Graco ULTRA 500 231-032 Скачать руководство пользователя страница 37

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307–758

DISPLACEMENT PUMP REPAIR

Tighten the packing retaining nut (211) against the
piston valve (222) to 19 ft-lb (27 N.m).

Note the alignment of the piston (222) to the pack-
ing retainer nut (211). Maintain this alignment
through Steps 5, 6 and 7.

Place the ball (225) on the piston valve (222). See Fig
37–1.

CAUTION

Step 5 is critical. Follow the procedure carefully to
avoid damaging the packings by overtightening.

Apply one drop of adhesive, supplied, to the piston
valve threads. Then hand tighten the valve assembly
into the piston rod just until the nut (211) contacts the
rod. See Fig 37–1.

211

Fig 37–1

POLY

*212

LIPS FACE UP

0029

222

203*

LIPS FACE DOWN

215*

225*

APPLY ONE DROP
OF SEALANT TO
THESE THREADS

224

TORQUE TO
10.5 in-lb (1.2 N.m)
to seat the packing,
and then back off and
tighten finger tight.

*210

214*

206*

LEATHER

LIPS FACE UP

Place the flats at the top of the rod in a vise.

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

Stack the male gland (208*), alternate packings
(213*,207*), and female gland (209*) into the top of
the cylinder (219). See Fig 37–3.

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

See Fig 37–3.

10. Coat the piston rod and packings with oil. Carefully

slide the assembly INTO THE TOP OF THE
SLEEVE.

NOTE: The tapered end of the sleeve is the bottom of it.

See Fig 38–1.

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

groove. See Fig 37–3.

219

Fig 37–3

212*

POLY
LIPS MUST
FACE UP

213*

POLY
LIPS MUST
FACE UP

205

*206

LEATHER

LIPS MUST

FACE UP

*203

U–CUP SEAL

LIPS MUST

FACE DOWN

215*

214*

*202

*217

*208

*207

LEATHER

LIPS MUST

FACE DOWN

*209

218

216

211

TORQUE TO:
67 ft-lb
(90 N.m)

*210

01197

Содержание ULTRA 500 231-032

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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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