Graco ULTRA 500 231-032 Instructions-Parts List Manual Download Page 10 | Manualshive

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10

307–758

SETUP

WARNING

To reduce the risk of serious bodily injury from static
sparking, fluid injection, or over pressurization and
rupture of the hose or gun, all hoses must be electri-
cally conductive, the gun must have a tip guard, and
each part must be rated for at least 2750 psi (195
bar) Maximum Working Pressure.

To avoid damaging the pressure control, which may
result in poor equipment performance and compo-
nent damage, follow these precautions:

1.

Always use grounded, flexible spray hose at
least 50 ft. (15 m) long.

2.

Never use a wire braid hose as it is too rigid to
act as a pulsation dampener.

3.

Never install any shutoff device between the fil-
ter and the main hose. See Fig 11–1.

4.

Always use the main filter outlet. Never plug this
outlet.

CAUTION

WARNING

Proper electrical grounding is essential to reduce
the risk of fire or explosion which can result in seri-
ous bodily injury and property damage. Read the
warning section FIRE OR EXPLOSION HAZARD
on page 5 for more detailed grounding
instructions.

NOTE: See Fig 11–1 while doing the setup.

1.

Fill the packing nut/wet-cup 1/3 full with Graco
Throat Seal Liquid (TSL), supplied.

2.

Connect the gun, 3 ft. hose and 50 ft. hose. Screw
the assembly onto the outlet nipple. Don’t use thread
sealant and don’t install the spray tip yet!

3.

Check the electrical service.

a. Electrical requirements: 120 V, 60 HzAC, 15

Amp (minimum).

b.

Use a grounded electrical outlet located at least
20 ft. (6 m) from the spray area.

b. Do not remove the grounding prong of the power

supply cord and do not use an adapter.

c.

Extension cord specifications: 15 Amps, 3 wires,
grounding type. (Long lengths reduce sprayer
performance.)

5. Plug in the sprayer. Turn the ON/OFF switch OFF.

Plug the cord into a grounded electrical.

6.

Flush the pump to remove the oil left in to protect
pump parts after factory testing. See the FLUSHING
GUIDELINES on page 15.

7.

Prepare the paint according to the manufacturer’s
recommendations. Remove any paint skin. Stir the
paint thoroughly. Strain the paint through a fine nylon
mesh bag to remove particles that could clog the filter
or spray tip.

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Summary of Contents for ULTRA 500 231-032

Page 1: ...body Drain all pressure before removing parts Avoid accidental trig gering 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 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 INSTRUCTI...

Page 2: ...ever there is fluid or pressure demand When the pump is cycling the motor sounds like an automobile starter cranking When the pump is not cycling the motor may hum intermittently un til the fluid pressure stabilizes then the motor will shut it self off However there will still be power to the sprayer and it will stay pressurized and ready to use until you manually shut it off and relieve pressure ...

Page 3: ... 9 m HOSE DRIVE ASSEMBLY FLUID FILTER PRESSURE ADJUSTING KNOB MOTOR ON OFF SWITCH TRIGGER SAFETY SHOWN ENGAGED PRESSURE CONTROL PAIL HANGER on upright sprayer only RESET BUTTON 50 FT 15 M MAIN HOSE CONTRACTOR GUN FLUID OUTLET 0137 RAC IV TIP GUARD SWITCH TIP 01556 ...

Page 4: ... reduces the risk 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 h...

Page 5: ...se DO NOT expose Graco hose to temperatures above 180 F 82 C or below 40 F 40 C Hose Grounding Continuity Proper hose grounding continuity is essential to maintaining a grounded spray system Check the electrical resistance of your fluid hoses at least once a week If your hose does not have a tag on it which specifies the maximum electrical resistance contact the hose supplier or manufacturer for t...

Page 6: ...e diffuseur du pistolet sert à diviser le jet et à réduire les risques d injection 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 en lever l ajutage du pulvérisateur Pointer le pistolet dans un seau en métal en le mainte...

