Graco Ultra 1500 Mark V 236-401 Operation manual

INSTRUCTIONS–P ARTS LIST 308–263
Rev D
Supersedes C
and PCN D
220 VAC, 50 HZ, 12 AMP
Ultra 1500 Mark V T exture Sprayer
210 bar (3000 psi) Maximum Working Pressure
Model 236–401, Series A
This model includes a basic sprayer , a 15 m hose,
a 1 m hose, a Contractor gun, RAC IV  DripLess tip
guard and a Size 621 DripLess SwitchT
ip
Model 236–400, Series A
This model includes a basic sprayer , a 15 m hose,
a 1 m hose, a Silver Plus  gun, a Heavy Duty RAC
IV tip guard and a Size 629 DripLess SwitchT ip
Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1993, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE


 
Table of Contents
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 11. . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 12. . . . . . . . . . . . . . . . . . . . .
Motor Replacement 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Replacement 17. . . . . . . . . . . . . . . . . .
Bearing Housing and
Connecting Rod Replacement
18. . . . . . . . . . . . . . . . . .
Drive Housing Replacement 19. . . . . . . . . . . . . . . . . . . .
Parts – Sprayer 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts – Displacement Pump 22. . . . . . . . . . . . . . . . . . . .
Technical Data 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data
Power Requirements (full output) 220 V AC, 50Hz, . . . .
1 phase, 10 amp minimum
W orking Pressure Range 0 – 210 bar (0–3000 psi) . . . .
Cycles/Liter 27.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cord No. 12 A WG, 3 wire, 3 m . . . . . . . . . . . . . .
Outlet Paint Filter 250 micron (60 mesh) . . . . . . . . . . . . .
Stainless steel screen, reusable
Fluid Outlet Size 1/4 npsm from fluid filter . . . . . . . . . . .
Wetted Parts:
Displacement Pump Carbon steel, Polyurethane, . . .
polyethylene,  Delrin  , Leather
Filter Aluminum, Carbon steel, Stainless Steel, . . . . .
NOTE:  and Delrin  are a registered trade -
marks of the DuPont Company .
Dimensions
W eight (basic sprayer) 55.5 kg . . . . . . . . . . . . . . . . . . . . .
Height 813 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length 616 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 572 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Labels
The English language DANGER label shown below is
also on your sprayer . If you have painters who do not
read English, order one of the following labels in an
appropriate language. Apply the label to the sprayer .
The drawing shows the best placement of the new la -
bels for good visibility .
Order the labels directly from your Graco distributor .
Language
Part No.
French 185–955
Spanish 185–962
German 186–042
Greek 186–046
Korean 186–050
Apply a label in
another language
at this location
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.A void accidental
triggering
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 inch.
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 INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable
liquids
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
cigarettes, arcs from connecting or disconnecting power cords or
turning light switches on and off.
Failure to follow this warning can result in death or serious injury .
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE

 
WARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
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 injury ,
including the need for amputation. Also, fluid injected or
splashed into the eyes or on the skin can cause serious dam-
age.
NEVER
point the spray gun at anyone or at any part of the body .
NEVER put hand or fingers over the spray tip. NEVER try to
“blow back inch paint; this is NOT an air spray system.
ALWAYS have the tip guard in place on the spray gun when
spraying.
ALWAYS
follow the Pressure Relief Procedure , below , before
cleaning or removing the spray tip or servicing any system
equipment.
NEVER
try to stop or deflect leaks with your hand or body .
Be
sure equipment safety devices are operating properly before
each use.
Medical Alert––Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
CUT.
T ell the doctor exactly what fluid was injected.
Note to Physician : Injection in the skin is a traumatic injury . It
is important to treat the injury surgically as soon as possible. Do
not delay treatment to research toxicity . T oxicity is a concern
with some exotic coatings injected directly into the blood
stream. Consultation with a plastic surgeon or reconstructive
hand
surgeon may be advisable .
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before
each use. Do not remove or modify any part of the gun; this can
cause a malfunction and result in serious injury .
Safety Latch
Whenever you stop spraying, even for a moment, always set
the gun trigger safety in the closed or “safe inch position, making
the gun inoperative. Failure to set the safety latch can result in
accidental triggering of the gun.
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
injection
when the tip is not installed. Check dif fuser 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 dif fuser immediately .
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. The tip guard alerts you to the fluid injection hazard
and
helps reduce, but does not prevent, the risk of accidentally
placing your fingers or any part of your body close to the spray
tip.
Trigger Guard
Always have the trigger guard in place on the gun when spray -
ing to reduce the risk of accidentally triggering the gun if it is
dropped
or bumped.
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If
the
spray tip clogs while spraying, engage the gun trigger safety
immediately. ALWAYS follow the Pressure Relief Procedure
and then remove the spray tip to clean it.
NEVER wipe of f build–up around the spray tip until pressure is
fully relieved and the gun trigger safety is engaged.
Pressure Relief Procedure
To reduce the risk of serious injury , including fluid injection,
splashing fluid or solvent in the eyes or on the skin, or injury
from moving parts or electric shock, always follow this proce -
dure whenever you shut off the sprayer, when checking or
servicing any part of the spray system, when installing,
cleaning or changing spray tips, and whenever you stop
spraying.
1. Lock
the gun trigger safety .
2. T
urn of f the ON/OFF switch.
3.
Unplug the power supply cord.
4. Unlock the gun trigger safety . Hold a metal part of the gun
firmly to the side of a grounded metal pail, and trigger the
gun to relieve the pressure.
5. Lock the gun trigger safety .
6. Open
the pressure drain valve, having a container ready
to catch the drainage. Leave the valve open until you are
ready to spray again.
If you suspect that the spray tip or hose is completely
clogged,
or that the pressure has not been fully relieved, fol -
low these additional precautions, VERY SLOWLY loosen
the
retaining nut on the tip guard or loosen a hose coupling
to relieve the pressure gradually . Now loosen the part com -
pletely. Clear the tip or hose obstruction.

