Graco ultra 750 Instruction Manual Download Page 38

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307–786

DISPLACEMENT PUMP REPAIR

CYLINDER

PISTON

ASSEMBLY

SLEEVE

TAPERED END

Fig 38-1

12. Slide the sleeve/piston rod assembly

INT O THE

BOTTOM OF THE CYLINDER

. This is to prevent

packing damage during reassembly .

Refer to Fig

38–1.

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

tight at the bottom of the external cylinder threads.

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

a new o-ring (202*). Screw the pump cylinder into the

valve. Torque to 67 ft–lb (90 N.m).

Refer to Fig 37–3.

15. Screw the displacement pump about 3/4 of the way

into the bearing housing (69). Hold the pin (43) up to

the pin hole in the connecting rod assembly (68) and

continue screwing in the pump until the pin slides

easily into the hole. Back of f the pump until the top

threads of the pump cylinder are flush with the face

of the bearing housing and the outlet nipple (40) is

straight back. Push the retaining spring (42) into the

groove all the way around the connecting rod. Tight-

en the locknut (47) very tight–about 70 ft-lb (97

N.m)–with a 2 in. open–end wrench and a light ham-

mer.

Refer to Fig 38–2.

WARNING

Be sure the retaining spring (42) 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 38–2.

If the pin works loose, it or other parts could break

off due to the force of the pumping action. These

parts could be projected through the air and result

in serious bodily injury or property damage, includ-

ing damage to the pump, connecting rod or bearing

housing.

If the locknut (47) loosens during operation, the

threads of the bearing housing (69) will be dam-

aged. Be sure to tighten the locknut firmly.

CAUTION

16. Tighten the packing nut (216) just enough to stop

leakage, but no tighter. Fill the wet–cup/packing nut

1/3 full with Graco TSL.

Fig 38–2

TORQUE TO

70 ft–lb

(95 N.m)

FACE OF

BEARING

HOUSING

Summary of Contents for ultra 750

Page 1: ...DA AND OTHER PATENTS PENDING GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1986 GRACO INC This manual contains IMPORTANT INSTRUCTIONS and WARNINGS READ AND RETAIN FOR REFERENCE MODEL 231 042 SHOWN Hazard of Using Fluids Containing Halogenated Hydrocarbons Never use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in thi...

Page 2: ...at the selected pressure Working together the pressure control and motor cause the pump to cycle whenever there is fluid or pressure demand When the pump is cy cling the motor sounds like an automobile starter crank ing When the pump is not cycling the motor may hum intermittently until the fluid pressure stabilizes then the motor will shut itself off However there will still be power to the spray...

Page 3: ...TOR GUN WITH RAC IV DRIPLESS TIP GUARD AND 517 SIZE SWITCHTIP DRIVE ASSEMBLY FLUID FILTER PRESSURE ADJUSTING KNOB MOTOR ON OFF SWITCH TRIGGER SAFETY SHOWN ENGAGED PRESSURE CONTROL PAIL HANGER RESET BUTTON SECONDARY HOSE OUTLET 50 FT 15 M MAIN HOSE FLUID OUTLET ON UPRIGHT CARTS ONLY ...

Page 4: ... fluid injec tion 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 guard i...

Page 5: ...l 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 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 reco...

Page 6: ... 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 vérifica tion 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 main te...

Page 7: ...NDIE 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 ris que d être dangereux Des étinc elles peuvent également ...

Page 8: ...tola 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 disp...

Page 9: ...mites 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 n...

Page 10: ...plied 4 Check the Electrical Service a Be sure the electrical serv ice is 120 V 60 HzAC 15 Amp minimum and that the outlet you use is prop erly grounded b Do not remove the third prong of the power supply cord which is the grounding prong and do not use an adapter c Use an extension cord which has 3 wires of a mini mum 12 gauge size a maximum of 150 ft long and is rated for 15 amps Longer lengths ...

Page 11: ...se Refer to Fig 12 1 5 Disengage the gun safety latch Refer to Fig 12 2 6 To prime the pump hold a metal part of the gun firmly against and aimed into a metal waste con tainer Refer to Fig 1 1 1 Squeeze the trigger and hold it open turn the ON OFF switch to ON and slowly increase the pressure setting until the sprayer starts Keep the gun triggered until all air is forced out of the system and the ...

Page 12: ... the gun safety latch and rotate the RAC IV handle 180 Refer to Fig 12 2 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 va...