Page 7: ...CENDIE OU D EXPLOSIÓN ci dessus RISQUES D INCENDIE OU D EXPLOSIÓN De l électricité statique est produite par le passage du fluide à grande vitesse dans la pompe et dans les tuyaux Si toutes les pieeces de l appareil de pulvérisation ne sont pas convenable ment 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: ...istola Difusor 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 di...

Page 9: ...ímites recomendados 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 ...

Page 10: ... EXPLOSION HAZARD on page 5 for more detailed grounding instructions NOTE See Fig 11 1 while doing the setup 1 Fill the packing nut wet cup 1 3 full with Graco Throat Seal Liquid TSL supplied 2 Connect the gun 3 ft hose and 50 ft hose Screw the assembly onto the outlet nipple Don t use thread sealant and don t install the spray tip yet 3 Check the electrical service a Electrical requirements 120 V...

Page 11: ...UARD MAIN HOSE 1 4 in x 50 ft ON OFF SWITCH 1 4 npsm m FLUID OUTLET NIPPLE DO NOT INSTALL ANY SHUTOFF DEVICE HERE PRESSURE ADJUSTING KNOB PRESSURE DRAIN VALVE 3 16 in x 3 ft HOSE PACKING NUT WET CUP FILL 1 3 FULL WITH TSL Fig 11 1 ...

Page 12: ...When fluid comes from the drain hose close the valve b Disengage the gun safety latch See Fig 12 1 Following the warning above trigger the gun until all air is forced out of the system and the paint flows freely from the gun c Release the trigger Engage the gun safety latch 7 Check all fluid connections for leaks Relieve the fluid pressure before tightening connections 8 Install the spray tip and ...

Page 13: ...er 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 en gage the gun safety latch and rotate the RAC IV handle 180 See Fig 13 1 3 Disengage the gun safety latch and trigger the gun into a waste container Engage the gun safety latch again 4 Return the handle to the original position disengage the gun safety...

Page 14: ...of operation First relieve pressure Remove the front cover Fill the bearing housing cavity with SAE 10 non detergent oil See Fig 14 2 4 For very short shutoff periods leave the suction tube in the paint relieve pressure and clean the spray tip 5 Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corro sion and freezing See page 15 CAUTION To prevent...

Page 15: ...ater to freeze in the pressure control Doing so prevents the sprayer from being started and causes serious damage to the pressure control Pump the water out with mineral spirits CAUTION 0143 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 1 Follow the illu...

Page 16: ... manual for tip cleaning Basic Mechanical Problems 1 Check for frozen or hardened paint in the pump 74 and or pressure control tube Us ing a screwdriver carefully try to rotate fan at back of motor by hand See page 22 1 Thaw Plug in sprayer and turn on Slowly increase pressure setting to see if motor starts If it doesn t see NOTE 1 below 2 Check displacement pump connecting rod pin 43 It must be c...

Page 17: ... substituting with a good bridge or performing bridge test See page 23 CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature will immediately burn out a good bridge 9 Replace bridge See page 23 Condition B continued Both lamps off 1 Check circuit breaker 309 button to be sure it has not popped up 1 Depress button to reset If circuit breaker or fuse co...

Page 18: ...ect TP6 connectors 10 Replace damaged terminals and recon nect securely 11 Check circuit board 72 by substituting with a good board See page 28 11 Replace circuit board See page 28 Condition C Red lamps on Clear lamp off Unplug sprayer 1 Check circuit board 72 by removing from box without disconnecting wires see page 28 for removal procedure WARNING Removing circuit board while still wired over ri...

Page 19: ... termi nals to motor Inspect wiring insulation and terminals 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 wiring Securely reconnect wires to bridge 8 Check for loose motor brush leads and termi nals See page 25 8 Tighten terminal screws Replace brushes if leads are damaged See page 25...

Page 20: ...e page 38 2 Check connecting rod assembly 70 for dam age See page 32 2 Replace connecting rod assembly See page 32 3 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 EXCESSIVE PRESSURE FLUCTUATIONS TYPE OF PROBLEM WHAT TO CHECK If check is OK go ...

