Graco ULTRA 500 Operation manual

INSTRUCTIONS–P ARTS LIST 307–889
Rev K
Supercedes Rev J, never released,
and Rev H
220/240 VAC
ULTRA 500
AIRLESS P AINT SPRA YER
195 bar (2750 psi) Maximum Working Pressure
Model 231–079, Series D
Complete sprayer on Upright cart with hose,
gun, RAC IV  DripLess  T ip Guard
and SwitchT ip
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1995, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE



Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spin Test 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 18. . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 19. . . . . . . . . . . . . . . . . . . . .
Power Supply Cord Replacement 20. . . . . . . . . . . . . . .
On/Off Switch Replacement 21. . . . . . . . . . . . . . . . . . . .
Pressure Control Replacement 22. . . . . . . . . . . . . . . . .
Filter Board Replacement 23. . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, and Crankshaft
Replacement 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Replacement 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 28. . . . . . . . . . . . . . . . . . . . .
Parts Drawing – Upright Sprayer 31. . . . . . . . . . . . . . . .
Parts List – Upright Sprayer 32. . . . . . . . . . . . . . . . . . . .
Parts Drawing and List – Displacement Pump 33. . . . .
Parts Drawing – Pressure Control 34. . . . . . . . . . . . . . .
Parts List – Pressure Control 34. . . . . . . . . . . . . . . . . . .
Wiring Diagram 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 36. . . . . . . . . . . . . . . . . . . . . . . . .
The Graco W arranty and Disclaimers 36. . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.

If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Electrically disconnect all equipment in the spray area.
 Extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
 Do not operate a gasoline engine in the spray area.
WARNING



EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .

This equipment is for professional use only .

Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are not sure, call Graco T echnical Assis -
tance at 1–800–543–0339.
 Do not alter or modify this equipment.
 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 T echnical Data on page 36 for the maximum working pressure of this equipment.
 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warn -
ings.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
 Do not use hoses to pull equipment.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82  C (180  F) or below –40  C (–40 F).

Do not lift pressurized equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
W ear hearing protection when operating this equipment.
WARNING
WARNING
INSTRUCTIONS
MOVING P ARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly
.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .

4307-889
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex -
tremely serious injury , including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury .
 Fluid injected into the skin is a serious injury . The injury may look like just a cut, but it is a serious
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 dif fuser operation weekly . Refer to the gun manual.
 Be sure the gun trigger safety operates before spraying.
 Lock the gun trigger safety when you stop spraying.
 Follow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten all fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING
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 trig -
gering
of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical
T reatment”.
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 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 .
NOTE: This is an example of the DANGER label on your sprayer . This label is available in other languages,
free of charge. See page 35 to order .

5
307-889
K
Fig. 1
J
S
P
E
D
A
C
T
L
R
M
N
B
H
Major Compo-
nents
0137A
05253
AMotor DC motor , 220/240 Vac, 50 Hz, 7A, 1 phase
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch Power switch that controls 220/240 V ac main power to sprayer
D Drive Assembly T ransfers power from DC motor to the displacement pump
E Fluid Filter Final filter of fluid between source and spray gun
H Displacement Pump T ransfers fluid to be sprayed from source through spray gun
J 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
K RAC IV T ip Guard Reverse-A-Clean (RAC) tip guard reduces risk of injection injury
L Contractor Gun High pressure spray gun with gun safety latch
M RAC IV Switch T ip 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 and
spray gun to allow more flexibility when spraying
P Primary Fluid Outlet Single spray gun operation is connected here
R Pressure Drain V alve Relieves fluid outlet pressure when open
S Pressure Control Controls motor speed to maintain fluid outlet pressure at displace -
ment pump oulet. W orks with pressure adjusting knob.
T Spray Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun