Table of Contents
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INSTRUCTIONS/PARTS LIST
manual contains
This
WARNINGS
and
READ AND RETAIN FOR REFERENCE
ULTRA@ 400
I
Hazard of Using Fluids Containing Halogenated Hydrocarbons
Never use l,l,l-tnchloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
such solvents in this eauimnent. Such use could result in a serious chemical reaction, with the possibility of explo-
.sion, which could cause death, serious bodily injury and/or substantial property damage.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc parts.
IMPORTANT
INSTRUCTIONS
e
507-671
Rev D
ORACO
SUPERSEDES A
B
and
PCN
I
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Table of Contents
Related Manuals for Graco ULTRA AIRLESS 230-963
Summary of Contents for Graco ULTRA AIRLESS 230-963
- Page 1 INSTRUCTIONS/PARTS LIST manual contains This IMPORTANT WARNINGS INSTRUCTIONS READ AND RETAIN FOR REFERENCE ULTRA@ 400 Hazard of Using Fluids Containing Halogenated Hydrocarbons Never use l,l,l-tnchloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this eauimnent. Such use could result in a serious chemical reaction, with the possibility of explo- .sion, which could cause death, serious bodily injury and/or substantial property damage.
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Page 2: Table Of Contents
WARNINGS INTRODUCTION SETUP OPERATION; SHUTDOWN CARE FLUSHING GUIDELINES TROUBLESHOOTING GUIDE Motor Won't Operate Low output No Output Excessive Pressure Fluctuations Motor Is Hot and Runs Intermittently Electrical Short Spin Test Bridge Test REPAIR SECTION General Repair Notes List of Tools Power Supply Cord Replacement Filter Replacement ON/OFF Switch Replacement... -
Page 3: Introduction
HIGH PRESSURE SPRAY C A N CAUSE EXTREMELY SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals, tags, and warnings before operating equipment. FLUID INJECTION HAZARD General S a f e t y This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. - Page 4 HANDLE AND ROUTE HOSES CAREFULLY. Do hoses to move equipment. Do not use fluids or solvents which are not comoatible with the inner tube and cover of the hose. DO NOT expose Graco hose to temperatures above 1180°F) or below -4OOC (-4OOF). Grounding Continuity...
- Page 5 The pump has wet-cup which, when filled with Graco Throat Seal Liquid, helps prevent damage to the throat packings and piston rod. Fluid Filter The fluid filter provides the final paint straining to help avoid clogs in the hose and spray tip.
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Page 6: Warnings
Always use the main filter outlet for one- gun operation. Never plug this outlet. 2. Fill Packing Nutiwet-Cup (See Fig 2.) Fill the packing nut/wet-cup 1/3 full with Graco Throat Seal Liquid (TSL), supplied. 3. Check Electrical Service Be sure the electrical service is properly rated for your sprayer and that the outlet you use properly grounded. -
Page 7: Operation
OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, in- cluding fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when check- ing or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying. -
Page 8: Shutdown 8 Care
4. Cleaning a Clogged Tip W A R N I N G To avoid fluid injection injury, your hand, body, or a rag in front of the spray tip when cleaning or checking a clogged tip. Always point the gun toward .the ground or into a waste container when checking to see if the tup DO NOT try to "blow back"... -
Page 9: Flushing Guidelines
FLUSHING GUIDELINES When t o Flush 1. New Sprayer. Your new UltraQ factory tested in lightweight motor'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. -
Page 10: Troubleshooting Guide
TROUBLESHOOTING GUIDE Pressure Relief Procedure To reduce the risk of serious .bodilv injury. in- cluding fluid injection, splashing fluid in i h e eyes or on the skin, or injury from moving parts or elec- tric shock, always follow this procedure whenever you shut off the sprayer, when checkingor servic- ing any part of the spray system, when Installing, cleaning or changing spray tips, and whenever... - Page 11 ~~~~~~ WHAT TO CHECK TYPE PROBLEM If check Is MOTOR W O N 7 OPERATE Check leads from bridge 1308) to motor Diagnosing circuit board in- to be sure they are securely fastened dicator lamps. The normal and properly mated. condition is red lamp on, clear lamp on when board is telling pump...
- Page 12 WHAT TO CHECK YPE OF PROBLEM check is OK, Condition Check microswitch pressure in the pressure control discon- (continued) nect wires TP18 and TP19. Check con- tinuity across switch terminals with an ohmmeter. Switch contact should be closed. Depress actuator bunon. An audible "click"...
