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Graco Ultra 400, Instructions And Parts List, Page: 2 / 37

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INDEX 

WARNINGS 

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

. 

SETUP 

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

5 

INTRODUCTION 

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

OPERATION; 

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

6. 

SHUTDOWN  CARE 

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

TROUBLESHOOTING GUIDE 

FLUSHING  GUIDELINES 

8 

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

Motor Won't  Operate 

................................... 

9-11 

Low output 

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

12 

No 

Output 

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

12.  13 

Excessive Pressure Fluctuations 

......................... 

13 

Motor 

Is 

Hot and Runs Intermittently 

.................. 

13 

Electrical Short 

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

....... 

14 

Spin Test 

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

15 

Bridge Test 

16 

General Repair Notes 

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

17 

Power Supply Cord Replacement 

18 

List of Tools 

17 

Filter  Replacement 

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

18 

Switch Replacement 

........................... 

19 

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

REPAIR SECTION 

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

....................... 

Microswitch Replacement 

................................ 

19 

Bridge Rectifier Replacement 

............................ 

Choke Replacement 

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

21 

Varistor Replacement 

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

21 

Pressure Control Replacement 

23 

Circuit Board Replacement 

Stall Pressure Calibration 

................................. 

24 

Connecting Rod.  Drive Housing or Crankshaft 

Replacement 

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

25.  26 

Motor Brush Replacement 

................................ 

27 

Motor Capacitor Replacement 

........................... 

Motor Replacement 

................................... 

29. 

Sprayer 

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

32. 

33 

Pressure Control 

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

34. 

35 

TECHNICAL DATA 

Back Cover 

How To Order Replacement Parts 

NOTE: 

See  manual 

supplied.  for  the 

displacement  pump repair instructions  and 

parts list 

. 

............................... 

.......................... 

PARTS LISTS  DRAWINGS 

...................... 

............................... 

Summary of Contents for Ultra 400

Page 1: ...ns such solvents in this eauimnent Such use could result in a serious chemical reaction with the possibility of explo Never use l l l tnchloroethane methylenechloride other halogenated hydrocarbon solvents or fluids containing I sion which could cause death serious bodily injury and or substantial property damage Consult your fluid suppliers to ensure that the fluids being used are compatible with...

Page 2: ...Switch Replacement 19 REPAIR SECTION Microswitch Replacement 19 Bridge Rectifier Replacement 20 Choke Replacement 21 Varistor Replacement 21 Pressure Control Replacement 23 Circuit Board Replacement 22 Stall Pressure Calibration 24 Connecting Rod Drive Housing or Crankshaft Replacement 25 26 Motor Brush Replacement 27 Motor Capacitor Replacement 28 Motor Replacement 29 30 Sprayer 32 33 Pressure Co...

Page 3: ...up spray and reduces the risk of fluid Diffuser 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 to an irregular stream replace the diffuser immediately pressure trigger the gun If the fluid emitted is notdiffused ...

Page 4: ...ly grounded hose can make HAZARD FIRE OR EXPLOSION HAZARD Static electricity is created by the flow of fluid through the pump and hose If every pan of the spray equipment is not properly grounded sparking may occur and the system may become hazardous Sparking may also occur when plugging in or unplugging a power supplycord Sparks can ignite fumes from solvents and the fluid being sprayed dust part...

Page 5: ...r and an extension cord of up to 45 m 150 feet can be used The sealed drive assembly transferspower from the DC Drive Assembly motor to the displacement pump 4 307 671 Displacement Pump The positivedisplacement volume balanced pump pro vides equal fluid delivery on both the up and down pump strokes The pump has a wet cup which when filled with Graco Throat Seal Liquid helps prevent damage to the t...

Page 6: ...d that the outlet you use Is properly grounded b Attach an appropriate plug to the powersupply cord according to your local electrical codes c Use an extension cord which has 3 wires of a minimum 12 gauge size and a maximum of 45 m 150 f t long Longer lengths may affect sprayer performance 4 Plug in the Sprayer a Be sure the ONlOFF switch is OFF Refer to Fig 3 Then plug the cord into a grounded el...

