Table of Contents
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INSTRUCTIONS-PARTS LIST
This manual contains IMPORTANT
INSTRUCTIONS and WARNINGS.
READ AND RETAIN FOR REFERENCE.
ELECTRIC, 120 VAC
ULTRA 500 AIRLESS PAINT SPRAYER
2750 psi (195 bar) MAXIMUM WORKING PRESSURE
Model 231–032, Series C
Basic sprayer on Upright cart
Model 231–041, Series B
Complete sprayer on Upright cart, hoses, gun,
RAC IV DripLess
Tip Guard and SwitchTip
Model 231–054, Series D
Basic sprayer on Lo-Boy cart without hose or gun
Model 231–055, Series B
Complete sprayer on Lo-Boy cart, hoses, gun,
RAC IV DripLess
Tip Guard and SwitchTip
U.S. PATENT NO. 4,323,741, 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
NOTE: This is an example of the DANGER label on your sprayer.
This label is available in other languages, free of charge.
See page 46 to order.
Spray painting, flushing or cleaning equipment with flammable liq-
uids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip-
ment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga-
rettes, arcs from connecting or disconnecting power cords or turn-
ing light switches on and off.
Failure to follow this warning can result in death or serious injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Parts
FIRE AND
EXPLOSION HAZARD
COPYRIGHT 1986, GRACO INC.
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 always setting safety latch when not spraying.
Never spray without a tip guard.
In
case
of
accidental
skin
"Surgical Treatment".
Failure to follow this warning can result in amputation or serious
injury.
307–758
Rev. R
Supersedes Rev. P
SKIN INJECTION
HAZARD
injection,
seek
immediate
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Related Manuals for Graco ULTRA 500 231-032
Summary of Contents for Graco ULTRA 500 231-032
- Page 1 Failure to follow this warning can result in death or serious injury. Failure to follow this warning can result in amputation or serious injury. READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1986, GRACO INC.
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Page 2: Table Of Contents
The pump has a wet-cup which, when filled with sprayer, the pressure adjusting control knob, a pressure Graco Throat Seal Liquid, helps prevent damage to the sensing device and a current overload circuit breaker throat packings and piston rod. - Page 3 TRIGGER SAFETY SHOWN ENGAGED MOTOR RESET BUTTON ON/OFF SWITCH PRESSURE ADJUSTING KNOB DRIVE ASSEMBLY FLUID FILTER PRESSURE CONTROL PRESSURE PAIL HANGER DRAIN VALVE (on upright sprayer only) FLUID OUTLET DISPLACEMENT PUMP RAC IV TIP GUARD SWITCH TIP 50 FT (15 M) MAIN HOSE 3 ft.
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Page 4: Safety Warnings
SAFETY WARNINGS HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS Read and understand all instruction manuals before operating equipment. FLUID INJECTION HAZARD General Safety Safety Latch This equipment generates very high fluid pressure. Spray from Whenever you stop spraying, even for a moment, always set the gun, leaks or ruptured components can inject fluid through the gun safety latch in the closed or “safe”... - Page 5 WORKING PRESSURE. Be sure that all spray equipment and cover of the hose. DO NOT expose Graco hose to temperatures accessories used are rated to withstand this pressure. DO NOT above 180 F (82 C) or below –40 F (–40...
- Page 6 AVERTISSEMENT La pulvérisation à haute pression peut causer des blessures très graves. Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité. Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel. RISQUES D’INJECTION Consignes generales de sécurité Dispositifs de sécurité...
- Page 7 RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIEL Consignes générales de sécurité Pression Toute utilisation anormale de l’appareil de pulvérisation ou des Ce pulvérisateur peut produire une PRESSION MAXIMUM DE accessoires comme, par exemple, la mise sous une pression TRAVAIL 190 bar (2750 lb/po2). S’assurer que tous les excessive, les modifications de pièces, l’utilisation de produits éléments du pulvérisateur et ses accessoires sont conçus pour chimiques et de matières incompatibles et l’utilisation de pièces...