Page 21: ...bstituting with a good bridge or by performing bridge test See pages 23 or 27 CAUTION Do not check bridge until arma ture is determined to be good A bad armature will immediately burn out a good bridge 4 Replace bridge See page 27 1 Check Basic Electrical Problems on page 16 2 Check ON OFF switch 303 See page 26 Be sure the sprayer is unplugged Disconnect wires from switch Check switch with ohmme ...

Page 22: ...fan by hand If there are no shorts the motor will coast two or three revo lutions before coming to a complete stop If the motor does not spin freely the armature is shorted and the mo tor must be replaced See page 34 Armature Brushes and Motor Wiring Open Circuit Test Continuity Relieve pressure Connect the two black motor leads to gether with a test lead Turn the motor fan by hand at about two re...

Page 23: ... chart at the right connect the meter wires as indicated by the black dots for each test and then check the continuity Fig 23 1 AC1 AC2 G2 G1 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 You should get NO continuity one way and YES continuity the other ...

Page 24: ...Phillips screwdriver Small flat blade screwdriver Needle nose pliers Plastic mallet Adjustable wrench Adjustable open end wrench Torque wrench 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 Tool List 1 Keep all screws nuts washers gaskets and electric...

Page 25: ... installing the brushes follow all steps care fully to avoid damaging the parts 6 Install a new brush so the lead is in the long slot of the holder See Fig 25 4 7 Slide the terminal under the terminal screw washer and tighten the screw Be sure the motor lead is still connected at the screw See Fig 25 3 8 Place the spring on the brush as shown in Fig 25 4 9 Install the spring clip and push it down ...

Page 26: ...ief Procedure warning on page 24 whenever you are instructed to relieve pressure NOTE Read the GENERAL REPAIR INFORMATION on page 24 before doing this procedure NOTE Refer to Fig 26 2 for this procedure 1 Relieve pressure 2 Remove the pressure control cover 62 3 Disconnect the upper terminal wire from the micro switch 302 and the two black wires from the ON OFF switch 303 See Fig 26 1 4 Using a 5 ...

Page 27: ...perly and route them carefully 332 333 308 331B BRIDGE INSTALLATION DETAIL Fig 27 1 SLOTTED END LOOSEN AND REMOVE LOOSEN THIS SCREW BUT DO NOT REMOVE 01229 331A 303 310 309 308 306 01225 G1 G2 62 CIRCUIT BREAKER REPLACEMENT WARNING To reduce the risk of serious injury follow the Pres sure Relief Procedure warning on page 24 when ever you are instructed to relieve pressure NOTE Read the GENERAL REP...

Page 28: ...en the nut if necessary CAUTION Step 2 is essential to reduce the risk of damaging the circuit board while removing or installing it 4 Disconnect all seven wires from the board Pay close attention to where connections are made 5 Pull out the plastic tipped pin 330 Push the bottom of the circuit board 72 toward the wall of the pres sure control and carefully slide the board out 6 Reinstall the new ...

Page 29: ...ain it See page 28 7 Remove the conduit 1 8 Remove the three pressure control mounting screws 7 lockwashers 9 and nuts 10 Remove the pressure con trol 9 Remove the screws 20 and back mounting bracket 64 CAUTION Do not allow the adapter 341 to turn while installing the new pressure control assembly Turning it can damage the sensitive bourdon tube Hold the adapter firmly with a 3 4 open end wrench w...

Page 30: ... under rated hose could develop a high pressure leak or rupture WARNING USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from component rupture electric shock fire explosion or moving parts WARNING To reduce the risk of serious injury follow the illus trated Pressure Relief Procedure warning...

Page 31: ...stall the pressure control cover Maximum Working Pressure Adjustment 13 Turn the sprayer OFF Disengage the gun safety latch Trigger the gun into a grounded waste contain er until pressure is relieved Engage the gun safety latch 14 Use the 3 8 in nut driver to turn the pressure adjust ment nut T counterclockwise one full turn 15 With the pressure control knob at the minimum set ting turn the spraye...

