Graco ULTRA PLUS+ 1500 User manual

INSTRUCTIONS-PARTS LIST e 308-551
Rev. B
Supercedes Rev. A
This manual contains Important GRACO
warnings and Information.
READ AND RETAIN FOR REFERENCE
..
c I
I 20 VAC, I aA
ULTRA@ Plus+ 1500
Airless Paint Sprayer..
3000 psi (2 10 bar) Maximum Working Pressure
Part No. 231 -351, Series A
Basic Sprayer on upright cart without hose or gun.
Part No. 231 -352
Complete sprayer on upright cart with hose, gun,
RAC
IV@ DripLess” Tip Guard and SwitchTip“
Part No. 223-773, Series A
Same as Model 231 -351, except CSA certified
Patents Pending
.
Olea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1994, GRACO INC.
Graco Inc. Is registered to 1.S. EN IS0 9001

Table of Contents
Warnings.. ....................................
2
Setup .........................................
6
Operation .....................................
7
Flushing ......................................
9
Troubleshooting.. .............................
10
Mdor Brush ......................
!. .......... 12
Pressure Control 18
Displacement Pump 13
Power Supply Cord ............................. 18
Motor ........................................ 19
............................
..............................
Bearing Housing &Connecting Rod ............. 20
Drive Housing ................................ 21
Sprayer Parts Drawing ......................... 22
Sprayer Parts List ............................. 23
Accessories .................................. 25
Technical Data ................................ 28
Dimensions ................................... 28
Graco Ultra@ Warranty and Disclaimers .......... 28
Phone Numbers .............................. 28
Displacement Pump Parts Drawing and List ...... 24
Symbols
Warning Symbol Caution Symbol
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment
if you do not follow the
instructions.
INSIRUCllONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
0 This equipment is for professional use only.
e 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 Technical Assis-
tance at
1-800-543-0339.
0 Do not alter or modify this equipment.
e Check equipment daily. Repair or replace worn or damaged parts immediately.
e Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page
28 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment welted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer's
warnings.
Do not use hoses to pull equipment.
Route hoses awayfrom traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82OC (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.

INJECTION HAZARD
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
Spray
from the gun, leaks or ruptured components can inject fluid into your body and cause ex-
can also cause serious injury.
0 fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a seri-
ous 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'"b1ow 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 manual.
0 Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
0 Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tghten 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.
TOXIC FLUID HAZARD
skin, inhaled, or swallowed.
Hazardous fluid or toxic fumes can cause serious injury or death
if splashed in the eyes or on the
0 Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all lo-
cal,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.

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 injuly.
a 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.
a Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
a Keep the spray area free of debris, including solvent, rags, and gasoline.
a Electrically disconnect all equipment in the spray area.
a Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
a Do not turn on or off any light switch in the spray area while operating or if fumes are present.
a Do not operate a gasoline engine in the spray area.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
a Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent
the equipment from starting unexpectedly.
NOTE This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge.
See page 25 to order.
EXPLOSION HAZARD
uids In conflned areas can result In fire or explosion.
Spray palntlng, flushlng orcleanlng equipmentwith flammable Ilq- Uqulds can be injected into the body by hlgh pressure alriess spray
or leaks - especially hose leaks.
Use outdoors or In extremely well ventilated areas. Gmund equip Keep body clear of the nozzle. Never stop leaks with any part of the
mSnZ hoses. containers and objects belng sprayed.
AvoldalllgniUonsourcessuchasataUcele*ricityfmmplsstlcdmp
gedng of gun by always settfng safetV latch when not fPWlW
body.Dralnallpressure beforaremoving parIs.Avoldaccldentaltrig-
Cloths, open flames such as pilot lights, hot objects such as clga- Never spray without a Up guard.
Ing light swltchea on and off.
rattes, arcsfmmconnectingordlsconnectlngpowercordsortum
In case acclden~ ,,qedon, seak lmme&ate
Failure to followthls wamlng can t-aStdt in death or serh~s Wry.
~dl~~ to follow this wamlng can result in ampmion or sedou~
"Surgical Treatment".
Injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
4 308-551