- Page 8 ADVERTENCIA EL ROCIADO a ALTA PRESIÓN PUEDE CAUSAR GRAVES LESIONES. SOLO PARA USO PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA. Lea y entienda todo el manual de instrucciónes antes de manejar el equipo. PELIGRO DE INYECCIÓN DE FLUIDO Seguridad general Aparatos de seguridad de la pistola pulverizadora Este equipo genera un fluido a una presión muy alta.
- Page 9 PELIGRO POR MAL USO DEL EQUIPO Seguridad general Presión del sistema Cualquier mal uso del equipo pulverizador o los accesorios, tal está pulverizadora puede desarrollar 190 barías (2750 psi) de como sobre presurización, modificación de piezás, uso de presión DE TRABAJO M XIMA. Asegurar que todo el equipo matériales y productos quimicos incompatibles, o utilización de pulverizador y sus accesorios tienen la capacidad para aguan- piezás dañadas o desgastadas, puede hacen que se rompan...
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Page 10: Setup
SETUP WARNING 1. Fill the packing nut/wet-cup 1/3 full with Graco Throat Seal Liquid (TSL), supplied. 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- 2. - Page 11 SETUP ON/OFF SWITCH PRESSURE ADJUSTING KNOB PACKING NUT/ WET–CUP FILL 1/3 FULL WITH TSL PRESSURE DRAIN VALVE 1/4 npsm(m) FLUID OUTLET NIPPLE DO NOT INSTALL ANY SHUTOFF DEVICE HERE RAC IV TIP GUARD MAIN HOSE 1/4 in. x 50 ft 3/16 in.
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Page 12: Operation
OPERATION Use this procedure each time you start the sprayer to 9. Adjust the spray pattern help ensure the sprayer is ready to operate and that you a. Increase the pressure just until spray from the start it safely. gun is completely atomized. Use the lowest pressure needed to get the desired results. -
Page 13: Cleaning A Clogged Tip
MAINTENANCE Cleaning a Clogged Tip 3. Disengage the gun safety latch and trigger the gun into a waste container. Engage the gun safety latch WARNING again. To reduce the risk of serious injury, follow the illus- trated Pressure Relief Procedure warning on 4. -
Page 14: Shutdown And Care
SHUTDOWN AND CARE WARNING PRESSURE To reduce the risk of serious injury, follow the illus- ADJUSTING KNOB trated Pressure Relief Procedure warning on page 4 whenever you are instructed to relieve pres- sure. 1. Check the packing nut/wet-cup daily. First relieve pressure. -
Page 15: Flushing Guidelines
FLUSHING GUIDELINES NOTE: Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be sprayed, or to store the sprayer. Use this chart to determine the required flushing order for the fluid you are using, and then follow the procedure below for flushing. -
Page 16: Troubleshooting Guide
TROUBLESHOOTING GUIDE WARNING Pressure Relief Procedure 5. Engage the gun safety latch. To reduce the risk of serious bodily injury, including 6. Open the pressure drain valve, having a con- tainer ready to catch the drainage. Leave the fluid injection, injury from splashing fluid or solvent in pressure drain valve open until you are ready to the eyes or on the skin, moving parts or electric spray again. - Page 17 MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1 . Check leads from bridge (308) to motor to be 1.
