Graco ULTRA PLUS+ 1000, Instructions-Parts List Manual

Page 1: ...LTRA PLUS 1000 AIRLESS PAINT SPRAYER 3000 psi 210 bar 21 MPa Maximum Working Pressure Model 231 373 Series A Complete sprayer on Upright cart with hose 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 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com COPYRIGHT 1996 GRACO INC Graco Inc is registered to I S...

Page 2: ...e pressure control and motor cause the pump to cycle whenever 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...

Page 3: ...ounded nylon hose with spring guards on both ends K RAC IV Tip Guard Reverse A Clean RAC tip guard reduces the 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 a...

Page 4: ...lter or modify this equipment Use only genuine Graco parts Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Refer to the Technical Data on page 39 for the maximum working pressure of this equipment Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Technic...

Page 5: ...injury Get immediate medical attention Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly Refer to the gun manua...

Page 6: ...t the equipment from starting unexpectedly 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 trigger ing of gun by always setting safety latch when not spraying Never spray without a tip guard In case of accidental skin...

Page 7: ... use thread sealant and don t install the spray tip yet 3 Two gun hookup Unscrew the cap from the 1 4 npsm m secondary hose outlet Connect a hose and gun to the outlet Use a 1 4 in ID 50 ft long minimum main hose For more flexible gun movement install a 3 16 ID 3 ft hose between the main hose and the gun 4 Check the Electrical Service Two gun hookup Unscrew the cap from the 1 4 npsm m secondary ho...

Page 8: ... 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 ...

Page 9: ...sure adjusting knob clockwise until the sprayer starts When fluid comes from the drain hose close the valve han dle 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 Relie...

Page 10: ...he 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 spray ti...

Page 11: ...273 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 ...

Page 12: ...s 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 13 Engage the gun safety latch 2 Turn the pressure adjusting knob fully counter c...

Page 13: ...ieve 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 76 and or pressure control tube Using a screwdriver carefully try to rotate fan at back of motor by hand See page 18 1 Thaw Plug in sprayer and turn on Slowly increase pressure setting to see if motor starts If it doesn t see NOTE 1 ...

Page 14: ... spots gouges and extreme roughness Re move motor cover and brush inspection plates to check See page 20 6 Remove motor and have motor shop resur face commutator if possible See page 28 7 Check motor armature for shorts using arma ture tester growler or perform spin test See page 18 7 Replace motor See page 28 8 Check pressure control board 301 by substi tuting with a good pressure control board S...

Page 15: ...nals for signs of overheating See page 28 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 20 6 Tighten terminal screws Replace brushes if leads are damaged See page 20 7 Check for worn motor brushes which should be 1 2 minimum Se...

Page 16: ...isplacement pump connecting rod pin 43 See page 32 1 Replace pin if missing Be sure retainer spring 42 is fully in groove all around con necting rod See page 32 2 Check connecting rod assembly 68 for dam age See page 25 2 Replace connecting rod assembly See page 25 3 Be sure crank in drive housing rotates plug in sprayer and turn on briefly to check Turn off and unplug sprayer See page 26 3 Check ...

Page 17: ...heck for missing inspection plate gasket see page 28 bent terminal forks or other metal to metal contact points which could cause a short 2 Correct faulty conditions 3 Check motor armature for shorts Use an ar mature tester growler or perform spin test See page 18 Inspect windings for burns 3 Replace motor See page 28 4 Check pressure control board 301 by substi tuting with a good control board Se...

Page 18: ...ressure control cover terminals M and M See Fig 10 Armature Short Circuit Test Relieve pressure Quickly turn the motor 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 28 Fig 9 J F 59 01224A Armature Brushes and Motor Wiring Open Circu...

Page 19: ...he 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 not...

Page 20: ...NG 01227 4 Loosen the brush lead terminal screw Pull the brush lead away leaving the motor lead terminal in place Remove the brush and spring See Fig 14 5 Inspect the commutator for excessive pitting burning or gouging A black color on the commuta tor 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 f...

Page 21: ...s to avoid damaging the displacement 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 13 when ever you...

Page 22: ...om 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 vertical groove in the threads of the switch 7 Install the switch guard 308 aligning the internal tab with the groove in the threads...

Page 23: ... 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 white M and black M leads ...

Page 24: ...eassemble in the reverse order attach ground wire C power leads L1 and L2 the red leads to the TS terminals on the circuit board B1 the M and M leads and the potentiometer cable to the connector on B1 Attach the pressure control board cover 301 using the four mounting screws and washers 302 303 304 Fig 18 304 L1 C 302 304 303 317 310 301 L2 B1 TS ...

Page 25: ...ll the bearing housing and the connecting rod assembly 68 straight off the drive housing 7 Remove the pail bracket assembly F and install it on the new bearing housing 8 Inspect the crank E for excessive wear and replace parts as needed Evenly lubricate the inside of the bronze bearing B with high quality motor oil Liberally pack the roller bearing C with bearing grease 9 Assemble the connecting r...

Page 26: ...e 36 from the pump 3 Remove the four bearing housing screws 25 and lockwashers 23 4 Lightly tap the lower rear of the bearing housing 69 with a plastic mallet to loosen it from the drive housing 67 Pull the assembled bearing housing and connecting rod straight off the drive housing 5 Remove the two drive housing screws 26 and lockwashers 20 6 Remove the two lower screws 13 and lockwash ers 20 and ...

Page 27: ... Drive Housing Replacement Fig 20 16 20 49 67 67b 51 67a 9 9 34 26 20 59 69 20 13 LIBERALLY APPLY GREASE 25 23 TORQUE TO 175 in lb 19 N m 03752 99 ...

