Graco Ultra 1000 Instructions And Parts List Download

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307-785

Displacement Pump Repair

Stack the glands and packings in the top of the
cylinder (219). Be sure to alternate the leather
(207*) and plastic (213) v–packings and stack the
v–packings so the lips face down. See Fig. 38.

Install the packing nut (216) and the plug (205),
but leave the nut loose for now.

See Fig. 38.

10. Oil the piston rod and the packings. Carefully slide

the assembly (A) into the top of the sleeve
(218).

NOTE: The tapered end (B) of the sleeve (218) is the
bottom of it. See Fig. 36.

0030

Fig. 36

Oil the piston rod
and the packings.

218

11. Place a new o–ring (217*) firmly in the cylinder

groove. See Fig. 38.

12. Slide the sleeve and piston rod assembly (C) into

the bottom of the cylinder (219). This is to pre-
vent packing damage during reassembly. See Fig.
36.

219

Fig. 37

13. Screw down the cylinder locknut (47) until it is fin-

ger tight at the bottom of the external cylinder
threads.

14. Place the flats of the intake valve (223) in a vise.

Install a new o-ring (202*). Screw the pump cylin-
der into the valve. Torque to 70 ft-lb (95 N.m). See
Fig. 38.

15. Install the pump.

219

205

215*

214*

*202

*217

*208

*209

218

216

*210

01197

Fig. 38

3
4

*207

213*

212*

*206

*203

223

Leather packings.

Poly packings.

The lips of these packings must face down.

The lips of these packings must face up.

Torque the intake valve to 70 ft–lb (95 N.m).

Summary of Contents for Ultra 1000

Page 1: ...t include a hose or a gun Model 231 043 Series B This is a complete sprayer on an upright cart and includes a hose a gun a RAC IV DripLess Tip Guard and a SwitchTip U S PATENT NO 4 323 741 4 397 610 PATENTED 1983 CANADA AND OTHER PATENTS PENDING GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1986 GRACO INC This manual contains important warnings and information READ AND RETAIN FOR REFE...

Page 2: ...d In case of accidental skin injection seek immediate Surgical Treatment Failure to follow this warning can result in amputation or serious injury FIRE AND EXPLOSION HAZARD SKIN INJECTION HAZARD READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE Spray painting flushing or cleaning equipment with flammable liq uids in confined areas can result in fire or explosion Use outdoors or in ...

Page 3: ... nut which when filled with Graco Throat Seal Liquid T SL helps prevent damage to the throat packings and piston rod Fluid Filter The fluid filter strains the paint to help avoid clogs in the hose and the spray tip The filter includes a reus able element and has a pressure drain valve for manu ally relieving fluid pressure Hoses The grounded nylon spray hoses have spring guards on both ends The 50...

Page 4: ...sk of fluid injection when the tip is not installed Check diffuser operation regularly Follow the Pressure Relief Procedure below then remove the spray tip Aim the gun into a metal pail holding the gun firmly to the pail Using the lowest possible pressure trigger the gun If the fluid emitted is not diffused into an irregular stream replace the diffuser immediately Tip Guard Always have the tip gua...

Page 5: ... on it which specifies the maximum electrical resistance contact the hose supplier or manufacturer for the maximum re sistance limits Use a resistance meter in the appropriate range for your hose to check the resistance If the resistance exceeds the recommended limits replace it immediately An un grounded or poorly grounded hose can make your system haz ardous Also read FIRE OR EXPLOSION HAZARD FI...

Page 6: ...seur du pistolet sert à diviser le jet et à réduire les risques d in jection accidentelle quand l ajutage n est pas en place Vérifier le fonctionnement du diffuseur régulièrement Pour cette vérification détendre la pression en observant la Marche à Suivre pour Détendre la Pression donnée plus loin puis enlever l ajutage du pulvérisateur Pointer le pistolet dans un seau en métal en le maintenant fe...