Page 32: ...ive housing 73 with a plastic mallet to loosen it from the front of the motor Then pull the drive housing straight off Do not allow the gear 71 to fall It may stay attached to the drive housing or to the motor Do not lose the thrust balls 8 located at each end of the gear 71 The balls are heavily covered with grease and usually stay in the shaft recesses but they could be dislodged If caught betwe...

Page 33: ...e face of the drive housing and the outlet nipple 39 is facing back Push the retaining spring 42 into the groove all the way around the connecting rod Tighten the locknut 41 very tight about 70 ft lb 95 N m with a 1 3 4 in open end wrench and a light hammer See Fig 33 1 and 33 2 Be sure the retaining spring 42 is firmly in the groove all the way around to prevent the pin 43 from working loose due ...

Page 34: ...rod so the pin hole faces straight back Insert a hex key wrench through the hole to unscrew the screw 25 See Fig 32 1 Re move the other two screws from the recess of the drive housing 14 Remove the motor shield 58 15 Remove the two screws 14 from the top of the mo tor 16 Use a plastic mallet to gently tap the displacement pump 74 from the rear to loosen the drive housing from the front of the moto...

Page 35: ... of conduit seal 26 in conduit connector 345 26 345 68 8 7 9 57 25 18 73 69a 69 71 69b 75 18 54 58 39 or 5 01581 WIRING DIAGRAM 01221 MOTOR LEADS AC1 AC2 G1 G2 _ WHITE BLUE YELLOW RED GREEN BLACK WHITE GROUND WIRE BLACK POWER SUPPLY CORD THERMAL SWITCH MOTOR 33 35 22 10 ...

Page 36: ...kings and glands See Fig 36 2 7 Clamp the flats of the piston rod in a vise Loosen the retaining nut 211 Unscrew the piston valve 222 from the rod Remove all parts from the piston valve 222 See Fig 36 3 8 Remove and clean the sleeve 218 Use ONLY the special sleeve removal tool P N 222 586 Always use the special sleeve removal tool to re move the sleeve Other removal methods could cause the pump to...

Page 37: ...6 Place the flats at the top of the rod in a vise 7 Use a wrench to CAREFULLY tighten the nut 211 onto the piston rod to 19 ft lbs 25 N m See Fig 37 2 Use two wrenches to maintain the alignment men tioned in Step 7 above Fig 37 2 224 211 TORQUE NUT AGAINST ROD TO 19 ft lb 27 N m DO NOT ALLOW NUT 211 TO MOVE WHEN INSTALLING PISTON ONTO ROD 01238 8 Stack the male gland 208 alternate packings 213 207...

Page 38: ...placement pump 3 4 of the way into the bearing housing 73 2 Hold the pin 43 up to the pin hole in the connecting rod assembly 70 and continue screwing in the pump until the pin slides easily into the hole Back off the pump until the top threads of the pump cylinder are flush with the face of the bearing housing and the outlet nipple 39 is straight back 3 Push the retaining spring 42 into the groov...

Page 39: ...82 V PACKING plastic 3 213 176 997 V PACKING plastic 3 214 180 161 WASHER backup 1 215 180 073 GLAND female 1 216 176 758 NUT packing 1 218 183 571 SLEEVE cylinder 1 219 183 562 CYLINDER 1 220 183 559 GUIDE ball 1 221 183 555 PIN ball stop 1 222 218 197 VALVE piston 1 223 221 098 VALVE intake 1 224 183 563 ROD piston 1 225 105 444 BALL 1 Supplied in repair kit 222 587 Keep a repair kit on hand to ...