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Page 13: Low Output
WHAT TO CHECK TYPE OF PROBLEM If check is OK. go t o next check LOW OUTPUT 1. Check for worn spray tip. 2. Check t o see that pump does not con- tinue released. Plug in and turn on sprayer. Prime with paint. -
Page 14: Excessive Pressure Fluctuations
TYPE OF PROBLEM WHAT TO CHECK If check is NO OUTPUT Check to see if intake valve ball and (Continued) piston ball are seating properly. manual 307-793. Check for leaking around throat packing nut which may indicate worn or damag- ed packings.See manual 307-793. -
Page 15: Electrical Short
TYPE PROBLEM WHAT check ELECTRICAL SHORT Buildino circuit breaker ooens Check all electrical wiring for damaged insulation, and all terminals for loose as sooi as sprayer switch is turned on. or damage. Be sure to check wires bet- ween pressure control and motor which CAUTION are encased in conduit 141 2 9 . -
Page 16: Spin Test
SPIN TEST WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning o n page the risk of a fluid injection injury, splashing fluids in the eyes or on the skin, injury from moving Darts. or electric shock. For checking armature, motor winding and brush elec- trical continuity. -
Page 17: Bridge Test
BRIDGE TEST Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional. See Bridge Rectifier Replacement, page continuity tester, such as multi-meter set on the X1 ohms scale Eight individual checks, or tests, must be performed. If the bridge fails even one test, must be replaced. -
Page 18: General Repair Notes
GENERAL REPAIR NOTES WARNING Pressure Relief Procedure To'reduce the risk of serious bodily injury, in- cluding fluid injection, splashing fluid in the eyes or on the skin, or injury from moving parts or elec- tric shock, always follow this procedure whenever you shut off the sprayer, when checking or servic: ing any part of the spray system, when installing, cleaning or changing spray tips, and whenever... -
Page 19: Power Supply Cord Replacement
POWER SUPPLY CORD REPLACEMENT WARNING follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts, or electric shock. 1. Use the 19 mm open end wrench to remove the nut (337) from the filter stud (310). -
Page 20: On/Off Switch Replacement
ON/OFF SWITCH REPLACEMENT WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts, or shock. electric 1. -
Page 21: Bridge Rectifier Replacement
BRIDGE RECTIFIER REPLACEMENT WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or electric shock. 1. -
Page 22: Choke Replacement
CHOKE REPLACEMENT (See Fig 17) 1. Remove the pressure control cover and screws. Remove the grounding screw (312) and remove the lead. Loosen the appropriate screw on the terminal strip (336) and discornect the yellow/green choke lead. the M8 wrench to remove the upper nut and lockwasher (337, U S ) on the outside of the pressure control box. -
Page 23: Circuit Board Replacement
CIRCUIT BOARD REPLACEMENT WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing eyes or on the skin, injury from moving parts, or electric shock. Be sure to unolua rhe soraverl 1. -
Page 24: Pressure Control Replacement
PRESSURE CONTROL REPLACEMENT the risk of a fluid injection injury, splashing in the 1. Disconnect the main fluid hose (72) and the secon- dary fluid hose, if used, from the sprayer. Disconnect the fluid hose ( 2 3 ) from between the displacement pump outlet nipple control inlet elbow (314). -
Page 25: Stall Pressure Calibration
STALL PRESSURE CALIBRATION USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from splashing, component rupture, electric shock, fire, explosion, or moving parts. This procedure sets the sprayer to 192 bar (2750 psi) MAXIMUM WORKING PRESSURE. -
Page 26: Connecting Rod. Drive Housing Or Crankshaft
CONNECTING ROD, DRIVE HOUSING, or CRANKSHAFT REPLACEMENT (See Fig WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or NOTE: Stop the sprayer at the bottom of its stroke to get the crank (81) in its lowest position. - Page 27 19. Install the connecting rod (9). 20. Screw the displacement pump about 3/4 of the way into the bearing housing (6). Hold the pin ( 2 0 ) up to the pin hole in the connecting rod assembly (9) and continue screwing in the pump until the pin slides easily into the hole.
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Page 28: Motor Brush Replacement
MOTOR BRUSH REPLACEMENT NOTE: New motor brushes are included with each Packing Repair Kit. Replace them when replacing the packings, and/or when they have been worn to a minimum of 9 / 1 6 on the longest side. Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or... -
Page 29: Motor Capacitor Replacement
MOTOR CAPACITOR REPLACEMENT (See Figs 29 & 30) WARNING Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or 1. Remove the control box cover (48). Disconnect the motor leads. -
Page 30: Motor Replacement
MOTOR REPLACEMENT (See Fig 31 WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17to reduce the risk of a fluid injection injury, splashmg in the eyes or on the skin, injury from moving parts, or electric shock. - Page 31 13. Use a plastic mallet to gently tap the displacement (19) from the rear to loosen the drive housing pump (6) from the front end bell. Then pull the drive hous- ing away from the front end bell. CAUTION DO NOT allow the gear cluster (26) to fall when removing the drive housing (6).
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Page 32: Parts Lists
PART DRAWINGS PARTS LISTS 307-671... - Page 33 PARTS DRAWING 4 0 0 . Model 230-963 Ultra" Series Includes items 1-112...
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Page 34: Pressure Control
Check the parts list to identih, the correct part number; use the ref. no. when,ordering. Order all parts from your nearest Graco distributor. 6 digit PART NUMBER DESCRIPTION BALL VALVE;1/4 npt Imbe) - Page 35 Ref No. PRESSURE C O N T R O L A S S E M B L Y Includes items PARTS LIST REF PART DES C RIPTION NO. NO. 301 218-351 BARE PRESSURE CONTROL BOX Includes items to 306 107-437 .ON/OFF SWITCH 105659 .BOOT, ONIOFF switch...
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Page 36: Wiring Diagram
WIRING DIAGRAM THESE WIRES ARE CONNECTED TO TWO TERMINALS ON THE OTHER SIDE OF THE ONlOFF SWITCH SERVICE INFORMATION Listed below by the assembly changed are NEW parts. ASSEMBLY PART REF PART CHANGED STATUS NO. NO. 14 218-618 Sprayer, 1 181-612 Series 16 217-593 Gun 74 220-955... -
Page 37: Technical Data
Factory E r n n c ~ . A t l e n t e . Dallas, Datrolt. Loa Angala. W a t Csldwall lN.J.1 Subsidby and ARlbte Canpanles:Canada; England; Switzerland France; Germany; Hong Kong; Japan GRACO INC. PRINTED IN U.S.A. 307811 1-84 ReViSed 7-87...