Page 7: ...increasethe Squeeze the trigger and hold it open turn the the gun triggered until all air isforced out of the pressure setting until the sprayer starts Keep system and the paint flows freely from the gun Release the trigger and engage the safety NOTE If the pump is hard to prime place a con tainer under the drain valve and open the drain valve When fluid comes from the valve close it Then disengag...

Page 8: ... buildup on the piston rod and premature wear of packings The packing nut should be tight enough to stop leakage but no tighter Overtightening may cause binding and ex cessive packing wear Use a screwdriver and light hammer to adjust the nut See Fig 6 2 Clean the fluid filter often and whenever the sprayer is stored First follow the Pressure Relief Procedure Warning on page 6 Refer to manual 307 2...

Page 9: ...CTWHEN FILTER SUPPORT Fig 8 4DRAIN VALVE SHOWN OPEN Fig 7 3 Close the filter drain valve 4 Pour 2 liters 112gal of compatible solvent into a bare metal pail Put the suction tube in the pail Always remove the spray tip from the gun before flushing to reduce the risk of a fluid injection in I W A R 5 Disengagethe gun safety latch 6 Point the spray gun into a grounded metal waste container and with a...

Page 10: ...reezing the pumpshouldoperate If painthardened dried1in the sprayer the pump packingsand or bare pressure control mum be replaced See page 23 or manual307 793 1 Check for frozen or hardened paint in the pump 19 andlor pressure control bourdontube Using a screwdriver carefully try to rotate fan at back of motor See page 15 2 Check displacement pump connecting rod pin m It must be completely pushed ...

Page 11: ...t voltmeter to electrical outlet Meter should read 190 250 Volts 2 Check power supply to circuit board with sprayer turned ON Measure voltage at TPl and TP2 Meter should read 190 250 Volts See page 7 2 3 Check a 1 1terminals and wires fog damage or loose fit 4 Check motor thermal cutout switch Unplug sprayer Allow motor to cool at TP9 to TPlO Use ohmmeter to check Disconnect motor thermal switch l...

Page 12: ...ndition then shut off immediate ly WARNING To reduce the risk of elec tric shock handle board by edges only1 Do not allow any metal objects to come in contacl with the boardl should be on now removing the circuit Plug in and turn on sprayer Clear lamp board over ridesthe optical detector Turn off and unplug sprayer Check bourdon tube flag and detector position Reinstall circuit board s e e page 22...

Page 13: ...n test See page 15 14 Check bridge 3 0 8 by substituting with a good bridge or by performing the bridge test See page 16 or 20 CAUTION Do not perform this check A bad armature will immediately burn until armature is determined to be good out a good bridge 1 Check paint supply 2 Check for clogged intake strainer 3 Check for loose suction tube or fittings WHAT TO DO Ifcheck is NOT OK refer to this c...

Page 14: ... see if sprayer has been operating at high pressure with small tips which causes low motor RPM and resultsin excessive heat build up I Check to see if ambient temperature where sprayer is located is more than 32 90 F or if sprayer is located in direct sun Check to see if sprayer has been left in a stalled condition sprayerturned on pressurized but not operating for long periods of time WHAT TO DO ...

Page 15: ...or missing inspection plate 2 Correct faulty conditions gasket see page 2 7 bent terminal forks which could cause a short or other metal to metal contact points Check motor armature for shorts by us 3 Replace motor See page 29 ing an armature tester growler or per form spin test See page 15 Inspect windings for bums Check bridge 3 0 8 1 by substituting with 4 Replace bridge See page 20 a good brid...

Page 16: ...ort Circuit Test shorts the motor will coast two or three revolutions Quickly turn the motor fan by hand If there are no before coming to a complete stop If the motor does not spinfreely and resists rotation the armature is shorted and the motor must be replaced See page 29 Armature Brushes and Motor Wiring Open Circuit Test Continuity Connect the two black motor leads together with a test lead Tu...

