Graco ULTRA 500 Instructions-Parts List Manual Download Page 24

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307-889

Drive Housing, Connecting Rod, and

Crankshaft Replacement (Fig. 20)

WARNING

FLUID INJECTION HAZARD

To reduce the risk of serious injury,

follow the illustrated

Pressure Relief

Procedure

warning on page 12 when-

ever you are instructed to relieve pressure.

NOTE:

Read the GENERAL REP AIR INFORMATION

on page 18 before doing this procedure.

NOTE:

See Fig. 20 for Steps 1 to 15 unless otherwise

noted.

NOTE:

Stop the sprayer at the bottom of its stroke to

get the crank (57) in its lowest position. If the crank

must be lowered manually, carefully rotate the blades

of the fan with a screwdriver.

1. Remove the displacement pump. See page 28.

2. Remove the connecting rod (9). Inspect it for wear

or damage. Replace the rod, if necessary.

3. Turn 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.

Fig. 19

8,7

See Step 3 for

procedure

01579

4. Remove the other two screws (8) and lockwashers

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

5. Remove the screws (12), spacers (15), screws

(16) and the motor shield (1).

6. Remove the two screws (58) and lockwashers (7)

holding the motor to the drive housing.

7. 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 off.

8. Inspect the drive housing (6) for excessive wear

and replace parts as needed.

9. Pull the crankshaft (57) out. Inspect it for wear or

damage and replace it, if necessary. Be sure the

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, or tap it into place with a plastic

mallet.

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

screws (12) and spacers (15).

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-

ture bearing wear.

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 (11,13). Re-

connect the suction tube (14) and pump outlet

hose (23).

Summary of Contents for ULTRA 500

Page 1: ...PRAYER 195 bar 2750 psi Maximum Working Pressure Model 231 079 Series D Complete sprayer on Upright cart with hose gun RAC IV DripLess Tip Guard and SwitchTip GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1995 GRACO INC This manual contains important warnings and information READ AND RETAIN FOR REFERENCE ...

Page 2: ...not follow the instructions Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions FIRE AND EXPLOSION HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury If there is any static sparking or you feel an electric sho...

Page 3: ...could result in a chemical reaction with the possibility of explosion 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 F Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations Wear hearing ...

Page 4: ...e Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings WARNING WARNING 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 Avoid accidental trig gering of gun by al...

Page 5: ...nds K RAC IV Tip Guard Reverse A Clean RAC tip guard reduces risk of injection injury L Contractor Gun High pressure spray gun with gun safety latch M RAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip without removing tip from spray gun N 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 sprayi...

Page 6: ...ailed grounding instructions WARNING NOTE See Fig 2 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 0 9 m 3 ft hose and 15 1 m 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 220 240 V AC 50 Hz 7A minim...

Page 7: ... Setup ON OFF SWITCH 1 4 npsm m FLUID OUTLET NIPPLE DO NOT INSTALL ANY SHUTOFF DEVICE HERE PRESSURE ADJUSTING KNOB PRESSURE DRAIN VALVE PACKING NUT WET CUP FILL 1 3 FULL WITH TSL Fig 2 05254 ...

Page 8: ...starts When fluid comes from the drain hose close the valve handle 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 c Release the trigger Engage the gun safety latch 5 Check all fluid connections for leaks Relieve the fluid pressure before tightening connectio...

Page 9: ...otate 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 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 off and unplug the sprayer and open the pres sure drain valve to relieve pressure Clean the s...

Page 10: ... supplied for the cleaning procedure 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 10 non detergent oil See Fig 7 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 min...

Page 11: ...its Relieve pressure Leave drain valve open 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 WARNING FIRE AND EXPLOSION HAZARD 1 Follow the illustrated Pressure Relief Procedure on page 12 Engage the gun safety latch 2 Turn the pressure adjusting knob fully counter...

Page 12: ...elieve pressure refer to the separate gun tip or fluid filter instruction manual for cleaning Basic Mechanical Problems 1 Check for frozen or hardened paint in the pump 19 and or pressure control tube Using a screwdriver carefully try to rotate fan at back of motor by hand See page 16 1 Thaw Plug in sprayer and turn on Slowly increase pressure setting to see if motor starts If it doesn t see NOTE ...