1235
4

4 308-263
EQUIPMENT MISUSE HAZARD
System Pressure
This sprayer can develop 210 bar (3000 psi ) Maximum
Working Pressure . Be sure that all spray equipment and acces -
sories used are rated to withstand this pressure. DO NOT ex-
ceed
the maximum working pressure of any component or ac -
cessory
used in the system.
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemi-
cals and fluids, or using worn or damaged parts, can cause
them
to rupture and result in fluid injection, splashing in the eyes
or on the skin, or other serious injury , or fire, explosion or prop -
erty
damage.
NEVER alter or modify any part of this equipment; doing so
could
cause it to malfunction.
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately .
Always
wear protective eyewear , gloves, clothing and respira -
tor as recommended by the fluid and solvent manufacturer .
Fluid and Solvent Compatibility
All chemicals used in the sprayer must be chemically compatible
with the wetted parts shown in the TECHNICAL DA TA on page
2. Consult your chemical supplier to ensure compatibility .
Do
not use 1,1,1-trichloroethane, methylene chloride, other ha -
logenated hydrocarbon solvents or fluids containing such sol-
vents in this equipment, which contains aluminum and/or zinc
parts.
Such use could result in a serious chemical reaction, with
the possibility of explosion, which could cause death, serious in -
jury
and/or substantial property damage.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear,
damage
or misuse, the high pressure spray emitted from it can
cause a fluid injection injury or other serious injury or property
damage.
All fluid hoses must have spring guards on both ends! The
spring guards help protect the hose from kinks or bends at or
close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high pres -
sure
spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the en -
tire
hose for cuts, leaks, abrasion, bulging cover , or damage or
movement of the hose couplings. If any of these conditions ex -
ist, replace the hose immediately . DO NOT try to recouple high
pressure hose or mend it with tape or any other device. A re-
paired hose cannot contain the high pressure fluid.
Handle and route hoses carefully . Do not pull on hoses to move
equipment. Keep hoses clear of moving parts and hot surfaces
of the pump and gas engine. Do not use fluids or solvents which
are not compatible with the inner tube and cover of the hose. DO
NOT expose Graco hose to temperatures above 82  C (180 F
or below –40  C (–40  F).
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 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 recommended limits, replace it immediately . An un-
grounded
or poorly grounded hose can make your system haz -
ardous. Also read FIRE OR EXPLOSION HAZARD.
FIRE OR EXPLOSION HAZARD
Static electricity is created by fluid flowing through the pump and
hose. If every part of the spray equipment is not properly
grounded, sparking may occur , and the system may become
hazardous. Sparking may also occur when plugging in or un-
plugging
a power supply cord or using a gasoline engine. Sparks
can ignite fumes from solvents and the fluid being sprayed, dust
particles and other flammable substances, whether you are
spraying
indoors or outdoors, and can cause a fire or explosion
and serious injury and property damage.
If you experience any static sparking or even a slight shock
while
using this equipment, ST OP SPRA YING IMMEDIA TELY.
Check the entire system for proper grounding. Do not use the
system again until the problem has been identified and
corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and all
other spray equipment used or located in the spray area.
CHECK
your local electrical code for detailed grounding instruc -
tions
for your area and type of equipment. BE SURE to ground
all of this spray equipment:
1. Sprayer: plug into a properly grounded outlet. Do not re-
move the grounding prong of the plug, and do not use an
adapter.
Extension cords must have three wires.
2. Fluid hoses: use only grounded hoses with a maximum of
150 m (500 feet) combined hose length to ensure grounding
continuity. See Hose Grounding Continuity.
3. Spray gun: obtain grounding through connection to a prop -
erly grounded fluid hose and sprayer .
4.
Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to local
code. Use only metal pails, which are conductive. Do not
place
the pail on a non–conductive surface, such as paper
or cardboard, which interrupts the grounding continuity .
7.
To maintain grounding continuity when flushing or relieving
pressure , always hold a metal part of the gun firmly to the
side of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce the risk of fluid injection injury , static sparking, or
splashing by following the flushing procedure given on page 7
of this manual. Follow the Pressure Relief Procedure on page
3, and remove the spray tip before flushing. Hold a metal part
of
the gun firmly to the side of a grounded metal pail and use the
lowest possible fluid pressure during flushing.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other body
parts. KEEP CLEAR of moving parts when starting or operating
the sprayer . Follow the Pressure Relief Procedure on page 3
before checking or servicing any part of the sprayer , to prevent
it from starting accidentally .