Major Components

Setup
sure the hoses are electrically
conductive, that the
If you supply your own hoses and spray gun, be
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-pressur-
izat!on and rupture of the hose or gun..
A CAUTION
To avoid damaging the pressur; 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 shutoff device between the
filter and the hose. See Fig.
2.
1.
Assemble the gun (106), 3 ft. whip hose (105)
and tip guard yet.
and
50 ft. hose (104). Don't install the spray tip
2. Two gun hookup. Remove the cap (12) from the
minimum
50 ft. long hose. For more flexible gun
1/4 npsm(m) secondary hose outlet and attach a
between the main hose and the gun.
movement, install a
3/16 in. ID, 3 ft. whip hose
3. Fill the packing nut/wet-cup (216) 113 full with
Graco Throat Seal Liquid
(TSL), supplied.
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.
4. Check the electrical service. Be sure the electri-
erly grounded outlet. Do not remove the ground-
cal service
is 120 VAG, 60 Hz, 20A. Use a prop-
ing prong of
the power supply cord. Do not use
an adapter. Extension cords must have 3 wires of
a minimum 12 gauge size. Long extension cords
available, flip the
15/20 Amp switch (U) to 15 set-
reduce sprayer performance.
If 20A service is not
ting to avoid nulsance tripping
of circuit breakers.
5. With the the ON/OFF switch OFF, plug the cord
into
a grounded electrlcal outlet located at least
20 ft. (6 m) 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.
A
Do not install any
1 fluid shutoff device here
Fig. 2
K 104 '05
01888
6 308-551

Operation
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
I pressure, follow the Pressure Relief
Procedure on page
10.
Startup (Fig. 2)
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 and tip guard until
the pump
Is primedl
4. Put the suction tube (42) into the paint con-
tainer.
5. Lower the pressure setting by turning the pres.
sure adjusting knob
(B) fully counterclockwise.
6. Disengage the gun safety latch. See Fig 3.
Gun safety latch
A shown engaged
A shown disengaged
Gun safety
latch
Fig. 3 0137
I A CAUTION
onds to avoid damaging the pump packings.
Do not run the sprayer dry for more than 30 sec-
7. To prime the pump:
a. Open the drain valve.
b. Turn the ON/OFF
(C) switch to ON.
c. Slowly increase the pressure setting until the
sprayer starts.
d. When fluid
is flowing from the valve, turn
down the pressure and close the valve.
e. Hold a metal part of the gun firmly against a
grounded metal waste container. See Fig.
4.
a
Maintain fin
1 metaltometal
flushing
contaci when
‘A
Flg. 4 0143
f. Trigger the gun and slowly increase the pres-
sure setting until the sprayer starts. Keep the
gun triggered until all.air
is forced out of the
system and the paint
flows freely from the
gun.
g. Release the trigger and engage the gun
safety latch. See Fig
3.
8. Check all fluid connections for leaks. If any
leaks are found, relieve pressure before tightenin4
the connections.

Operation
9. Install the spray tip and Up guard. Engage the 3. Return the switch tip to the original position, dis-
gun safety latch. Install the spray tip. If you are engage the gun safety latch, and resume spray-
using the
RAC IV tip guard, refer to manual ing.
307-848 for installation instructions.
4. If the tip is still clogged, engage the gun safetv
IO. Adjust the pressure.
a. Turn the pressure adjusting knob clockwise
just until spray from the gun is completely at-
omized. To avoid excessive overspray and
fogging, and to decrease tip wear and extend
. the life of the sprayer, always use the lowest
possible pressure needed to get the desired
results.
b.
If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. Test the spray pattern. To 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.
Cleaning a Clogged Tip
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you
are instructed to relieve
pressure, follow the Pressure
Relief
Procedure on page 10.
1. If the spray tip clogs, release the gun trigger, en-
gage the gun safely latch, relieve pressure, and
rotate the
RAC IV switch tip 180'. See Fig. 5.
2. Disengage the gun safety latch and trigger the
gun into a waste container. Engage the gun
safety latch again.
Switch tip
shorn
in spraying position
Gun safety latch
shown engaged
A
Flg. 5
latch, shut off and-inplug thesprayer, and opkn
the pressure drain valve to relieve pressure. Clean
the spray tip as shown in manual
307-848, sup-
plied with the
RAC IV.
Shutdown and Care
I. Check the packing nWwet-cup (216) daily. Re-
lieve the pressure. Keep the packing nut/wet-cup
113 full with TSL at all times to help prevent fluid
buildup on the piston rod and premature wear of
packings. Tighten the packing nut
just enough to
and excessive packing wear. Use a screwdriver
stop leakage. Overtightening may
cause binding
and light hammer to adjust the
nut. See Fig. 6.
2. Clean the fluid filter (48) often and whenever
the sprayer
is stored. First relieve pressure. See
manual 307-273 for the cleaning procedure.
3. Fill the connecting rod cavity (A) with motor oil
evely
100 hours of operation. Relieve pressure
first.
See Fig. 6.
d
//
6/
Fig. 6
01892
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
5. Coll the hose and hang it on the hose rack
when storing
it, even for overnight, to help protect
the hose from kinking, abrasion, coupling dam-
age, etc.

