Graco ULTRA PLUS+ 1500 Parts list manual


INSTRUCTIONS–P ARTS LIST 308–552
Rev. B
Supercedes Rev. A
220 V AC, 50 HZ, 12A
ULTRA Plus + 1500
Airless Paint Sprayer
210 bar (3000 psi) Maximum Working Pressure
Model 231–321, Series A
Complete sprayer on upright cart with hose,
gun, RAC IV  , DripLess  T ip Guard
and SwitchT ip
Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 12. . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Pump 13. . . . . . . . . . . . . . . . . .
Displacement Pump Repair 14. . . . . . . . . . . . . . . . . . . . .
Pressure Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Replacement 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod 18. . . . . . . . . . . . .
Drive Housing Replacement 19. . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 20. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts List 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose and Gun Parts Drawing and List 22. . . . . . . . . . .
Displacement Pump Parts Drawing and List 22. . . . . .
Accessories 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Ultra
)Warranty
and Disclaimers 24. . . . . . . . . .
Phone Numbers 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 24 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 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.
WARNING
WARNING
INSTRUCTIONS

 
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 .
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 10 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

4 308-552
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
WARNING
MOVING P ARTS HAZARD
Moving parts 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 10 to prevent 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.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 23 to order .

 
C
Fig. 1
J
E
F
D
A
G
K
R
0137 M
N
B
H
S
U
L
TP
03796A
Major Components
AMotor (Under shield shown) DC motor , 120 V ac, 12A, 1 phase
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch, Circuit
Breaker
Power switch that controls 120 V ac power to sprayer; with circuit breaker
D Drive Assembly T ransfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Secondary Fluid Outlet Second spray gun operation is connected here
G Pail Hanger Container for fluid to be sprayed may be hung here
H Displacement Pump Pressures fluid to be sprayed 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 the risk of fluid injection injury
L Contractor Gun High pressure spray gun with gun safety latch
M RAC IV SwitchT ip RAC SwitchT ip atomizes fluid and removes 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 Pressure Drain V alve Relieves fluid pressure when open
R Pressure Control Controls motor speed to maintain fluid pressure. W orks with pressure ad -
justing knob.
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
T Primary Fluid Outlet Hose and spray gun is connected here
U 10/12 Amp Switch Allows sprayer to operate on 10A service with reduced performance

 
Setup
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read FIRE OR
EXPLOSION HAZARD on page 4.
WARNING
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar) Working Pressure . This
is to reduce the risk of serious injury caused by
static sparking, fluid injection or over-pressurization
and rupture of the hose or gun.
CAUTION
T o avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
1. Always use a nylon spray hose at least 50 ft.
(15 m) long.
2.
Never use a wire braid hose as it is too rigid to
act as a pulsation dampener .
3. Never install any shutof f device between the
pump and the hose. See Fig. 2.
1. Connect the gun, 1 m hose (78) and 15 m hose
(79).
Don’t install the spray tip yet.
2. Two gun hookup. Remove the cap (12) from the
1/4 npsm(m) secondary hose outlet and attach a
minimum 15 m long hose. For more flexible gun
movement, install a 3/16 in. ID, 1 m whip hose be -
tween the main hose and the gun.
3. Fill the packing nut/wet–cup (216) 1/3 full with
Graco Throat Seal Liquid (TSL), supplied.
4. Check the electrical service. Be sure the electri -
cal service is 220 V , 50 Hz. Use a properly
grounded outlet. Have a licensed electrician attach
an appropriate plug to the power supply cord. Do
not remove the grounding prong of the power sup -
ply cord. Do not use an adapter . Extension cords
must have 3 wires of a minimum 2.5 mm (12
gauge) size. Long extension cords reduce sprayer
performance. Set the 10/12 Amp switch to the ap -
propriate setting.
5. With the the ON/OFF switch (A) OFF, plug the
cord into a grounded electrical outlet
located at
least 6 m (20 ft.) away from the spray area.
6. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after fac -
tory testing. See page 9.
Fig. 2
1
2
03797
AB
C
50
46
12
216
78
79
55
Do not install any shutof f device here
Fill packing nut 1/3 full with TSL
1
2

 
Operation
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 10.
Startup
Always use this procedure to help ensure the sprayer
is ready to operate and that you start it safely .
1.
For a first time startup , flush the sprayer . See
page 9.
2. Close the pressure drain valve (50).
3. Don’t install the spray tip until the pump is
primed!
4. Put the suction tube into the paint container.
5.
Lower the pressure setting by turning the pres -
sure adjusting knob (B) all the way counterclock -
wise.
6. Disengage the gun safety latch.
See Fig. 3.
Fig. 3
Gun safety latch
shown engaged
Gun safety latch
shown disengaged