Page 13: ...100 hours of operation Remove the front cover Fill the bearing housing cavity with SAE 10 non detergent oil Refer to Fig 13 2 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 Refer to FLUSHING GUIDE LINES on page 14 CAUTION To prevent pump corrosion and to reduce the chance of fluid freezing in the pump or pressure con tr...

Page 14: ...was factory tested in lightweight oil which was left in to protect pump parts Before using water base paint flush with mineral spirits followed by soapy water and then a clean water flush Before using oil base paint flush with mineral spirits only 2 Changing Colors Flush with a compatible solvent such as mineral spirits or water 3 Changing from water base to oil base paint Flush with warm soapy wa...

Page 15: ...to ON and slowly increase the pressure setting until the sprayer starts Keep the gun trig gered until all air is forced out of the system and the solvent flows freely from the gun Release the trigger and engage the gun safety latch This procedure helps reduce the risk of static sparking and splash ing NOTE If the pump is hard to prime place a container under the pressure drain valve and open it Wh...

Page 16: ...un or tip instruction manual for tip cleaning Basic Mechanical Problems 1 Check for frozen or hardened paint in the pump 76 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 ro...

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 27 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 con...

Page 18: ...t TP6 connectors 10 Replace damaged terminals and recon nect securely 11 Check circuit board 71 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 71 by removing from box without disconnecting wires see page 28 for removal procedure WARNING Removing circuit board while still wired over ride...

Page 19: ...dge 308 and leads and 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 ar...

Page 20: ...See page 39 2 Check connecting rod assembly 68 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 g...

Page 21: ...y substituting with a good bridge or by performing bridge test See page 24 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 302 See page 26 Be sure the sprayer is unplugged Disconnect wires from switch Check switch with ohmme ter...

Page 22: ...e Short Circuit Test Quickly turn the motor fan by hand If there are no shorts the motor will coast two or three revolutions before com ing to a complete stop If the motor does not spin freely the armature is shorted and the motor must be replaced Refer to page 34 Armature Brushes and Motor Wiring Open Circuit Test Continuity Connect the two black motor leads together with a test lead Turn the mot...

Page 23: ... 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 way In Tests 7 and 8 connect the meter wires as indicated by the black dots To...

Page 24: ...l malfunction 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 CAUTION 10 Route wires carefully in the pressure control as sembly guiding them through the legs of the U shaped bourdon tube This is to avoid interfering with the bourdon tube which moves as the pressure set ting changes and to avoid pinching the w...

Page 25: ... a new brush in the holder so the lead is in the long slot of the holder Slide the terminal under the terminal screw washer Ensure the motor lead is still connected at the screw Refer to Fig 25 4 7 Place the spring on the brush as shown in Fig 25 4 Do not install backwards to avoid damage when the spring clip is installed 8 Install the spring clip and push it down until its hooks catch the short s...

Page 26: ...tric shock Unplug the sprayer WARNING Refer to Fig 26 2 except where noted 1 Remove the pressure control cover 2 Use a needle nose pliers to disconnect the upper ter minal wire from the microswitch 302 for ease in re moving the ON OFF switch 303 Refer to Fig 26 1 3 Use pliers to disconnect the two black wires from the ON OFF switch 303 Refer to Fig 26 1 4 Use a 5 8 in socket wrench to loosen and r...

Page 27: ...lated male connector is centered in the wrap around blade of the female connector when the connections are made Improper connections may cause the sprayer to malfunction Route all wires carefully to avoid interference with the movement of the bourdon tube circuit board or control box cover which could cause a malfunction CAUTION 7 Reinstall the pressure control cover 332 333 308 331 BRIDGE INSTALL...

Page 28: ... Pay close attention to where connections are made Refer to Fig 28 2 4 Pull out the black plastic tipped pin 330 Push the bottom of the circuit board toward the wall of the con trol and carefully slide the board out 5 Reinstall the new board in the box at the same angle as it was removed 6 Reconnect all wires Refer to the wiring diagram in Fig 28 2 Ease the pin 330 into the retainer PRESSURE CONTR...

Page 29: ...board and retain it Refer to page 28 6 Remove the conduit 1 7 Remove the three screws 8 and lockwashers 10 and nuts 11 located below the pressure control Re move the pressure control 8 Remove the screws 22 holding the back mounting bracket 64 to the pressure control 9 Install the new pressure control assembly in the re verse order of disassembly Reinstall the conduit seal 29 around the wires in th...