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Page 18: Repair
MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Condition B (continued) 6. Check motor thermal cutout switch. Connect 6. Allow motor to cool. Correct cause of over- volt meter to TP6 female and TP9 female. -
Page 19: Low Output
LOW OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warn- ing then replace tip. -
Page 20: No Output
NO OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Motor runs and pump strokes 1. Check paint supply. 1. Refill and reprime pump. 2. -
Page 21: Motor Is Hot And Runs Intermittently
MOTOR IS HOT AND RUNS INTERMITTENTLY TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1. Determine if sprayer was operated at high 1. -
Page 22: Spin Test
SPIN TEST WARNING Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) To reduce the risk of serious injury, follow the illus- Relieve pressure. Connect the two black motor leads to- trated Pressure Relief Procedure warning on gether with a test lead. Turn the motor fan by hand at page 24 whenever you are instructed to relieve about two revolutions per second. -
Page 23: Bridge Test
BRIDGE TEST WARNING To reduce the risk of serious injury, follow the illus- trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. BRIDGE WIRES Remove the bridge from the pressure control box and CONTINUITY –... -
Page 24: General Repair Information
GENERAL REPAIR INFORMATION WARNING Pressure Relief Procedure Disengage the gun safety latch. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trig- To reduce the risk of serious bodily injury, including fluid in- ger the gun to relieve pressure. -
Page 25: Motor Brush
MOTOR BRUSH REPLACEMENT NOTE: Replace the brushes when they have worn to HOOK SPRING less than 1/2 in. See STEP 1, Fig 25–3. Note that the brushes wear differently on each side of the motor, so check them both. Brush Repair Kit BRUSH 220–853 is available. -
Page 26: Power Supply Cord
POWER SUPPLY CORD REPLACEMENT WARNING 1. Relieve pressure. To reduce the risk of serious injury, follow the illus- 2. Remove the pressure control cover (62). trated Pressure Relief Procedure warning on 3. Disconnect the power supply cord lead from the ON/ page 24 whenever you are instructed to relieve OFF switch (303), the white wire going to the bridge pressure. -
Page 27: Bridge Rectifier
BRIDGE RECTIFIER REPLACEMENT WARNING 2. Remove the pressure control cover (62). To reduce the risk of serious injury, follow the Pres- 3. Disconnect all wires from the bridge (308). sure Relief Procedure warning on page 24 when- 4. Loosen but don’t remove the screw (331A). Remove ever you are instructed to relieve pressure. -
Page 28: Circuit Board
CIRCUIT BOARD REPLACEMENT WARNING 5. Pull out the plastic-tipped pin (330). Push the bottom of the circuit board (72) toward the wall of the pres- To reduce the risk of serious injury, follow the illus- sure control and carefully slide the board out. trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve 6. -
Page 29: Pressure Control
PRESSURE CONTROL REPLACEMENT WARNING UPRIGHT CART To reduce the risk of serious injury, follow the illustrated Pressure Relief Procedure warning on page 24 when- ever you are instructed to relieve pres- sure. NOTE: Read GENERAL REPAIR INFORMATION on page 24 before doing this procedure. -
Page 30: Pressure Control Adjustment
PRESSURE CONTROL ADJUSTMENT 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. This procedure sets the sprayer to 2750 psi (195 bar) NEVER try to increase the sprayer’s maximum work- MAXIMUM WORKING PRESSURE and sets the ing pressure of 2750 psi (195 bar) by performing these... - Page 31 PRESSURE CONTROL ADJUSTMENT 6. Plug in the sprayer. 12. Install the pressure control cover. Maximum Working Pressure Adjustment 7. Turn the pressure control knob (B) to the minimum setting (fully counterclockwise), and turn the sprayer 13. Turn the sprayer OFF. Disengage the gun safety ON.
- Page 32 DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT WARNING 5. Loosen the jam nut (41) with an adjustable wrench. Unscrew and remove the pump. To reduce the risk of serious injury, follow the illus- trated Pressure Relief Procedure warning on 6. See Fig 32–1 to remove one of the screws (25) which page 24 whenever you are instructed to relieve is hidden.
- Page 33 DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT 14. Screw the displacement pump about 3/4 of the way into the drive housing (73). 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.
- Page 34 MOTOR REPLACEMENT WARNING 13. Turn the displacement rod so the pin hole faces straight back. Insert a hex key wrench through the To reduce the risk of serious injury, follow the illus- hole to unscrew the screw (25). See Fig 32–1. Re- trated Pressure Relief Procedure warning on move the other two screws from the recess of the page 24 whenever you are instructed to relieve...
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Page 35: Motor
MOTOR REPLACEMENT WIRING DIAGRAM DETAIL Shows position of conduit seal (26) in conduit connector (345) BLUE WHITE BLACK YELLOW MOTOR LEADS BLACK WHITE MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD 39 or 5 Fig 35–1 307–758... - Page 36 If the sleeve cannot be removed easily using the tool, return the sleeve and cylinder to your 210* Graco distributor for removal. 212* 9. Screw the large nut (B) of the tool into the top of the *206 cylinder (219).