Page 7: ...INCENDIE OU D EXPLOSIÓN ci dessus RISQUES D INCENDIE OU D EXPLOSION De l électricité statique est produite par le passage du fluide à grande vitesse dans la pompe et dans les tuyaux Si toutes les pièces de l appareil de pulvérisation ne sont pas convenablement reliées à la masse ou à la terre des étincelles peuvent se produire et l appareil risque d être dangereux Des étincelles peuvent également ...

Page 8: ...ifusor El difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyección cuando no está instalada la boquilla Revisar con regularidad el funciónamiento del difusor Seguir el procedimiento de descarga de presión dado más abajo y después sacar la boquilla Apuntar la pistola a un balde metáli co sosteniéndola bien firme contra el Utilizando la presión más bajo posible disparar l...

Page 9: ...ndados reemplazarla de inmediato Es muy ar riesgado tener una manguera sin puestá a tierra o con la puestá a tierra en malas condiciónes Leer también la información sobre RIESGO DE INCENDIO O EXPLOSION más arriba PELIGRO DE INCENDIO O EXPLOSION El flujo a alta velocidad del fluido al pasar por la bomba y man guera crea electricidad estática Si todas las partes del equipo pulverizador no tienen bue...

Page 10: ...injury and property damage Read the warning section FIRE OR EXPLOSION HAZARD on page 5 for more detailed grounding instructions NOTE Refer to Fig 2 while following this procedure 1 Fill the packing nut until it is 1 3 full with Graco Throat Seal Liquid TSL 2 Connect the gun the 3 foot 0 9 meter hose and the 50 foot 25 2 meter hose Screw the assembly onto the outlet nipple Don t use thread sealant ...

Page 11: ... protect it during shipment Follow the flushing procedure on page 15 7 Prepare the paint according to the manufacturer s recommendations Remove the skin which may have formed on top of the paint Stir the paint thor oughly Strain the paint through a fine nylon mesh bag to remove particles that could clog the filter or the spray tip 72 66b 74 C B 66 75 E D 102 101 100 01217A Fig 2 ...

Page 12: ...e adjusting knob C fully counter clockwise to the minimum pressure CAUTION Do not operate the pump without fluid in it for more than 30 seconds to avoid damage to the pump packings WARNING To 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 0143 5 Prime the pump a Ope...

Page 13: ...whenever you are instructed to relieve the pressure To reduce the risk of a serious injury from acciden tally injecting fluid into the skin follow these pre cautions Never operate the spray gun with the tip guard removed Do not hold your hand body or a rag in front of the spray tip when cleaning or checking a clogged tip Always point the gun toward the ground or into a pail when checking to see if...

Page 14: ...e flushing procedure on page 15 or refer to manual 307 273 for the cleaning procedure 3 Lubricate the bearing housing 69 after each 100 hours of operation Relieve the pressure Remove the front cover 49 Fill the cavity in the bearing housing with SAE 10 non detergent oil See Fig 6 4 For very short shutoff periods leave the suction tube in the paint relieve the pressure and clean the spray tip 5 Flu...

Page 15: ...l If water freezes in the pressure control it may be seriously damaged and the sprayer may not start Always pump the water out with mineral spirits before the water could freeze in the pressure con trol WARNING To 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 WARNI...

Page 16: ...ure it has not popped up 1 Depress the button to reset If the circuit breaker continues to open see the section There is an electrical short on page 21 2 Check the electrical supply with a volt meter The meter should read 105 to125 VAC 2 Reset the building circuit breaker replace the building fuse Try another outlet 3 Check the extension cord for visible damage Check the outlet of the extensions c...

Page 17: ... if possible See page 34 8 Use an armature tester or perform the sping test to check the motor armature for electrical shorts See page 22 8 Replace the motor See page 34 9 Check the bridge 308 by substituting it with a good bridge or performing the bridge test See page 23 CAUTION Do not perform this check until the motor armature is determined to be good A bad armature will immediately burn out a ...

