drain valve (handle in down ward position). If you did not install a secondary hose, be sure the nipple is tightly plugged with the cap provided. T urn the ON/OFF switch to ON. Slowly turn the pressure adjusting knob clockwise until the sprayer starts. When fluid comes dle
in forward position).
b. Disengage the gun safety latch. See Fig. 3.
Following the warning, above, trigger the gun until all air is forced out of the system and the paint
flows freely from the gun.
.
from the drain hose, close
the valve (han
Fig.
3
ON/OFF
GUN SAFETY LA SHOWN DISENGAGED
SWITCH
TCH
0137
PRESSURE ADJUSTING KNOB
-
-
OUTLET NIPPLE
Fig.
4
DRAIN HOSE
PRESSURE DRAIN VALV E
04243

Startup
Cleaning a Clogged Tip
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
ever you are instructed to relieve pressure.
1. Clean the front of the tip frequently during the day’s operation. First, relieve pressure.
2. If the spray tip does clog, release the gun trigger gage the gun safety latch, and rotate the RAC IV handle
180. See Fig. 5.
3.
Disengage the gun safety latch and trigger the gun into a waste container. Engage the gun safety latch again.
,
-
, en
4. Return
the handle to the original position, disengage
the
gun safety latch, and resume spraying.
5. If the tip is still clogged, engage the gun safety latch, shut
of
f and unplug the sprayer
sure
drain valve to relieve pressure. Clean the spray
, and open the pres-
tip as shown in manual 307–848, supplied with the RAC
IV
.
TIP GUARD HANDLE
SHOWN IN SPRA
TURN HANDLE 180
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
YING
POSITION
,
GUN LA ENGAGED
-
Fig.
5
SAFETY
TCH SHOWN



Shutdown
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
1.
Check
pressure. to help prevent fluid buildup on the piston rod and premature
the packing nut/wet-cup daily. First relieve
Keep the wet-cup
wear of packings.
warning on page 13 when
Pressure Relief
1/3 full of TSL at all times
and Care
6.
Coil
the hose and hang it on the
storing
it, even for overnight, to help protect the hose
from
kinking, abrasion, coupling damage, etc.
,
-
PACKING
NUT/
WET–CUP
hose rack
when
Tighten Over ing wear. Use a round punch or brass rod and light hammer
2.
Clean
er 12 or refer to manual 307–273, supplied, for the cleaning
3.
Lubricate the bearing housing after every 100 hours of operation. First relieve pressure. Remove the front cover. Fill the bearing housing cavity with SAE
4. For very short shutoff periods, leave the suction tube in the paint, relieve pressure, and clean the spray
5. Flush fill sion
the packing nut just enough to stop leakage.
tightening causes binding and excessive pack
to adjust the nut. Refer to Fig. 6.
the fluid filter often
is stored. Follow the Flushing Guidelines on
procedure.
10 non-detergent oil. See Fig. 7.
tip.
the sprayer at the end of each work day
it with mineral spirits to help prevent pump corro
and freezing. See page 12.
and whenever the spray
page
and
CAUTION
-
TIGHTEN
-
Fig.
6
FILL BEARING HOUSING
CA
VITY WITH SAE
NON-DETERGENT OIL
AFTER EVER
HOURS OF OPERATION
FRONT COVER
-
Y 100

To
prevent pump corrosion,
type
of paint in the sprayer when it is not in use. Pump
water
or paint out with mineral spirits.
never leave water or any
Fig.
7



Flushing
NOTE:
Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be sprayed, or to store the sprayer
. Use this chart to determine the required flushing order for the fluid you are
using, and then follow the procedure below for flushing.
*Use this category for flushing a brand new sprayer and flushing after storage.
System has this fluid in it:
Next fluid to be sprayed.
Flushing order:
Flush 1 Flush 2 Flush 3
*Oil-based solvent or paint
Oil-based solvent or paint
Oil-based solvent or paint
Water or water­based paint
Water or water­based paint
Water or water­based paint
Oil-based paint – new color
W
ater-based paint
Prepare for storage
W
ater-based paint
– new color
Oil-based paint
Prepare for storage
Mineral spirits
none none
Mineral spiritsWarm soapy
water
Mineral spirits
W
arm soapy
none none
Clean water
water
W
arm soapy
Clean water
water
W
arm soapy
Clean water
water
Clean water
none
Mineral spirits
Mineral spirits
Before you spray or store sprayer:
Prime with oil-based paint
Prime with water-based paint
Relieve pressure, Leave drain valve open
Prime with water
Prime with oil
Relieve pressure, Leave drain valve open
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and splashing when flushing, always remove the spray tip from the gun and hold a
metal part of the gun firmly to the side of a grounded metal pail.
1.
Follow the illustrated on page 13. Engage the gun safety latch.
2. T
urn the pressure adjusting knob fully counter
clockwise to zero pressure.
3.
Remove the spray tip from the gun. Remove the filter bowl and screen; see manual 307–273. Clean the screen separately and install the bowl without the screen to flush it. See Fig. 8.
4.
Put the suction tube into a grounded metal pail with 1/2 gallon of compatible solvent.
Pressure Relief Procedure
6.
Do not run the pump dry for more than 30 seconds to avoid damaging the pump packings!
7.
Follow the illustrated
Pressure Relief Procedure
on page 13. Engage the gun safety latch.
8.
Unscrew the filter bowl and reinstall the clean screen. Install the bowl and hand tighten.
9.
Remove the suction tube and screen and clean them separately
.
-
FILTER
SCREEN
FIL
TER
SUPPORT
BOWL
5.
Start the sprayer still in the sprayer
. See page 9. T
o save the fluid
, trigger the gun into another container until the next fluid appears, then trigger the gun back into the fluid you are pumping. Circu late the flushing fluid a couple of minutes to thor oughly clean the system.


PRESSURE DRAIN
V
ALVE
-
-
Fig.
8

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