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Page 37: Displacement Pump Repair
DISPLACEMENT PUMP REPAIR 3. Tighten the packing retaining nut (211) against the 9. Install the packing nut (216) and plug (205), but leave loose for now. See Fig 37–3. piston valve (222) to 19 ft-lb (27 N.m). Note the alignment of the piston (222) to the pack- 10. -
Page 38: Removing And Installing A Pump
Fill the wet-cup/packing nut lower the rod. 1/3 full with Graco TSL. See Fig 38–2. 2. While holding the pump intake valve (223) steady with a wrench, unscrew the suction tube (61). -
Page 39: Parts Drawings & Lists Displacement Pump
PARTS DRAWING & LIST – DISPLACEMENT PUMP Model 222–584, Series A Sleeved Displacement Pump Includes items 202 to 225 NO. PART NO. DESCRIPTION 108–954* PACKING, o–ring, PTFE 209* 105–522* SEAL, u–cup, polyurethane 105–445* BALL, sst 180–656 PLUG 225* 176–749* V–PACKING, leather 176–755* V–PACKING, leather 176–754* GLAND, male 176–757* GLAND, female... -
Page 40: Upright Sprayer
PARTS – COMPLETE SPRAYER Model 231–032, Series C Basic Sprayer with Upright Cart Includes items 1 to 98 Model 231–041, Series B Complete Sprayer with Upright Cart Includes items 1 to 102 ID LABEL DANGER LABEL ID LABEL DANGER LABEL COVER ID LABEL DANGER LABEL... -
Page 41: Displacement Pump
PARTS DRAWING – UPRIGHT SPRAYER Model 231–032, Series C Model 231–041, Series B Includes items 1 to 98 Includes items 1 to 102 NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 065–099 CONDUIT, 187–603 SLEEVE specify length when ordering 0.8 ft 103–846 CAPSCREW, soc hd 110–963... -
Page 42: Lo-Boy Sprayer
PARTS DRAWING – LO-BOY SPRAYER Model 231–054, Series D Basic Sprayer with Lo-Boy Cart Includes items 1 to 98 Model 231–055, Series B Complete Sprayer with Lo-Boy Cart Includes items 1 to 102 ID LABEL, THIS SIDE ID LABEL, OTHER SIDE DANGER LABEL OTHER SIDE THIS SIDE... - Page 43 PARTS LIST – LO-BOY SPRAYER Model 231–054, Series D Model 231–055, Series B Includes items 1 to 98 Includes items 1 to 102 NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION 065–099 CONDUIT, 185–470 BRACKET, shield specify length when ordering 0.8 ft 206–994 THROAT SEAL LIQUID,...
- Page 44 PARTS DRAWING & LIST – PRESSURE CONTROL PRESSURE CONTROL ASSEMBLY 220–455 Includes all items listed below, except the terminals. Part numbers for items 15, 23, 26, 50, 72, 75a, 75b, and 75c shown in the drawings below are given on pages 41 The terminals are included with the circuit board (item and 43.
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Page 45: Wiring Diagram
WIRING DIAGRAM CIRCUIT BOARD 218–405, 5 WIRES 321 (75c) BLUE WHITE BLACK YELLOW Ref 23,50 BLACK WHITE MOTOR GREEN GROUND WIRE THERMAL SWITCH POWER SUPPLY CORD 307–758... -
Page 46: Accessories
The drawing shows No. No. Name the best placement of these labels for good visibility. 156–589 UNION Order the labels directly from Graco, free of 214–961 HOSE, 3/4 ID, 6 ft charge. Toll Free: 1–800–328–0211 156–591 ELBOW 156–593... -
Page 47: Technical Data
....1/4 npsm from fluid filter Wetted Parts: TO PLACE AN ORDER , contact your Graco distributor, Displacement Pump .. -
Page 48: The Graco Warranty And Disclaimers
Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box on EM and GM sprayers or power train on EH &...