Page 18: ...repair 10 Check all the terminals for damage or a loose fit Reconnect the TP6 connectors 10 Replace any damaged terminals and recon nect the terminals securely 11 Check the circuit board 71 by substituting it with a good board See page 28 11 Replace the circuit board See page 28 WIRING DIAGRAM NOTE These leads have interchangeable connections TP9 and TP10 TP13 and TP14 TP15 and TP16 308 TP9 TP10 T...

Page 19: ... Check bridge 308 and leads and termi nals to motor Inspect wiring insulation and ter minals for signs of overheating See page 27 7 Be sure male terminal blades are centered and firmly connected to female terminals Replace any loose terminal or damaged wir ing Securely reconnect wires to bridge 8 Check for loose motor brush leads and termi nals See page 25 8 Tighten terminal screws Replace brushes...

Page 20: ...g rod See Fig 29 page 36 6 Check connecting rod assembly 68 for dam age See page 32 2 Replace connecting rod assembly See page 32 7 Be sure crank in drive housing rotates plug in sprayer and turn on briefly to check Turn off and unplug sprayer See page 33 3 Check drive housing assembly for damage and replace if necessary See page 33 6 There are excessive fluctuations of the pressure PROBLEM WHAT T...

Page 21: ... and repair all the electri cal shorts before checking and replacing the bridge 3 Check motor armature for shorts Use an armature tester growler or perform spin test See page 22 Inspect windings for burns 3 Replace motor See page 34 4 Check bridge 308 by substituting with a good bridge or by performing bridge test See page 23 or 27 CAUTION Do not check bridge until arma ture is determined to be go...

Page 22: ... Quickly and manually turn the motor fan If there are no electrical shorts the motor will spin two or three revolutions before completely stopping If the motor does not spin freely the armature is electri cally shorted and the motor must be replaced See page 34 Test for electrical continuity between the armature the brushes and the motor wiring 1 Relieve the pressure 2 Connect the two black motor ...

Page 23: ...nect the meter wires as indicated by the black dots for each test and then check the continuity AC1 AC2 G2 G1 Fig 10 In Tests 1 2 and 3 there should be NO continuity In Tests 4 5 and 6 connect the and meter wires as indicated check continuity then switch the meter wire connections and check continuity again There should be NO continuity one way and YES continuity the other way In Tests 7 and 8 con...

Page 24: ...bare motor Always have the motor shield in place during regular operation These tools are needed for the repairs Phillips screwdriver Small flat blade screwdriver Needle nose pliers Plastic mallet Adjustable wrench Adjustable open end wrench Torque wrench 1 4 inch hex key wrench 3 16 inch hex key wrench 5 8 inch socket wrench 3 8 inch open end wrench 1 2 inch open end wrench 3 4 inch open end wren...

Page 25: ...mutator resurfaced by a qualified motor repair shop 6 Install the new brush C so its electrical lead is in the long slot K of the brush holder H Slide the terminal of the brush s electrical lead E under the washer of the screw F Make sure the motor s electrical lead G is still connected the at the screw Tighten the screw F See Fig 14 7 Place the spring B on the brush C as shown in Fig 14 8 Push in...

Page 26: ...edure on page 4 whenever you are instructed to relieve the pressure NOTE Refer to Fig 16 for this procedure 1 Relieve the pressure 2 Remove the cover 63 See Fig Fig 15 3 Disconnect the upper terminal wire from the micro switch 302 and the two black wires from the ON OFF switch 303 See Fig 15 4 Using a 5 8 inch socket wrench remove the nut and rubber boot 304 Remove the switch guard 305 See Fig 16 ...

Page 27: ... in Fig 17 6 Connect all the wires properly and route them carefully 332 333 308 331B 01229 331A 303 310 309 308 306 01225 G1 G2 Fig 17 63 01225 Circuit Breaker Replacement WARNING To reduce the risk of a serious injury follow the Pressure Relief Procedure on page 4 whenever you are instructed to relieve the pressure NOTE Refer to Fig 17 for this procedure 1 Remove the cover 63 2 Use a small screw...