Page 17: ...at the right connect the meter wires as in dicated by the black dots for each test then check the continuity In Tests 1 2 and 3 there should be NO continuity indicated check continuity then switch the meter wire In Tests 4 5 and 6 connect the and meter wires as get NO continuity one way and YES continuity the connections and check continuity again You should other way In Tests 7 and 8 connect the ...

Page 18: ...ing connectors When reconnectingthe wires be sure the flat blade wrap around blade of the female connector when of the insulated male connector is centered in the the connection is made CAUTION tion be sure to properly mate connectors and never pull on a wire to disconnect it Pulling on a wire could loosen the connector from the wire 2 Route wires in the pressure control assembly carefully through...

Page 19: ... a screwdriver 5 Install the new power supply cord 3111 in the reverse order of disassembly Install a new plug on the other end o f the cord Be Fig 12 sure to follow all local codes regarding the type of olua to use I FILTER REPLACEMENT See Fig 12 WARNING Before doing this procedure follow the Pressure the risk of a fluid injection injury splashing in the Relief Procedure Warning on page 17to redu...

Page 20: ... guard 304 aligning the internal tab with the groove in the threads 9 Powder the inside of the rubber boot 303 with talcum then shake excess out of boot 10 Install the nut and rubber boot and tighten 11 Reconnect the wires to TP1 and TP2 12 Reinstall the pressure control cover and screws MICROSWITCH REPLACEMENT See Fig 15 Before doing this procedure follow the Pressure the risk of a fluid injectio...

Page 21: ...he screws securely 3 Outsidethe pressurecontrol box on the right side are Be sure the flat blade of the insulated male con two screws 331 Loosen but don t remove the nector is centered in the wrap around bladeof the screw near the back mounting plate 50 Then female connector when the connections are loosen and remove the front screw Slide the bridge made Improper connections may cause the out spra...

Page 22: ... 8 19 WARNING Relief ProcedureWarning on page 17to reduce the risk of a fluid injection injury splashing in the eyes or on the skin injury from moving parts or n 1 2 3 4 5 Remove the control box screws and cover Remove the two screws A the wiring harnesses 318 319 and the old varistor from the ONlOFF switch 302 Trim the leads on the new varistor 339 to 28 5 mm 1 118in Turn each lead outward to for...

Page 23: ...the circuit board while removing or installing it 3 Disconnect ALL wires from the board includingthe two heavyblack wires Paycloseattentionto where connections are made See Fig 21 4 To remove the board from the box pull out the black plastic tipped pin 330 Push the bottom of the circuit board toward the wall of the box and carefully slide the board out 5 Install the board in the box at the Same an...

Page 24: ...er 53 5 Removethe pressurecontrol cover and screws and terminals disconnect the four motor leads at the appropriate 6 Refer to CIRCUIT BOARD REPLACEMENT on page 2 2 remove the circuit board and retain 7 Remove the conduit 411 Fig 22 8 Use a 13 mm open end wrench to loosen and remove the pressure control mounting screws 165 and washers 64 located below the pressure con trol box Remove the box 9 Ins...

Page 25: ...h the pressurecontrol knob B at the minimum setting turn the sprayer switch ON THE SPRAYER SHOULD NOT STARTI If it does start shut the sprayer switch OFF disengagethe gun safety latch trigger the gun into a grounded waste container until pressureis reliev ed Engagethe gun safety latch Turn the pressure adjustment nut S a littlefurther counterclockwise Turn the sprayer on to be sure it does nor sta...

Page 26: ...loosen itfromthe motorfront end bell Then pull the housing off 811 r CAUTION DO NOT allow the gear cluster 26 to fall when removing the drive housing 6 It is easiiy damag ed if dropped DO NOT lose the thrust balls 24 located at each end of the gear cluster 26 or allow them to fall between gears The ball which is heavily covered with grease usually stays in the shaft recesses and not removed the ba...

Page 27: ...ghten the jam nut 8 6 to 94 N m 70 ft lb very tight to prevent it from looseningwhich will damage the bearing housing See Figures 25 and 26 I w Be sure the retaining spring 21 is firmly in the groove of the connecting rod all the way around Iio prevent the pin 20 from working loose due to vibration See Fig 26 I off due to the force of the pumping action These If the pin works loose it or other par...