CAUTION
Do not run the sprayer dry for more than 30 sec -
onds to avoid damaging the pump packings.
7. T o prime the pump, hold a metal part of the gun
firmly against into a metal waste container . See
Fig. 4 . Squeeze the trigger and hold it open, turn
the ON/OFF switch to ON, and slowly increase the
pressure setting until the sprayer starts. Keep the
gun triggered until all air is forced out of the sys
-
tem and the paint flows freely from the gun. Re -
lease the trigger and engage the gun safety latch.
8. Check all fluid connections for leaks . If any
leaks are found, relieve pressure before tightening
the connections.
9. Install the spray tip and tip guard. Engage the
gun safety latch. Install the spray tip. If you are
using the RAC IV tip guard, refer to manual
307–848 for installation instructions.
10. Adjust the pressure.
a. T urn the pressure adjusting knob clockwise
just until spray from the gun is completely at -
omized. T o avoid excessive overspray and fog -
ging, and to decrease tip wear and extend the
life of the sprayer , always use the lowest pos -
sible pressure needed to get the desired re -
sults.
b.
If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. T est the spray pattern. T o adjust the direction
of the spray pattern: engage the gun safety
latch, loosen the retaining nut, position the tip
guard horizontally for a horizontal pattern or
vertically for a vertical pattern and tighten the
retaining nut.
Fig. 4



Maintain
firm metal–to–metal
contact between gun and
grounded pail when flushing

 
Operation
Cleaning a Clogged Tip
To reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 10.
WARNING
INJECTION HAZARD
1. If the spray tip does clog, release the gun trigger ,
engage the gun safety latch, and rotate the
RAC IV handle 180  . See Fig. 5.
2. Disengage the gun safety latch and trigger the gun
into a waste container . Engage the gun safety
latch again.
3. Return the handle to the original position, disen -
gage the gun safety latch, and resume spraying.
4. If the tip is still clogged, engage the gun safety
latch, shut of
f and unplug the sprayer , and open
the pressure drain valve to relieve pressure. Clean
the spray tip as shown in manual 307–848, sup -
plied with the RAC IV .
Fig. 5
1
2
0137
Tip handle shown in spraying position;
turn handle 180  , disengage safety
latch and trigger gun to clear clog.
T rigger safety latch shown engaged.
1
2
Shutdown and Care
1. Check the packing nut/wet–cup daily. Relieve
the pressure. Keep the packing nut/wet–cup 1/3
full with TSL at all times to help prevent fluid buil -
dup on the piston rod and premature wear of pack -
ings. T ighten the packing nut just enough to stop
leakage. Overtightening may cause binding and
excessive packing wear . Use a screwdriver and
light hammer to adjust the nut. See Fig. 6.
2. Clean the fluid filter often and whenever the
sprayer is stored. First relieve pressure. See man -
ual 307–273 for the cleaning procedure.
3. Fill the connecting rod cavity with motor oil ev -
ery 100 hours of operation. Relieve pressure. Re -
move the front cover . See Fig. 6.
Fig. 6
1Fill
connecting rod cavity with motor oil after
every 100 hours of operation
1
216
03798A
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
5. Coil the hose and hang it on the hose rack
when storing it, even for overnight, to help protect
the hose from kinking, abrasion, coupling damage,
etc.