Page 28: ... if necessary CAUTION Step 2 is essential to reduce the risk of damaging the circuit board while removing or installing it 4 Disconnect the seven wires from the board Pay close attention to where the connections are made 5 Pull out the plastic tipped pin 330 Push the bot tom of the circuit board 71 toward the wall of the pressure control and carefully slide out the board 6 Reinstall the new board ...

Page 29: ...retain it See page 28 7 Remove the conduit 1 8 Remove the three screws 8 lockwashers 10 and nuts 11 Remove the pressure control 9 Remove the screws 22 and the bracket 64 CAUTION To avoid damage to the bourdon tube do not allow the adapter 341 to turn while installing the new pressure control Hold the adapter firmly with a wrench while screwing in the swivel union 39 10 Install the new pressure con...

Page 30: ...s may result in component rupture fire or explosion To perform this adjust ment however the sprayer pressure must be tempo rarily increased above the normal working pressure Use a new 50 ft 15 2 m spray hose rated for at least 3000 psi 210 bar Maximum Working Pressure A used under rated hose could develop a high pressure leak or rupture WARNING To reduce the risk of a serious injury follow the Pre...

Page 31: ...d lock the gun trigger safety Repeat Step 9 to verify the results 12 Install the cover on the pressure control Adjust the maximum working pressure 13 Turn off the sprayer Unlock the gun trigger safety Trigger the gun into a grounded waste container until the pressure is relieved Lock the gun trigger safety 14 Use the 3 8 inch nut driver to turn the pressure adjustment nut T counterclockwise one fu...

Page 32: ...the bearing housing 69 with a plastic mallet to loosen it from the drive housing 67 Pull the bearing housing and the connecting rod 68 straight off the drive housing 7 Remove the pail hanger 61 and install it on the new bearing housing 8 Inspect the crank E for excessive wear Lubricate the inside of the bronze bearing B with a high quality motor oil Pack the roller bearing C with a liberal amount ...

Page 33: ...t to loosen the bearing housing from the drive housing 67 Pull the bearing housing and the connecting rod straight off of the drive housing 5 Remove the two screws 26 6 Remove the two lower screws 13 and then remove the two upper screws 16 from the motor 7 Tap the drive housing with a plastic mallet to loosen the drive housing from the motor 73 Pull the drive housing straight off of the motor 8 Ap...

Page 34: ... electrical leads through the conduit one at a time 8 Unscrew the elbow from the motor 9 Pull the wires through the elbow one at a time 10 Remove the cover 49 from the drive housing 11 Remove the two screws 26 12 Remove the two lower screws 13 and then remove the two upper screws 16 from the front of the motor 73 13 Tap the drive housing 67 with a plastic mallet to loosen it from the front of the ...

Page 35: ... big gear in the drive housing 67 18 Align the gears and push the drive housing 67 straight on to the front of the motor and the locat ing pins 19 Continue to reassemble the sprayer Rotate the conduit 1 as you feed wires through the conduit Install the seal 29 around the wires in the elbow 345 of the pressure control The seal keeps con taminants from entering the conduit and the motor See Fig 26 F...

Page 36: ...slides easily into the hole Back off the pump until the top threads of the pump cyl inder are flush with the face A of the bearing housing and the outlet nipple 40 is facing straight back 3 Push the spring 42 into the groove all the way around the connecting rod 4 Torque the locknut 47 to 70 ft lb 97 N m using a 2 inch open end wrench and a light hammer WARNING Be sure the retaining spring 42 is f...

Page 37: ...no further service is needed reassemble the intake valve assembly Use a new gasket 202 5 Remove the packing nut 216 and the plug 205 See Fig 30 6 Use a plastic mallet to tap the piston rod 224 down Pull the rod out from the bottom of the cylinder 219 See Fig 30 7 Remove the throat packings and the glands B See Fig 31 8 Clamp the flats of the piston rod 224 in a vise Loosen the nut 211 Unscrew the ...