Page 28: ...e drive housing 67 with a plastic mallet to loosen it from the front of the motor 73 and then pull the drive housing straight off CAUTION DO NOT drop the gear cluster 51 when removing the drive housing 67 The gear cluster may stay en gaged in the motor front end bell or the drive housing DO NOT lose the thrust balls 9 located at each end of the gear cluster 51 or drop them between gears The balls ...

Page 29: ...9 34 26 20 59 69 73 20 13 70 40 301 31 70 8 10 11 DETAIL Shows position of conduit seal 29 in conduit connector 345 29 318 LIBERALLY APPLY GREASE 01232 04245 99 Fig 21 Fig 22 Motor Replacement 318 1 04772 MOTOR B1 M M POWER CORD ...

Page 30: ...intake valve 223 from the cylinder 219 Remove all parts See Fig 23 3 If no further service is needed reassemble the intake valve Be sure you use a new o ring 202 4 Remove the packing nut 216 and plug 205 See Fig 23 5 Use a plastic mallet to tap the piston rod 224 down then pull the rod out through the bottom of the cylinder 219 See Fig 23 6 Remove the throat packings and glands See Fig 24 7 Clamp ...

Page 31: ...7 4 Place the ball 225 on the piston valve 222 See Fig 27 CAUTION Step 5 is critical Follow the procedure carefully to avoid damaging the packings by overtightening 5 Apply one drop of adhesive supplied to the piston valve threads Then hand tighten the valve assem bly into the piston rod just until the nut 211 con tacts the rod See Fig 27 Fig 27 211 POLY 212 LIPS FACE UP 0029 222 203 LIPS FACE DOW...

Page 32: ...T FACE DOWN 215 214 202 202 208 207 LEATHER LIPS MUST FACE DOWN 209 47 218 216 211 TORQUE TO 67 ft lb 90 N m 210 01197 Fig 30 219 PISTON ASSEMBLY 218 TAPERED END 0030 12 Slide the sleeve piston rod assembly INTO THE BOTTOM OF THE CYLINDER This is to prevent packing damage during reassembly See Fig 30 13 Screw down the cylinder locknut 47 until it is finger tight at the bottom of the external cylin...

Page 33: ... of the pump cylinder are flush with the face of the bearing housing and the outlet nipple 40 is straight back 3 Push the retaining spring 42 into the groove all the way around the connecting rod 4 Tighten the locknut 47 very tight about 70 ft lb 97 N m with a 2 in open end wrench and a light hammer WARNING Be sure the retaining spring 42 is firmly in the groove of the connecting rod all the way a...

Page 34: ...53 47 40 70 78 20 13 8 31 77 59 34 83 44 34 34 16 20 73 9 67a 51 67b 9 67 68 69 23 25 49 26 20 8 11 10 73D LABEL 58 LABEL LABEL 56 LABEL 57 12 38 LABEL 41 LABEL 17 21 14 19 66a 40 102 101 100 76 27 Ultra PLUS 1000 Sprayers Model 231 373 Series A Includes items 1 102 Complete Sprayer 65 64 80 REF 77 62 48 52 37 35 REF 78 ...

Page 35: ... 179 961 GEAR REDUCER 1 52 183 350 WASHER 2 53 187 147 STRAINER 1 56 290 032 LABEL ID motor cover left 1 57 290 031 LABEL ID motor cover right 1 58 290 030 LABEL ID front cover 1 59 237 095 SHIELD motor 1 includes items 34 41 56 57 61 186 277 HANGER pail 1 62 192 027 SLEEVE 2 63 290 024 LABEL ID control top 1 64 290 023 LABEL ID control bottom 1 65 206 994 THROAT SEAL LIQUID 8 OZ 1 66 214 570 FLUI...

Page 36: ...8 944 GLAND male 1 211 178 945 NUT hex retaining 1 212 178 964 V PACKING plastic 3 213 178 965 V PACKING plastic 3 214 181 338 WASHER backup 1 215 178 969 GLAND female 1 216 179 809 NUT packing 1 218 185 213 SLEEVE cylinder 1 219 185 211 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 ...

Page 37: ...anhead 10 24 x 2 2 304 100 020 WASHER lock 10 4 305 189 095 HOUSING cast 1 306 290 034 LABEL caution 1 307 112 826 SWITCH toggle 1 308 112 608 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 1 314 239 050 CORD SET power 1 315 108 295 BUSHING strain relief 1 316 112 376 LOCKNUT 1 317...

Page 38: ...LOW BLACK WHITE GROUND WIRE POWER SUPPLY CORD THERMAL SWITCH MOTOR WINDINGS POTENTIOMETER ON OFF SWITCH TP7 BLACK PRESSURE TRANSDUCER CIRCUIT BOARD B1 M M TP3 TP2 FILTER BOARD BLUE L2 TP8 73a M GREEN YELLOW BROWN BLUE L2 BLUE BROWN L1 73b TP1 behind TP4 behind TP5 BLACK TP6 ...

Page 39: ...he drawing shows the best placement of these labels for good visibility Order the labels directly from Graco free of charge Toll Free 1 800 328 0211 04244 Technical Data Power Requirements 120 VAC 60Hz 1 phase 15A minimum or 3500W generator Motor 1HP DC Noise Level Sound power 98 3 dBa per ISO 3744 Sound pressure 89 8 dBa measured at 3 1 feet 1 m Working Pressure Range 0 3000 psi 0 210 bar 0 21 MP...

Page 40: ...rty or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not ...