Page 13: ...motor and have motor shop resur face commutator if possible See page 26 7 Check motor armature for shorts using arma ture tester growler or perform spin test See page 16 7 Replace motor See page 26 8 Check pressure control board 301 by substi tuting with a good pressure control board See page 22 8 Replace with new pressure control board 301 See page 22 Refer to the wiring diagram on page 35 to ide...

Page 14: ...erheating See page 26 5 Be sure male terminal blades are centered and firmly connected to female terminals Replace any loose terminal or damaged wiring Securely reconnect terminals 6 Check for loose motor brush leads and termi nals See page 19 6 Tighten terminal screws Replace brushes if leads are damaged See page 19 7 Check for worn motor brushes which should be 12 mm 1 2 in minimum See page 19 7...

Page 15: ...eck displacement pump connecting rod pin 20 See page 30 1 Replace pin if missing Be sure retainer spring 42 is fully in groove all around con necting rod See page 30 2 Check connecting rod assembly 68 for dam age See page 24 2 Replace connecting rod assembly See page 24 3 Be sure crank in drive housing rotates plug in sprayer and turn on briefly to check Turn off and unplug sprayer See page 24 3 C...

Page 16: ...e control board 301 by substi tuting with a good control board See page 22 4 Replace with a new pressure control board 301 See page 22 1 Check Basic Electrical Problems on page 12 1 Perform necessary procedures 2 Check ON OFF switch 307 See page 21 Be sure the sprayer is unplugged Disconnect wires from switch Check switch with ohmme ter The reading should be infinity with the ON OFF switch OFF and...

Page 17: ...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 26 Fig 9 J F 1 05210 Armature Brushes and Motor Wiring Open Circuit Test Continuity Relieve pressure Connect the two black motor leads to gether with a test lead T urn the motor fan by hand at about two revolutions per second If there is uneven o...

Page 18: ...re the problem is corrected WARNING To reduce the risk of serious injury in cluding electric shock DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair Shut off the sprayer and unplug it as soon as you complete the inspection Reinstall all covers gas kets screws and washers before operating the sprayer ELECTRIC SHOCK HAZARD 3 If the sprayer does...

Page 19: ...K SPRING 01227 4 Loosen the brush lead terminal screw Pull the brush lead away leaving the motor lead terminal in place Remove brush and spring See Fig 14 5 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...

Page 20: ...t pump packings CAUTION 12 Install the brush inspection covers and gaskets 13 Break in the brushes Operate the sprayer for at least one hour with no load Install the connecting rod pin Power Supply Cord Replacement Fig 15 WARNING INJECTION HAZARD To reduce the risk of serious injury follow the illustrated Pressure Relief Procedure warning on page 12 when ever you are instructed to relieve pressure...

Page 21: ...s from the ON OFF switch 307 See Fig 15 4 Using a 5 8 in socket wrench remove the nut and rubber boot 309 Remove the switch guard 308 See Fig 16 5 Remove the ON OFF switch 307 6 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 7 Install the switch guard 308 aligning the internal tab with the groove in the th...

Page 22: ...the screws may shift the calibration of the pressure control CAUTION 3 Remove the four mounting screws and washers 302 303 304 from the pressure control board cover 301 See Fig 18 4 Carefully remove the pressure control board cover 301 so as not to stress the cables 5 Remove the potentiometer cable 310 from the pressure control board cover 301 6 Disconnect the pressure control board cover black wh...

Page 23: ... Board Replacement WARNING FLUID INJECTION HAZARD To reduce the risk of serious injury follow the illustrated Pressure Relief Procedure warning on page 12 when ever you are instructed to relieve pressure 1 Relieve pressure 2 Perform the Pressure Control Replacement pro cedure steps 2 through 11 3 Remove the three screws holding the filter board in place and remove the filter board 4 Reassemble in ...

Page 24: ...r shield 1 6 Remove the two screws 58 and lockwashers 7 holding the motor to the drive housing 7 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 off 8 Inspect the drive housing 6 for excessive wear and replace parts as needed 9 Pull the crankshaft 57 out Inspect it for wear or damage and replace i...