Page 38: ...valve 222 See Fig 34 CAUTION Step 4 is critical Follow the procedure carefully to avoid damaging the packings by overtightening 4 Apply one drop of adhesive supplied to the threads of the piston valve assembly Hand tighten the assembly in to the piston rod just until the nut 211 makes contact with the rod 224 See Fig 34 Torque the nut to 10 5 in lb 1 2 n m to seat the packing Loosen the nut and th...

Page 39: ...ing 217 firmly in the cylinder groove See Fig 38 12 Slide the sleeve and piston rod assembly C into the bottom of the cylinder 219 This is to pre vent packing damage during reassembly See Fig 36 219 Fig 37 C 13 Screw down the cylinder locknut 47 until it is fin ger tight at the bottom of the external cylinder threads 14 Place the flats of the intake valve 223 in a vise Install a new o ring 202 Scr...

Page 40: ...6b 50 8 01239A Ref 99 47 24 61 43 99 86 53 40 70 78 20 13 8 31 77 59 34 85 90 34 34 16 20 73 9 67a 51 67b 9 67 68 69 23 25 49 26 20 10 11 10 73D 58 56 57 98 91 41 97 21 14 19 66a 40 102 101 100 76 94 65 62 48 89 37 Ref 78 Ref 77 35 32 42 45 1 See page 42 for the pressure control parts 1 ...

Page 41: ... identification 1 56 181 639 LABEL ID motor cover left 1 57 181 640 LABEL ID motor cover right 1 58 181 641 LABEL ID front cover 1 59 223 095 SHIELD includes items 41 46 56 57 1 61 189 918 HANGER 1 62 187 603 SLEEVE 2 63 183 995 COVER 1 64 183 365 BRACKET 1 65 206 994 THROAT SEAL LIQUID 8 OZ 1 66 214 570 FLUID FILTER Includes 66a and 66b see manual 307 273 for parts 1 66a 100 040 PLUG 1 66b 162 45...

Page 42: ... 317 107 396 TERMINAL male 1 318 107 262 TERMINAL female 1 319 107 260 TERMINAL female 1 320 107 266 TERMINAL female 1 321 103 885 TERMINAL male 1 322 103 886 TERMINAL female 3 323 107 265 TERMINAL female 1 324 107 263 TERMINAL female 1 325 102 799 RING TERMINAL 1 327 157 021 LOCKWASHER no 8 1 328 108 295 STRAIN RELIEF BUSHING 1 331 101 273 SCREW flat hd no 10 24 x 5 8 2 332 100 179 NUT hex no 10 ...

Page 43: ... 5 Wires AC1 AC2 G1 G2 _ 336 Ref 27 52 75a 323 320 302 317 318 316 324 306 304 309 322 321 75c 312 337 308 323 319 75b 75a 71 303 314 A B C D E C B F G H J KEY A Blue B White C Black D Yellow E Red F Green Ground wire G Power cord H Motor J Thermal switch ...

Page 44: ...1 338 BACKUP WASHER 1 215 178 969 GLAND female 1 216 179 809 PACKING NUT 1 218 185 213 SLEEVE 1 219 185 211 CYLINDER 1 220 185 214 BALL GUIDE 1 221 178 938 PIN 1 222 218 036 PISTON VALVE 1 223 222 437 INTAKE VALVE 1 224 222 438 PISTON ROD 1 225 105 444 BALL 1 These parts are also included in Repair Kit 222 588 which may be purchased separately Keep a repair kit on hand to reduce down time NOTE A s...

Page 45: ...45 307 785 Notes ...

Page 46: ...46 307 785 Notes ...

Page 47: ...0 ID chamfer Fluid Outlet Size 1 4 npsm from fluid filter Wetted Parts Displacement Pump Carbon steel polyurethane Delrin Packing Material Leather UHMW polyethylene Filter Aluminum carbon steel stainless steel 60 mesh 250 micron reusable stainless steel screen NOTE Delrin is a registered trademark of the DuPont Co Dimensions Weight dry w o packaging 95 lb 43 Kg Height 28 in 711 mm Length 26 in 660...

Page 48: ...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 defec...

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