308-263 5
Setup
Proper electrical–grounding is essential to reduce
the risk of a fire or an explosion. A fire or an explo -
sion can cause a serious injury and property dam -
age. For the detailed grounding–instructions, refer
to the warning section, FIRE OR EXPLOSION
HAZARD, on page 4.
WARNING
If you supply the hoses and the spray gun for the
sprayer , follow these precautions. Be sure the
hoses are electrically conductive. Be sure the spray
gun has a tip guard. Be sure that each part is rated
for at least 210 bar (3000 psi) working pressure .
These precautions reduce the risk of a serious
injury , including skin injection, due to static spark -
ing, over–pressurizing or rupturing the hose or the
gun.
WARNING
A damaged pressure control can cause poor
sprayer performance and may damage other parts
of the sprayer . Follow these precautions to avoid
damaging the pressure control.
1. Use a nylon spray hose (99) that is at least
15 m (50 feet) long.
2. Never use a wire braid hose. It is too rigid to
absorb the pulsations of the fluid in the hose.
3. Never install a shutoff device between the fluid
filter and the main hose. See Ref. B in Fig. 1.
CAUTION
1. Connect the gun (101) and the 15 m (50 feet) hose
(99). Do not install the spray tip yet.
2. Fill the wet–cup (216) with Graco Throat Seal Liq -
uid, supplied, until it is 1/3 full.
3. Be sure the electrical service is 220 V , 50 Hz. Use
an electrical outlet that is properly grounded. Have
a licensed electrician attach an appropriate plug to
the power supply cord. Do not remove the ground -
ing prong of the power supply cord. Do not use an
ungrounded adapter . Extension cords must have
three wires which have a minimum 2.5 mm2 (12
gauge) size. Long extension cords reduce the per -
formance of the sprayer .
4. T
urn of f the power switch (A). Plug the power
supply cord into a grounded electrical outlet which
is located at least 6 m (20 feet) away from the
spray area.
5. If you are spraying texture material, remove the
screen from the fluid filter . Refer to the Flushing
procedure on page 8.
6. Flush the pump before using it. Refer to page 8.

Fig. 1
A
B
216
99
101

 
Operation
WARNING
T o reduce the risk of a serious injury , always follow
the Pressure Relief Procedure W arning on page
3 before checking, adjusting, cleaning, and shut -
ting of f the sprayer .
Startup
Always use this procedure to help ensure that the
sprayer is ready to operate and that you start the
sprayer safely .
1.
Flush the sprayer before you use it for the first
time. Refer to page 8.
2. Close the pressure drain valve (55).
3. Do not install the spray tip until the pump is primed
with fluid!
4. Put the pump (39) into the supply pail .
5. T
urn the pressure–adjusting knob (A) counter -
clockwise to the lowest setting.
6. Unlock the gun trigger safety .
WARNING
T ake precautions to reduce the risk of static spark -
ing and splashing when you prime or flush the
sprayer . Be sure the spray tip is removed. Hold a
metal part of the gun firmly to the side of grounded
metal pail. See Fig. 2.
Fig. 2
7. Prime the pump. Squeeze the gun trigger and hold
it open. T urn of f the power switch (A). Slowly turn
the pressure–adjusting knob (B) clockwise only
until the sprayer starts. Keep the gun triggered
until the air is forced out of the system and the
fluid flows freely from the gun. Release the gun
trigger and lock the gun trigger safety .
NOTE: T o avoid damaging the pump packings, do not
operate the sprayer without fluid in it for more than 30
seconds.
8.
Check all fluid connections for leaking. If you find
any leaks, relieve the pressure before tightening
the connections.
9. Lock the gun trigger safety . Install the spray tip
and the tip guard (96, 103). Follow the instructions
supplied with the tip guard.
10. Adjust the pressure.
a. Slowly , turn the pressure–adjusting knob (B)
clockwise just until spray from the gun is com -
pletely atomized. T o reduce the overspray and
fogging, and to lengthen the life of the spray
tip and sprayer , use the lowest fluid pressure
needed for good atomization.
b. If more fluid coverage is needed, use a larger
spray tip rather than increasing the pressure.
c. T est the spray pattern. Follow this procedure
to adjust the direction of the spray pattern.
Lock the gun trigger safety . Loosen the retain -
ing nut on the tip guard. T urn the tip guard to a
hozontal position for a horizontal pattern. T urn
the tip guard to a vertical position for a vertical
pattern. T ighten the retaining nut.
Fig. 3
A
B
55
96,
103