 
Flushing
When to Flush
1. New Sprayer . The sprayer was factory tested in
lightweight oil which was left in to protect pump
parts.
Before using water–base paint , flush with mineral
spirits, then warm, soapy water , and then clean
water.
Before using oil–base paint, flush with mineral spir -
its.
2. Changing
Colors. Flush with a compatible solvent.
3. Changing from water–base to oil–base paint.
Flush
with warm, soapy water , then mineral spirits.
4. Changing from oil–base to water–base paint.
Flush with mineral spirits, then warm, soapy water ,
and then clean water .
5.
Storage. Flush as indicated below , shut of f the
sprayer , open the pressure drain valve to relieve
pressure and leave it open.
W ater–base paint: flush with water , then mineral
spirits. Leave the system filled with mineral spirits.
Oil–base paint: flush with mineral spirits.
CAUTION
Never allow water to freeze in the pressure control.
Doing so prevents the sprayer from being started
and causes serious damage to the pressure control.
Push the water out with mineral spirits.
6. Startup after storage. Before using water–base
paint, flush out mineral spirits with soapy water and
then clean water. When using oil–base paint, flush
out
the mineral spirits with the paint to be sprayed.
How to Flush
1. Relieve pressure.
2. Remove the filter bowl (A) and screen (B); see
manual 307–273. Clean the screen separately and
install the bowl without the screen to flush it. See
Fig. 7.
3. Close the pressure drain valve.
4. Pour 2 liters of compatible solvent into a grounded
metal
pail. Put the suction tube in the pail.
5. Remove the spray tip from the gun, if it is installed.
Fig. 7
A
B
C
50
01893A
6. T urn the pressure adjusting knob all the way coun -
terclockwise to lower the pressure setting.
T o reduce static sparking and splashing,
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 when
flushing.
WARNING
FIRE AND EXPLOSION HAZARD
7. Hold a metal part of the gun firmly against a metal
waste container . See Fig. 4. Hold the trigger open,
turn on the sprayer , and slowly increase the pres -
sure just until the sprayer starts. Keep the gun trig -
gered until all air is forced out of the system and
the solvent flows freely from the gun. Release the
trigger and engage the gun safety latch.
NOTE: If the pump is hard to prime, open the drain
valve. When fluid comes from the valve, close it. Pro -
ceed as in Step 7.
8. Remove the suction tube from the pail. Disengage
the gun safety latch and trigger the gun to force
solvent from the hose. Do not run the pump dry for
more than 30 seconds to avoid damaging the
pump packings! Relieve pressure.
9. Leave the pressure drain valve open until you are
ready to use the sprayer again. If the screen was
removed, unscrew the filter bowl and reinstall the
clean screen. Reinstall the bowl, hand tight only .
10.
If you flushed with mineral spirits and are going to
use a water–base paint, flush with soapy water
and then clean water. Relieve pressure.

10 308-552
Troubleshooting
Pressure Relief Procedure
To reduce the risk of serious injury , including fluid injec -
tion,
injury from splashing fluid or solvent in the eyes or
on the skin, moving parts or electric shock, always fol -
low this procedure whenever you shut off the
sprayer ,
when checking or servicing any part of the spray sys-
tem, when installing, cleaning or changing spray tips,
and
whenever you stop spraying.
1. Engage the gun safety latch.
2. T urn the ON/OFF switch to OFF .
3.
Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal
part of the gun firmly to a grounded metal pail.
T rigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the pres -
sure drain valve open until you are ready to
spray again.
If you suspect that the spray tip or hose is completely
clogged,
or that pressure has not been fully relieved af -
ter following the steps above
, VERY SLOWLY loosen
the tip guard retaining nut or hose end coupling to re-
lieve
pressure gradually , then loosen completely . Now
clear the tip or hose obstruction.
Check everything in the guide 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
Building circuit breaker opens Check all electrical wiring for damaged
insulation.
Replace any damaged wiring.
Check for other electrical appliances on
circuit.
Shutdown other electrical appliances on
circuit.
Check position of 10–12 (Lo–High) amp
switch.
Put switch in 10 amp (LO) position.
Sprayer circuit breaker opens Check for locked motor rotor . Unplug cord
and try to turn fan blades with a screwdriver .
Repair gear train or pump, if damaged. Thaw
the sprayer , if frozen; See NOTE 1. Replace
the pressure control, if damaged.
Check for shorted motor . Use ohmmeter to
check for shorts between motor leads or
between motor leads and motor frame.
Inspect for damage to motor brush leads.
Replace motor , if necessary.
Check electrical supply with voltmeter . Meter
should read 210–250 V
AC.
Connect to outlet of correct voltage.
Sprayer will not run Check pressure control knob setting. Motor
will not run if it is at minimum setting (fully
counterclockwise).
Slowly increase pressure setting to see if
motor starts.
Check for a clogged spray tip. Refer to
separate gun or tip instruction manual.
Relieve pressure. Refer to separate gun or
tip instruction manual for tip cleaning.
Check extension cord for visible damage.
Use a volt meter or test lamp at extension
cord outlet to check.
Replace extension cord.
Check sprayer power supply cord for visible
damage such as broken insulation or wires.
Replace power supply cord.
Check electrical supply with volt meter . Meter
should read 210–250 V
AC.
Reset building circuit breaker; replace
building fuse. T ry another outlet.
Check for motor damage. Remove drive
housing assembly . See page 17. T ry to rotate
fan by hand.
Replace motor (1) if fan won’t turn.
Poor spray pattern Check for worn spray tip. Relieve pressure and then replace the tip.
See the separate gun or tip manual.