Page 30: ...pray hose Part No 214 915 1 Follow the Pressure Relief Procedure Warning on page 24 2 Refer to the above list of tools and equipment need ed Remove the plug A from the top of the fluid filter and install the fluid filled pressure gauge Refer to Fig 30 1 Connect the gun to the new test hose and connect the hose to the sprayer outlet A Fig 30 1 3 Remove the pressure control cover 4 Place the pump su...

Page 31: ...si 210 bar 17 Turn the pressure control knob to the minimum set ting Release the gun safety latch and trigger the gun into a grounded waste container until pressure is re lieved Engage the gun safety latch Slowly increase the pressure to verify that the maximum working pressure is set at 3000 psi 210 bar To prevent pump corrosion flush the water out of the pump hose and gun with mineral spirits Be...

Page 32: ...es of the bearing and drive housings 10 Align the connecting rod with the crank E and care fully align the locating pins in the drive housing with the holes in the bearing housing 69 Push the bear ing housing onto the drive housing or tap it into place with a plastic mallet CAUTION DO NOT use the bearing housing screws 25 to try to align or seat the bearing housing the bearing and drive housing wi...

Page 33: ...d bell R then pull it straight off CAUTION DO NOT allow the gear cluster 51 to fall when re moving the drive housing 67 It is easily damaged if dropped The gear may stay engaged in either the front end bell or the drive housing DO NOT lose the thrust balls 9 located at each end of the gear cluster 51 or allow them to fall be tween gears The ball which is heavily covered with grease usually stays i...

Page 34: ...l the drive housing away from the end bell CAUTION DO NOT allow the gear cluster 51 to fall when re moving the drive housing 67 It is easily damaged if dropped The cluster may stay engaged in either the front end bell or the drive housing DO NOT lose the thrust balls 9 located at each end of the gear cluster 51 or allow them to fall be tween gears The ball which is heavily covered with grease usua...

Page 35: ... 70 40 36 63 345 75 31 1 87 8 10 11 DETAIL Shows position of conduit seal 29 in conduit connector 345 29 345 302 303 309 MOTOR LEADS WIRING DIAGRAM SEE DETAIL ABOVE R AC1 AC2 G1 G2 _ WHITE BLUE YELLOW RED GREEN BLACK WHITE THERMAL SWITCH GROUND WIRE BLACK POWER SUPPLY CORD MOTOR ...

Page 36: ...ig 37 3 4 Use a plastic mallet to tap the piston rod 224 down then pull the rod out through the bottom of the cylinder 5 Remove the throat packings 207 213 and glands 208 209 Refer to Fig 37 3 NOTE Whenever you disassemble the pump for clean ing or repair remove the sleeve A special sleeve removal tool is available Order Graco Part No 222 586 Do not use any other type of tool Always use the specia...

Page 37: ... Use a wrench to CAREFULLY tighten the nut 211 onto the piston rod to 19 ft lbs 25 N m Refer to Fig 37 2 Use two wrenches to maintain the alignment men tioned in Step 7 above Fig 37 2 224 211 TORQUE NUT ONTO ROD TO 19 ft lb 27 N m DO NOT ALLOW NUT 211 TO MOVE WHEN INSTALLING PISTON ONTO ROD 8 One at a time stack the male gland 208 alternate the packings 213 207 and then install the female gland 9 ...

Page 38: ...ing and the outlet nipple 40 is straight back Push the retaining spring 42 into the groove all the way around the connecting rod Tight en the locknut 47 very tight about 70 ft lb 97 N m with a 2 in open end wrench and a light ham mer Refer to Fig 38 2 WARNING Be sure the retaining spring 42 is firmly in the groove of the connecting rod all the way around to prevent it from working loose due to vib...

Page 39: ...85 211 CYLINDER 1 220 185 214 GUIDE ball 1 221 178 938 PIN ball stop 1 222 218 036 VALVE piston 1 223 222 437 VALVE intake 1 224 222 438 ROD piston 1 225 105 444 BALL 1 Supplied in repair kit 222 588 REPAIR KIT 222 588 Must be purchased separately Includes REF NO DESCRIPTION QTY 202 PACKING o ring 1 203 SEAL u cup polyurethane 1 204 BALL sst 1 206 V PACKING leather 2 207 V PACKING leather 2 208 GL...