39

 
Operation
Cleaning a Clogged Tip
Follow these precautions to reduce the risk of a
serious injury when cleaning a clogged tip.
Do not hold a hand, a body , or a rag in front of the
spray tip. Always point the gun toward the ground
or into a waste container when triggering the gun to
see if the spray tip is unclogged.
DO NOT try to “blow back inch fluid; this is NOT an
air spray sprayer .
WARNING
1. Release the gun trigger .
2.
Lock the gun trigger safety (B).
3. Rotate the HD RAC IV handle 180  . See Ref. A in
Fig. 4.
4. Unlock the gun trigger safety (C).
5. T rigger the gun into a waste container .
6.
Lock the gun trigger safety again. See Ref. A in
Fig. 4.
7. Rotate the tip handle to the original position.
8. Unlock the gun trigger safety .
9.
If the tip is still clogged, lock the gun trigger safety ,
shut of f and unplug the sprayer , and open the
pressure drain valve to Relieve the pressure.
Remove the spray tip and soak it in solvent. Do
not scrape or chip debris from the spray tip.
10. Resume spraying.
Fig. 4
A
B
0137
1
3
2
1
2
3
The
tip handle (A) is shown in the spraying
position. Rotate the tip handle 180  in the
direction of the arrow for clearing a clog.
C
T rigger safety shown in the locked position.
T rigger safety shown in the unlocked position.
Shutdown and Care
1. Keep the wet–cup (216) 1/3 full with Graco Throat
Seal Liquid. The liquid helps prevent fluid from
building up on the piston rod. Fluid build–up
causes the packings to wear prematurely . Always
relieve the pressure before checking, filling or
tightening the wet–cup. See Fig. 5. Remove the
plug from the wet-cup. T ighten the wet cup, which
is also the packing nut, just enough to stop leak -
age. If you over–tighten the wet–cup, the packings
may bind and wear out more quickly . Use a screw -
driver and a light hammer to adjust the wet-cup.
2. Clean the fluid filter (48) often and whenever the
sprayer is stored. See manual 307–273 for the
cleaning procedure.
3. After each 100 hours of operation, fill the cavity of
the connecting rod (D) with motor oil. First Relieve
the pressure and then remove the front cover . See
Fig. 5.
Fig. 5
D
216
48
02067A
4. When you shut of f the sprayer for a short time,
leave the pump in the fluid–supply container , re-
lieve the pressure, and clean the spray tip.
5. Before you store the sprayer , flush it thoroughly .
Always use mineral spirits for the final flushing.
Relieve the pressure.
6. T o protect the hose, coil it and hang it on the cart
handle when storing the sprayer .

 
Flushing
1
Use this category when flushing a new sprayer and
when flushing the sprayer after it has been stored.
The system has
this fluid in it:
The next fluid to
be sprayed is:
Flushing the sprayer in the order given.
Before you use the
sprayer:
this fluid in it: be sprayed is:
First flush Second flush Third Flush
sprayer:
1
Oil-base solvent
or paint.
Oil-base fluid in a
new color
Mineral spirits none none Prime the sprayer with
oil-base paint.
Oil-base solvent
or paint.
W ater-base paint. Mineral spirits W arm, soapy
water
Clean water Prime the sprayer with
water-base paint.
Water or water-
base paint.
W ater-base fluid
in a new color .
W arm, soapy
water
Clean water none Prime the sprayer with
water-base paint.
Water or water-
base paint.
Oil-base paint. W arm, soapy
water
Clean water Mineral spirits Prime the sprayer with
oil-base paint.
Use the following information to prepare the sprayer for storage.
The system has this
fluid in it:
Flush the sprayer in the order given.
Before you store the
sprayer:
fluid in it:
First flush Second flush Third flush
sprayer:
Oil-base solvent or
paint.
Mineral spirits none none Relieve the pressure.
W ater or water-base
paint.
W arm, soapy
water
Clean water Mineral spirits Relieve the pressure.
Never allow water to freeze in the pressure
control. A frozen pressure control prevents the
sprayer from being started and causes serious
damage to the pressure control. Pump out the
water with mineral spirits.
CAUTION
Fig. 6 
A
C
D
E
55
1. Relieve the pressure.
2. Remove the bowl (C) and the screen (D) from the
filter . Leave the filter support (E) in place. Install
the bowl (C), only . See Fig. 8.
3. Close the pressure drain valve (55). See Fig. 8.
4. Pour two liters of a compatible solvent into a
grounded metal pail. Put the pump in the pail.
5. Remove the spray tip from the gun.
6. T urn the pressure–adjusting knob (A) counter -
clockwise to the lowest pressure setting.

 
Flushing
WARNING
T ake precautions to reduce the risk of static spark -
ing and splashing when you prime or flush the
sprayer . Be sure the spray tip is removed. Hold a
metal part of the gun firmly to the side of grounded
metal pail. See Fig. 7.
Fig 7
7. Hold a metal part of the gun firmly against a
grounded metal pail. See the W ARNING, above.
T rigger the gun. T urn on the power switch (B).
Slowly , increase the pressure just until the sprayer
starts. Keep the gun triggered until all air is forced
out of the system and the solvent flows freely from
the gun. Release the trigger . Lock the gun trigger
safety.
NOTE:
If the pump is hard to prime, open the pres -
sure drain valve. Close the pressure drain valve when
fluid comes from it. Proceed as in Step 7.
8. Remove the pump from the pail. Unlock the gun
trigger safety . T rigger the gun to force solvent from
the hose. T
o avoid damaging the pump packings,
do not operate the pump without fluid in it for more
than 30 seconds! Shut of f the sprayer .
9.
Leave the pressure drain valve (55) open until you
are ready to use the sprayer again. See Fig. 8.
10. Clean the filter screen (D). Remove the bowl (C)
from the filter . Install the screen. Install the bowl
and tighten it by hand. See Fig. 8.
11. If you flushed with mineral spirits and now plan to
use a water–base paint, flush the sprayer with
soapy water and then with clean water . Relieve the
pressure.
Fig. 8 
A
B
C
D
E
55