Page 25: ...25 307 889 Drive Housing Connecting Rod and Crankshaft Replacement 05259 Fig 20 1 24 26 24 1 16 58 7 2 57b 57 57a 6 7 8 9 11 13 21 23 19 20 15 12 1 Fill cavity with SAE non detergent motor oil ...

Page 26: ...with a plastic mallet to loosen it from the front of the motor 2 and then pull the drive housing straight off CAUTION DO NOT drop the gear cluster 26 when removing the drive housing 6 The gear cluster may stay en gaged in the motor front end bell or the drive housing DO NOT lose the thrust balls 24 located at each end of the gear cluster 26 or drop them between gears The balls which are heavily co...

Page 27: ...26 57b 24 9 16 8 7 1 2 13 70 40 301 39 23 4 10 11 LIBERALLY APPLY GREASE 318 41 17 04772 DETAIL Shows position of conduit seal 31 in conduit connector 318 31 318 01232 MOTOR B1 M M Fig 21 Fig 22 Motor Replacement POWER CORD ...

Page 28: ...pump outlet hose 23 See Fig 23 5 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 6 Push the retaining spring 21 up Push the pin 20 out the rear Disassembling the pump 1 Unscrew the intake valve 223 and remove all parts See Fig 25 Fig 25 02396 220 221 204 202 223 2 Remove the plug 205 Unscrew the packing nut 216 See Fig 26 3 Tap...

Page 29: ... new packings will not seal properly 2 Stack the piston packings onto the piston 222 as shown in Fig 31 3 Tighten the piston nut 211 onto the piston to 0 7 N m Fig 29 1 211 222 225 224 0029 1 Apply one drop of sealant to these threads 4 Note the alignment of the piston 222 to the pis ton nut 211 and maintain this alignment through Steps 5 6 and 7 5 Apply ONE drop of adhesive supplied with the repa...

Page 30: ...ily into the hole See Fig 32 2 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 WARNING Be sure the retaining spring 21 is firmly in the groove of the connecting rod all the way around to prevent it from working loose due to vibration Refer to Fig 32 If the pin works loose parts could break off due to the ...

Page 31: ... 55 14 19 20 21 4 4 16 30 27 41 40 318 54 59 53 9 8 7 6 22 23 24 78 Model 231 079 Series C 38 81 71 87 88 13 16 88 16 86 85 22 60 10 1 3 4 2 1 Danger or Warning Label 1 Identification Label 2 2 On outside of cover On inside of cover 5 See page 34 5 90 91 92 Ref 91 28 Ref 69 Ref 33 68 67 83 66 84 ...

Page 32: ...CONDUIT electrical specify length when ordering 0 79 ft 42 106 062 WHEEL semi pneumatic 2 44 101 242 RING retaining 2 45 104 811 HUBCAP 2 49 107 264 TERMINAL see page 35 2 52 107 267 TERMINAL female see page 35 2 53 214 570 FILTER fluid see manual 307 273 for parts 1 54 237 677 PRESSURE DRAIN VALVE 1 55 181 610 LABEL identification 1 56 176 762 NUT hex 1 1 2 18 1 57 218 242 CRANKSHAFT ASSEMBLY inc...

Page 33: ...1 212 176 882 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 These parts are also included in Repair Kit 222 5...

Page 34: ...head 10 24 x 2 2 304 100 020 WASHER lock 10 4 305 189 095 HOUSING cast 1 306 290 034 LABEL caution 1 307 111 826 SWITCH toggle 1 308 107 255 GUARD locking 1 309 105 659 BOOT switch 1 310 236 352 POTENTIOMETER pressure 1 adjustment 311 108 358 SEAL shaft 1 312 112 768 KNOB control 1 313 185 565 LABEL knob 1 314 237 822 CORD power 1 315 105 746 BUSHING strain relief 1 316 112 376 LOCKNUT 1 317 100 0...

Page 35: ... instructions included Motor Brush Kit 222 157 Repair instructions included with kit Spring Clip 110 816 Holds in motor brushes not included with brush kit 05263 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 4 is also on your sprayer If you have painters who do not read English orde...

Page 36: ...upplied 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 a...

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