Page 28: ...shop if the brushes seem to be wearing too fast edges are as shown in the first part of Fig 2 8 and Place a new brush in the holder so the beveled the brush lead is routedas shown inthe second part of Fig 28 the brush holder until the clip tab engages in the Slowly push the tabbed end of the spring clip into holder and the rolled portion of the tension spring rests squarely on the brush Routethe b...

Page 29: ... the rear end bell MI 9 Gently tap alternate ears of the rear end bell with a plastic mallet to loosen it then pull it straight off Do not pull the motor armature out Retain any washers that fall out when the bell is removed 10 To replacethe capacitor removethe brushleadter minal screws Y and the screw Z going into the insulation plate of the rear end bell Install a new capacitor X making sure the...

Page 30: ... 3 from the displacement pump outlet nipple 22 2 Remove the screws 51 and pressure control cover 48 and disconnect the four motor leads 3 Use an adjustable wrench to loosen the conduit connector nut 313 at the pressure control assembly 401 4 Swing the conduit 41 away from the pressure control elbow 313 5 Pull the motor leads through the elbow one at a time 9 10 11 12 Remove the front cover and scr...

Page 31: ...4 Use a 6 mm 114 hex key wrench to remove the two screws 35 and lockwashers 34 from the underside of the motor mountingframe Be sure to support the motor to keep the sprayer from tlppmg 15 Lift the motor assembly off the frame 16 Place the new motor assembly on the frame and align with the frame mounting holes Install the screws 351 and lockwashers 34 tightly 17 Liberally grease the gear cluster 2...

Page 32: ...PART DRAWINGS AND PARTS LISTS 307 671 31 ...

Page 33: ...PARTS DRAWING Model 230 963 Ultra 4 0 0 Series D Includes items 1 112 11 ...

Page 34: ...ACKET mounting SCREW thread forming 10 24x 1 I UiION adapter 318 npt m x 318 npsm If1swivel FILTER fluid Refer to 307 273for parts REF PART NO NO 54 60 59 61 62 63 64 71 65 72 73 74 78 79 81 81a 81b 86 105 108 110 111 112 210 657 178 034 100 509 179 945 100 322 150 513 100 214 100 001 210 541 181 073 214 701 220 955 107 423 100 028 218 242 180 131 107 434 176 762 107 447 178483 108 865 108 663 108...

Page 35: ...wire O N 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF PART DESCRIPTION NO NO 324 107 438 SCREW machine fil head No 5 40 325 326 327 328 329 331 330 332 333 334 335 337 336 338 339 340 100 975 101 792 157 021 108295 107 258 180 041 101 273 100 179 100 718 107 436 105329 100 109 218 355 1080 x 518 long NUT hex machine No 5 shakeproof No 5 LOCKWASHER external BUSHING strain relief LOCKWASHER No 8 inte...

Page 36: ...ANGED STATUS NO NO NAME Sprayer Series OLD OLD NEW NEW OLD OLD NEW OLD NEW OLD NEW NEW 14 218 618 Motor Cover 1 181 612 Motor Shield 74 220 955 Gun 16 217 593 Gun 39 218 215 Displ Pump 19 220 647 DisDl PUmD 47 214 638 Hose 2 3 218 083 Hose 58 178 392 Pin 135 102 952 Strainer 44 101 242 Ring 71 181 073 Strainer Other major changesto the sprayer are the upright cart 33 and changes to the suction tub...

Page 37: ...inum Delrin Nitralloy Nylon Ultra High Molecular Weight Polyethylene Polyurethane Rubber Tungsten Carbide Zinc plated steel impregnated leather Stainless Steel Height Handle extended 939 8 mm 37 in Length Handle extended 660 4 rnrn 26 in Dimensions Width 546 1 mm 21 5in Handle down 723 9 mm 28 5 in Handle down 609 6 mm 24in Delrin and are registered trademarks of the Du Pont Company Subsidby and A...

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