10 308-263
Troubleshooting
WARNING
T o reduce the risk of a serious injury , follow the
Pressure Relief Procedure W arning on page 3
before checking, adjusting or repairing the sprayer .
Read the entire T roubleshooting section before disassembling the sprayer .
TYPE OF PROBLEM WHA T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK refer to this column
The building’ s circuit breaker
opens.
Check all electrical wiring to see if there is
damaged insulation.
Replace any damaged wiring.
Check to see if there are other electrical
appliances on the same circuit.
Shut of f other electrical appliances on the
same circuit.
Check the position of the 10–12 (Lo–High)
amp switch.
Put the switch in the 10–12 amp (LO) posi -
tion.
The sprayer’s circuit breaker
opens.
Check to see if the motor rotor is dislocated.
Unplug the power supply cord. T ry to turn
the motor ’ s fan blades with a screwdriver .
Repair the gear train or the pump, if either of
them is damaged. Thaw the sprayer if it is
frozen–see the NOTE on page 11. Replace
the pressure control, if it is damaged.
Check to see if the motor has an electrical
short. Use an ohmmeter to check for electri -
cal shorts between the electical leads of the
motor and the motor frame.
Inspect the leads of the motor brushes to see
if they are damaged. Replace the motor
brushes or the motor as necessary.
Check the electrical supply using a volt
meter . The meter should indicate 210–250
VAC.
Connect the sprayer to an electrical outlet
which has the correct voltage.
The sprayer will not operate. Check the pressure control knob. If the knob
is turned fully counterclockwise, which is the
minimum pressure setting, the motor will not
operate.
Slowly increase the pressure to see if motor
will start.
Check to see if the spray tip is clogged.
Refer to page 7.
Relieve the pressure. Refer to page 7 for
instruction on how to clean the spray tip.
Check the extension cord for visible dam -
age. Check the extension cord outlet with a
volt meter or a test lamp.
Replace the extension cord.
Check the power supply cord for visible
damage such as broken insulation or broken
wires.
Replace the power supply cord.
Check the electrical supply using a volt me -
ter
. The meter should indicate 210–250 V AC.
Reset the building’ s circuit breaker , or replace
circuit’s fuse. T ry another electrical outlet.
Check the motor for damage. Remove the
drive housing assembly . Refer to page 17.
T ry to rotate the blades of the fan manually .
Replace the motor (1) if the blades of the fan
won’t rotate.
The spray from the gun has a
poor pattern.
Check to see if the spray tip is worn. Relieve the pressure. Replace the spray tip.
Refer to the instruction manual supplied with
the spray tip.

308-263 11
Troubleshooting
TYPE OF PROBLEM WHA T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK refer to this column
The motor operates and the
pump strokes, but the fluid
output is low or there is no fluid
output
Check to see if the spray tip is worn. Follow Pressure Relief Procedure
Warning , then replace the spray tip. See
your separate gun or tip manual.
output.
Check the motor brushes for these
problems: Loose electrical leads or
terminals, a brush which is worn to less than
10 mm long, a broken or misaligned spring,
brushes which are binding in their holders.
Refer to page 12.
Replace any damaged parts as needed.
Refer to page 12.
Check the armature of the motor for
electrical shorts by using an armature tester
(growler).
Replace the motor . Refer to page 17.
Check to see if the pump continues to stroke
when the gun trigger is released.
Repair the pump. Refer to page 14.
Check to see if the intake valve ball and the
piston ball are seating properly .
Remove the intake valve and clean it.
Check the balls and seats for nicks; replace
if necessary . Refer to page 14. Strain the
paint before using it to remove particles that
could clog the pump.
Check for leaks around the throat packing
nut which may indicate that the packings are
worn or damaged.
Replace the packings. Refer to page 14.
Also check the piston valve seat for
hardened paint or nicks and replace any
damaged parts. T ighten the packing
nut/wetcup.
The motor operates but the
pump does not stroke.
Check the connecting–rod pin (20) in the
displacement pump. Refer to page 13.
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. Refer to page 13.
Check for frozen or hardened paint in the
pump (39).
Thaw. See the NOTE below. Plug in sprayer
and turn on. Slowly increase pressure
setting to see if motor starts.
Be sure the crank in drive housing can
rotate. Remove the front cover from the drive
housing. Plug in the sprayer and briefly turn
on the sprayer . T urn of f and unplug the
sprayer.
Check the drive housing assembly for
damage. Replace damaged parts. Refer to
page 20.
The motor is hot and operates
intermittently.
Determine if the sprayer was operated at a
high pressure while using a small–orifice
spray tip. These conditions cause the motor
to function at a low RPM and produce
excessive heat.
Decrease the pressure setting or use a
larger tip.
Locate the sprayer where the ambient
temperature is no higher than 32  C. Do not
place the sprayer in the direct sunlight.
Move the sprayer to a shaded, cooler area,
if possible.
Determine if the sprayer was turned on and
pressurrized, but not operating, for long
periods of time.
T urn of f the sprayer whenever you stop
spraying for a while and whenever you
relieve the pressure.
NOTE: Thaw the sprayer if water or water–base paint has frozen in it. Place the sprayer in a warm area. Do not try
to start the sprayer until it has thawed completely . If fluid has hardened or dried in the sprayer, replace the pump
packings. Refer to page 14.