Page 40: ... 57 58 16 20 9 67a 51 67b 9 68 69 23 25 49 24 43 61 32 60 42 47 76 86 53 45 39 50 12 38 10 8 22 75 SEE PARTS ON PAGE 44 36 63 44 INSIDE LABEL 55 OUTSIDE LABEL 1 66 21 14 19 20 26 13 20 40 67 64 74 77 33 87 73 46 Ref 70 IDENTIFICATION LABEL 34 Ref 8 Ref 64 34 34 85 90 WARNING LABEL 41 WARNING LABEL SEE PARTS ON PAGE 39 78 48 89 37 35 62 Ref 78 Ref 77 72 10 8 40 IDENTIFICATION LABEL 59 IDENTIFICATIO...

Page 41: ... 899 COVER housing 1 50 179 945 ADAPTER elbow special 1 4 18 npt m x f 1 51 179 961 GEAR REDUCER 1 52 180 041 PIN straight see page 44 1 53 181 072 STRAINER 1 55 181 608 LABEL identification 1 56 222 693 SHIELD motor includes 8 of item 34 and one each of items 41 57 and 58 1 57 181 636 LABEL ID motor cover left 1 58 181 637 LABEL ID motor cover right 1 59 181 638 LABEL ID front cover 1 60 183 035 ...

Page 42: ...2 37 11 10 67b 92 16 73 14 19 99 47 76 23 25 49 59 69 26 20 42 43 67 67a 51 20 9 58 56 21 8 11 10 8 11 10 31 97 98 93 91 24 5 92 83 34 8 REF 97 57 41 13 20 WARNING LABEL 68 ID LABEL ID LABEL 9 87 SEE PAGE 39 45 39 50 22 36 63 44 INSIDE LABEL 55 OUTSIDE LABEL 1 64 38 12 72 53 70 74 66 89 35 33 34 34 85 90 30 62 77 78a 100 101 102 4 Ref 70 ID LABEL 46 WARNING LABEL 40 46 WARNING LABEL 11 8 3 ...

Page 43: ...961 GEAR REDUCER 1 52 180 041 PIN straight see page 44 1 53 183 770 STRAINER 1 55 181 608 LABEL identification 1 56 222 693 MOTOR SHIELD KIT includes 8 of item 34 and one each of items 41 57 and 58 1 57 181 636 LABEL ID motor cover left 1 58 181 637 LABEL ID motor cover right 1 59 181 638 LABEL ID front cover 1 62 178 566 SLEEVE 2 63 183 995 COVER pressure control 1 64 183 365 BRACKET mounting 1 6...

Page 44: ...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 mach flat hd no 10 24 x 5 8 2 332 100 179 NUT hex mscr no 10 24 thd 2 333 100 718 LOCKWASHER...

Page 45: ...T BOARD 218 405 AC1 AC2 G1 G2 _ WHITE BLUE YELLOW RED GREEN BLACK WHITE THERMAL SWITCH GROUND WIRE BLACK POWER SUPPLY CORD MOTOR 336 Ref 27 52 73a 323 320 302 317 318 316 324 306 303 309 312 321 73c 322 337 308 323 323 314 319 73b 73a ...

Page 46: ... 589 UNION 1 2 214 961 HOSE 3 4 ID nylon 6 ft 1 3 156 591 ELBOW 1 4 156 593 PACKING 1 5 100 220 THUMBSCREW 6 176 684 ADAPTER 1 7 156 592 TUBE 1 8 159 100 RETAINER 1 9 161 377 SCREEN 1 10 159 101 NUT 1 REF NO PART NO DESCRIPTION QTY 1 101 818 CLAMP 1 2 160 327 UNION 90 1 3 170 705 ADAPTER 1 4 170 706 HOSE 48 1 5 170 957 TUBE 1 6 181 072 STRAINER 1 5 6 7 8 9 10 2 1 1 3 2 6 5 4 ...

Page 47: ...fluid filter Wetted Parts Displacement Pump Carbon steel Polyurethane Polyethylene Delrin Leather Filter Aluminum Carbon steel Stainless Steel NOTE Delrin DIMENSIONS Weight dry w o packaging 95 lb 43 Kg Height 28 in 711 mm Length 26 0 in 660 mm Width 22 5 in 572 mm GRACO PHONE NUMBERS TO PLACE AN ORDER contact your Graco distributor or call Graco 7 00 a m to 6 00 p m Central Time 1 800 423 8594 To...

Page 48: ...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 include...

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