Page 40: ...02 42 43 68 39 41 74 44 60 63 22 70 25 18 73 69b 8 69 71 69a 37 11 49 12 67b REF 95 76 38 46 67 67a 7 64 20 35 1 62 COVER 45 WARNING LABEL INSIDE 54 ID LABEL OUTSIDE 13 17 19 79 9 10 7 29 32 9 10 75 18 14 30 DANGER LABEL 47 33 78 ID LABEL 56 DANGER LABEL 40 ID LABEL 55 58 33 65 89 33 44 SEE PAGE 39 98 DANGER LABEL ON OUTSIDE FRAME COVER 57 ID LABEL 53 94 95 93 61 52 66 77 SEE PAGE 44 59 48 88 36 3...

Page 41: ... see page 44 1 52 187 190 STRAINER 1 53 181 607 LABEL identification 1 54 181 608 LABEL identification 1 55 181 609 LABEL identification 1 56 181 610 LABEL identification 1 57 181 611 COVER housing 1 58 223 096 SHIELD MOTOR includes items 30 32 33 46 55 56 1 59 187 603 SLEEVE 2 60 103 846 CAPSCREW soc hd 2 61 185 417 TUBE suction 1 62 183 995 COVER pressure control 1 63 185 365 HANGER pail 1 64 18...

Page 42: ...IDE 56 ID LABEL OTHER SIDE 58 DANGER LABEL 47 33 30 DANGER LABEL 40 14 18 75 8 69 71 69a 69b 73 18 25 70 9 10 9 33 89 9 10 65 OTHER SIDE 96 THIS SIDE 32 29 7 31 90 19 3 13 17 35 1 62 COVER 45 WARNING LABEL INSIDE 54 ID LABEL OUTSIDE 46 76 REF 95 37 11 REF 64 49 12 67b 38 67 67a 7 64 20 77 SEE PAGE 44 68 42 5 41 74 91 93 43 6 22 COVER 57 ID LABEL 53 52 61 95 94 93 87 97 98 DANGER LABEL ON OUTSIDE F...

Page 43: ...n 1 54 181 608 LABEL identification 1 55 181 609 LABEL identification 1 56 181 610 LABEL identification 1 57 181 611 COVER housing 1 58 223 096 SHIELD MOTOR includes items 30 32 33 47 55 56 1 61 170 113 TUBE suction 1 62 183 995 COVER pressure control 1 64 183 365 BRACKET mounting pc 1 65 185 470 BRACKET shield 1 66 206 994 THROAT SEAL LIQUID 8 oz 0 27 liter 1 67 214 570 FILTER fluid Includes item...

Page 44: ...MINAL 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 TERMINAL ring 1 327 157 021 LOCKWASHER no 8 internal 1 328 108 295 BUSHING strain relief 1 331 101 273 SCREW flat hd no 10 24 x 5 8 2 332 100 179 NUT hex no 10 24 thd 2 333 100 718 LOCKWASHER int...

Page 45: ...2 _ WHITE BLUE YELLOW RED GREEN BLACK WHITE GROUND WIRE BLACK POWER SUPPLY CORD THERMAL SWITCH MOTOR CIRCUIT BOARD 218 405 5 WIRES 336 Ref 23 50 75a 323 320 302 317 318 316 324 306 304 309 322 321 75c 312 337 308 323 319 75b 75a 72 303 314 ...

Page 46: ...r size Includes SUCTION TUBE 218 402 5 gallon 19 liter size includes manual French 185 955 Spanish 185 962 German 186 042 Greek 186 046 Korean 186 050 Apply other language here DANGER LABELS The English language DANGER label shown on page 1 is also on your sprayer If you have painters who do not read English order one of the following labels to apply to your sprayer The drawing shows the best plac...

Page 47: ...ent Pump Carbon steel Polyurethane Delrin Packing Material Leather UHMW polyethylene Filter Aluminum Carbon steel Stainless Steel 60 mesh 250 micron reusable SST screen NOTE Delrin is a registered trademark of the DuPont Co DIMENSIONS Upright Cart LoBoy Cart Height 29 in 737 mm 18 in 457 mm Length 22 in 559 mm 27 in 686 mm Width 20 5 in 521 mm 18 in 457 mm Weight 83 lb 37 kg 81 lb 36 kg GRACO PHON...

Page 48: ...ective 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 tive 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 ...

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