12 308-263
Motor Brush Replacement
NOTE: Replace the brushes when they have worn to
about 10 mm in length. Always check both of the
brushes. A Brush Repair Kit, part number 222–157,
and a new spring clip, part number 110–816, may be
purchased separately .
NOTE: The replacement brushes may last only half as
long as the original brushes. To maximize the life of the
brushes,
operate the sprayer for at least one hour without
allowing the pump to stroke. See Steps 10 to 12.
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
1. Relieve the pressure.
2. Remove the shield (14). Remove the covers (A)
from both brush inspection ports. See Fig. 9.
Fig. 9
A
14

3. Push in the clip (D) to unhook it, and then pull out
the clip. See Fig. 10.
4. Loosen the screw (F). Pull away the brush’ s elec -
trical lead (E), leaving the motor ’ s electrical lead
(G) in place. Remove the brush (C) and the spring
(B). See Fig. 1 1.
5.
Inspect the motor ’ s commutator for excessive pit -
ting, burning or gouging. A black color on the com -
mutator is normal. If the brushes seem to wear too
quickly , have the commutator resurfaced by a
qualified motor repair shop.
6. Install the new brush (C) so its electrical lead is in
the long slot (K) of the brush holder (H). Slide the
terminal of the brush’ s electrical lead (E) under the
washer of the screw (F). Make sure the motor ’s
electrical lead (G) is still connected the at the
screw. T ighten the screw (F). See Fig. 12.
7. Place the spring (B) on the brush (C) as shown in
Fig. 12.
8. Push in the clip (D) and hook it. See Fig. 12.
9. Repeat this procedure for the other side.
10. T est the brushes.
a. Remove the connecting rod pin (20) only . See
Fig. 13, page 13.
b. With the sprayer turned of f, turn the pressure
control knob to the minimum pressure setting.
Plug in the sprayer .
c. T
urn on the sprayer . Slowly increase the pres -
sure until the motor is at full speed.
d. Inspect the contact area of the brush and com -
mutator
. The arcs should not circle around the
commutator surface.
CAUTION
Do not touch the brushes, leads, springs, or brush
holders while the sprayer is plugged in, to reduce
the risk of an electric shock and a serious injury .
11.
Install the brush inspection plates, gaskets, and
covers.
12.
Operate the sprayer for at least one hour . Then,
install the pump connecting rod pin. See page 13.
Fig. 10 01227
B
C
D
Fig. 11 01227
B
C
D
E
F
G
Fig. 12 01227
H
J
C
D
B


The
spring must coil in
this direction.


The minimum brush
length is 10 mm.

308-263 13
Displacement Pump Repair
Removing the pump See Fig. 13.
1. Flush the pump, if possible. Relieve the pressure.
Stop the pump with the piston rod in its lowest po -
sition, if possible.
2. Remove the hose (47).
3. Remove the intake screen (99).
4. Push the retaining spring (35) up and push out the
pin (20).
5.
Loosen the locknut (38). Unscrew the pump from
the bearing housing (27) by one half turn.
6. Remove the check valve assembly (A) from the
pump.
7.
Remove the pump.
Installing the pump See Fig. 13 and 14.
1. Screw the pump into the bearing housing (27) until
the pin holes in the connecting rod assembly (29)
and the displacement rod (224) are aligned. Install
the pin (20).
2. Continue to screw the pump into the bearing hous -
ing until the top threads of the pump cylinder are
even with the face of the bearing housing and the
pump outlet faces straight back. Unscrew the
pump one half turn so the pump outlet is at the
side. Push the retaining spring (35) into the groove
all the way around the connecting rod. T
ighten the
locknut (38) to 95 N.m (70 ft-lb).
WARNING
Push the retaining spring (35) completely and firmly
into the groove around the connecting rod to pre -
vent it from working loose due to vibration.
If the pin works loose, the pin or other parts could
break off as the pump operates. The broken parts
could damage the sprayer or they could be pro -
pelled toward the operator and cause a serious
injury.
CAUTION
If the locknut (38) loosens during operation, the
threads of the bearing housing (27) will be dam
-
aged. Ttighten the locknut firmly .
3.
Install the intake screen (99). See Fig. 13..
4. Install the check valve assembly (A).
5. T ighten the wet-cup just enough to stop leakage,
but no tighter . Fill the wet–cup with Graco TSL
until it is 1/3 full.
02069A
Fig. 13
47
35
20
38
39
27
224
A
99
Fig. 14 02083
27
38
20
35
29
1
2
1
2
Torque to the nut to 95 N.m. (70 ft–lb).
This is the face of the
bearing housing.

14 308-263
Displacement Pump Repair
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
NOTE:
Use the Packing Repair Kit, part number
223–41 1. The parts included in the kit are marked with
an asterisk (*). Use all the new parts in the kit. Clean
all parts. Inspect all parts, including the inside of the
sleeve (218) and the outside of the displacement rod
(224). Replace worn or damaged parts.
Disassembling the Pump
1. Unscrew and disassemble the intake valve (223)
Clean the parts. If no further repair is needed,
reassemble the intake valve, using a new o-ring
(202*). See Fig. 15.
2. Remove the packing nut (216) and plug (205). T ap
down the piston rod (224) using a plastic mallet.
Pull the piston rod out the bottom of the cylinder
(219). Remove the throat packings and the glands.
See Fig. 16.
3. Clamp the piston rod (224) in a vise. Loosen the
piston nut (21 1). Unscrew the piston valve (222)
and remove all the parts. See Fig. 17.
WARNING
If the pump sleeve (218) cannot be removed easily ,
use the sleeve–removal tool, part number
235–376, as instructed in Step 4. T o reduce the
risk of a serious injury , do not use any other
method to remove the pump sleeve.
NOTE: If you have an old–style sleeve–removal tool,
part number 220–991, you can purchase just the
sleeve–removal extension, part number 188–734. The
extension makes the old tool equivalent to the tool
235–376.
4. T o remove the pump sleeve (218), screw the large
nut (C) of the sleeve–removal tool into the top of
the cylinder (219). Screw the rod (B) downward to
push out the sleeve. Remove the tool. See Fig. 18.
Fig. 15 
219
220
204*
223
226
202*
Fig. 16 
224
*205
216
*209
*213
*208
207*



The
lips of the v-packings in the throat
must face down.
219

The throat packings and glands.


The throat packings and glands.
Fig. 17
224
211
222
02086
The
piston packings
and glands.

Fig. 18

218
219
B
C

308-263 15
Displacement Pump Repair
Fig. 19
1
3
4
2
02073
224
219
225*
217*
216
205
213*
*209
*207
*208
*210
211
218
212*
*206
222
203*
*215
*214
220
*202
226
202*
223 1
22
3
3
4
The
lips of the V -packings in the throat must face up.
The lips of the V -packings in the piston must face down.
The lips of the U-cup seal must face down.
T orque the intake valve to 146 N.m (1 10 ft–lb).
Reassembling the Pump
NOTE: Follow all of the notes in the drawings to avoid
an incorrect installation.
NOTE: Soak the leather packings in oil before reas -
sembling the pump.
1. Stack the following parts onto the piston valve
(222): the backup washer (214), the seal
(203*)–with the lips of the seal facing downward,
and the female gland (215*). Alternately install the
three plastic packings (212*) and the two leather
packings (206*) with the lips of the packings facing
up. Install the male gland (210*). See Fig. 19.
2. Screw the retaining nut (211) on to the piston valve
(222). T orque the nut to 0.35 N.m (4 in-lb). See
Fig. 20.
3. Place the ball (225) on the piston valve (222). See
Fig. 20.
4. Apply one drop of the adhesive, supplied, to the
threads of the piston valve. Hand tighten the pis -
ton–valve assembly in to the piston rod just until
the nut (21 1) contacts the piston rod. See Fig. 20.
5. Note the alignment of the piston (222) to the nut
(21 1). Use two wrenches to maintain the alignment
through Steps 6 and 7.
6. Place the flats at the top of the piston rod (224) in
a vise.
7. Using two wrenches, carefully tighten the nut
(21 1) against the piston rod. Torque the nut to 26
N.m (56 in–lb). See Fig. 21.
225
222
Fig. 20 02074
211 1
1Torque
the nut (21 1)
to 0.35 N.m (4 in–lb).
224
T orque the nut (21 1) against
rod to 27 N.m (56 in–lb).
Do not allow the nut (21
1)
to move when screwing it
on to rod.
Apply one drop of the adhe -
sive to the threads of the
piston valve (222).
Fig. 21
02075
1
3
2
211
1
222
2
3

16 308-263
Displacement Pump Repair
8. Place a new seal (217*) into the cylinder (219).
Lubricate the inside of the cylinder with oil. See
Fig. 20.
9. Install the male gland (208*) in the top of the cylin -
der (219). Alternately install the three plastic pack -
ings (213*) and the two leather packings (207*) so
that the lips of the packings face up. Install the fe -
male gland (209). See Fig. 20.
10. Install the packing nut (216) loosely . Install the
plug (205) in the packing nut. See Fig. 20.
11. Lubricate the piston rod and the packings with oil.
Slide the assembly into the top of the sleeve (218).
See Fig. 22.
12. Slide the sleeve and the piston rod assembly into
the bottom of the cylinder (219). See Fig. 23.
13. Screw the cylinder locknut (38) downward to the
bottom of the external threads on the cylinder .
T
ighten the locknut gently .
14.
Place the intake valve (223) in a vise. Install a new
o-ring (202*). Screw the cylinder (219) on to the
intake valve. T orque the intake valve to 146 N.m
(1 10 ft-lb). See Fig. 20.
15. Refer to page 13 to install the pump.
Fig. 22 02087
218
224
1
1
Lubricate.
Fig. 23 02076
218
219
217*
1
1
Lubricate

308-263 17
Motor Replacement
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
NOTE:
See Fig. 24 except where noted.
1. Remove the shield (14), the front cover (31), and
the pressure control cover (36). Disconnect the
hose (47).
2. Disconnect the motor ’ s electrical leads. See Fig.
25, page 18.
3. Unscrew the connector (44) on the pressure con -
trol. Pull out the motor ’ s electrical leads.
4. Unscrew the connector (54) from the motor .
Remove the conduit (22).
5. Remove the screws (51) from the drive housing.
Remove the screws (21,30) from the motor (1).
6. T ap the rear of the pump (39) with a plastic mallet
to loosen the drive housing (18) from the motor
(1). Pull of f the drive housing.
NOTE: Do not drop the gear cluster (9), which may
stay engaged in the front of the motor or in the drive
housing. Do not lose the balls (10) or drop them be -
tween the gears. The balls usually stay in the recesses
for the shaft, but the balls could be dislodged. If the
balls are not in place, the bearings will wear prema -
turely.
7. Remove the screws (37). Lift of f the motor .
8.
Mount the new motor on the cart. Install the
screws (37).
9. Slide the connector (54) over the electrical leads of
the new motor . Screw two or three threads of the
connector into the motor . T ighten the connector ’s
locknut until it contacts the motor .
10.
Grease the gear cluster (9) and the pinion gear (G)
liberally . Pack all the bearings in the front of the
motor with grease. Be sure the balls (10) are in
place.
11.
Place the bronze–colored washer (18b) and then
the silver–colored washer (18a) on the shaft which
protrudes from the large gear in the drive housing
(18).
12.
Align the gears and push the drive housing (18)
straight onto the front of the motor (F) and its
locating pins.
13. Continue to reassemble the sprayer .
Fig. 24
02080
31 49
33 51
27
18
10
18b
9
18a
163 21
14
37
30
63
40
41
44,22
47
1
3
4
2
Torque
the screw to 34 N.m (300 in-lb).
The bronze–colored washer .
Apply 175 cc of bearing grease.
The silver–colored washer .
1
2
4
3
G
36
54

18 308-263
Pressure Control Replacement
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
NOTE:
See Fig. 26 except where noted.
1. Disconnect the hose from the outlet of the fluid
filter (48).
2.
Loosen the nut (28). Loosen the swivel fitting (8).
Remove the fluid filter (48).
3. Remove the cover (36) from the pressure control.
Disconnect the four motor leads. See Fig. 25.
4. Unscrew the connector (44) from the pressure
control (43). Loosen the nuts on the connector .
Pull out the conduit (22) and the motor ’ s electrical
leads from the pressure control.
5. Remove the screws (37) which hold the pressure
control (43) to the cart. Remove the pressure con -
trol. Install the connector (44) on the new pressure
control.
6.
Remove the screws (84) and the mounting plate
(16) from the old pressure control. Install these
parts on the new pressure control.
7. Install the new pressure control. Mount the pres -
sure control with the screws (37). Place the seal
(93) around the motor’ s electrical leads and push
the seal into the top of the connector (44). See Fig.
25.
8. Install the cover (36) on the pressure control.
9. Connect the swivel fitting (8) to the fluid filter (48).
TIghten the nut (28) so that the filter is held
securely to the mounting plate (16).
01897
Fig. 25
1
44
93
The seal (93) is located inside this fitting.
Black(–)
Black/
White(–)
Red
1
24
Fig. 26
41
40 84
16
8
37
28
13
43
36
44,22
47
02077A
48

308-263 19
Bearing Housing and Connecting Rod
Replacement
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
NOTE:
Stop the sprayer at the bottom of its stroke to
get the crank (H) in its lowest position. T o lower the
crank manually , use a screwdriver to rotate the blades
of the motor ’ s fan.
1. Remove the pump. Refer to page 1 1.
2. Remove the front cover (31). Remove the screws
(33).
3. T
ap the lower rear of the bearing housing (27) with
a plastic mallet to loosen it from the drive housing
(18). Pull the bearing housing and the connecting
rod (29) straight of f of the drive housing.
4. Inspect the crank (H) and all other parts for exces -
sive wear . Replace worn or damaged parts.
5. Lubricate the inside of the bronze bearing (K)
evenly with motor oil. Pack the roller bearing (J)
liberally with bearing grease.
6. Assemble the connecting rod (29) and the bearing
housing (27).
7. Clean the mating surfaces of the bearing housing
and the drive housing.
8. Align the connecting rod with the crank (H). Align
the locating pins in the drive housing with the holes
in the bearing housing (27). Push the bearing
housing on to the drive housing or tap the bearing
housing into place using a plastic mallet.
9. Install the screws (33). T orque the screws evenly
to 34 N.m (300 in–lb).
10. Reinstall all the parts. Refer to page15 to install
the pump.

Fig. 27



49
27
29
JH
18
K
33
47
35
20
38
39

31
Torque to 3 N.m (300 in-lb)
Lubricate



 
Drive Housing Replacement
WARNING
Follow the Pressure Relief Procedure W arning
on page 3 to reduce the risk of a serious injury .
NOTE: See Fig. 28 for this procedure .
NOTE: Stop the sprayer at the bottom of its stroke to
get the crank (H) in its lowest position. T o lower the
crank manually , use a screwdriver to rotate the blades
of the motor ’ s fan.
1. Remove the front cover (31). Remove the shield
(14).
2.
Disconnect the spray hose.
3. Remove the screws (33) from the bearing
housing.
4. T
ap the rear of the pump (39) with a plastic mallet
to loosen it from the drive housing (18). Pull the
bearing housing (27) straight of f of the drive
housing (18).
5. Remove the screws (51) from the drive housing.
6. Remove the screws (30, 21) from the motor (1).
7. T ap the drive housing (18) with a plastic mallet to
loosen it from the motor . Pull the drive housing
straight of f of the motor .
NOTE:
Do not drop the gear (9), which may stay en -
gaged in the front of the motor or in the drive housing.
Do not lose the balls (10) or drop them between the
gears. The balls usually stay in the recesses for the
shaft, but the balls could be dislodged. If the balls are
not in place, the bearings will wear prematurely .
8. Use approximately 175 cc of the bearing grease,
supplied with the drive housing replacement kit, to
grease the gear cluster (9). Check to be sure the
balls (10) are in place.
9. Place the bronze–colored washer (18b) and the
the silver–colored washer (18a) on the shaft which
protrudes from the large gear in the drive housing
(18).
10.
Align the gears. Push the new drive housing
straight onto the motor and its locating pins.
11. Continue to reassemble the sprayer . T orque the
screws (33) to 34 N.m (300 in–lb).
Fig. 28
1
3
4
2
02082
31
47
33
49
27
51
63
18
18b
10
9
18a
1
63 21
30
63
1
2
3
4
Torque
the screws to 34 N.m (300 in-lb).
The bronze–colored washer
.
Apply 175 cc of bearing grease.
The silver–colored washer .
H
39
14