Flushing
When to Flush 5. Storage. Flush as indicated below, shut off the
1. New Sprayer, The sprayer was factory tested in
sprayer, open the pressure drain valve to relieve
lightweight oil which was left in to protect pump
pressure and leave it open.
parts. Water-base paint: flush with water, then mineral
Before using water-base
paint, flush with mineral
spirits, then warm, soapy water, and then clean Oil-base paint: flush with mineral spirits.
water.
spirits. Leave the system filled with mineral spirits.
Before using oi/-base paint, flush with mineral
spirits.
2. Changing Colors. Flush with a compatible sol-
vent.
A CAUTION
Never allow water to freeze in the pressure control.
Doing
so prevents the sprayer from being started
trol. Push the viater out with mineral spirits.
and causes serious damage to the pressure con-
3. Changing water-base to oil-base paint. Flush
with warm, soapy water, then mineral spirits.
6. Startup after storage. Before using water-base
4. Changing from oil-base to water-base paint. water and then clean water. When using oil-base
Flush with mineral spirits, then warm, soapy paint, flush out the mineral spirits with the paint
to
water, and then clean water. be sprayed.
paint, flush out the mineral spirits with soapy
How to Flush
A
'B
-C
"
Flg. 7
1. Relieve pressure.
2. Remove the filter bowl (A), support (C) and
3U
and support. Clean the
screen separately and
screen (e); see manual
307-273. Install the bowl
install after flushing.. See Fig
7.
3. Close the pressure drain valve.
4. Pour one-half gallon 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 in-
stalled.
6. Turn the pressure adjusting knob all the way
counterclockwise to lower the pressure setting.
7. Open the drain valve. Turn on the sprayer and
When fluid comes from the valve, close
it. Hold a
increase the pressure until until the sprayer starts.
container. Trigger the gun until all air is forced out
metal part of the gun firmly against a metal waste
of the system
and the solvent flows freely from the
gun. Release the trigger and engage the gun
safety latch.
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splash-
the gun, and hold a metal part of the
ing, always remove the spray tip from
when flushing.
gun firmly to the side of a grounded metal pail
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 packingsl 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.
IO. 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.
." ". -

Troubleshooting
~ ~~
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
fluid injection, injury from splashing fluid or solvent
in the eyes or on the skin, moving parts or electric
shock, always follow this procedure whenever you
shut off the sprayer, when checking or servicing any
part of the spray system, when Installing, cleaning
or changing spray tips, and whenever you stop
spraying.
1. Engage the gun safety latch.
2. Turn 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.
Trigger 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.
pletely clogged, or that pressure has not been fully
If you suspect that the spray tip or hose is com-
relieved after following the steps above, VERY
SLOWLY loosen the tip guard retaining nut or hose
end coupling to relieve pressure gradually, then
loosen completely. Now clear the tip or hose ob-
struction.
Check evetything in the troubleshooting table
before disassembling the sprayer.
NPE OF PROBLEM WHATTO CHECK
If check is OK, go to nexf check
WHAT TO DO
When check Is not OK refer to this column
Building circuit breaker opens 1 Check all electrical wiring for damaged I Replace any damaged wiring. I
insulation.
circuit.
Check for other electrical appliances on
Check position of 15-20 [Lo-High) amp
circut
Shutdown other electrical appliances on
switch.
Put switch in 15 amp (LO) position.
Sprayer circuit breaker opens Repair geartrain or pump, if damaged. Thaw Check for locked motor rotor. Unplug cord
and try to turn fan blades with a screwdriver. the sprayer, if frozen; See NOTE 1. Replace
Check for shorted motor. Use ohmmeter to Inspect for damage to motor brush leads.
check for shorts between motor leads or
between motor leads and motor frame.
Replace motor, if necessary.
should read 105-125 VAC.
Check electrical supply with voltmeter. Meter Connect to outlet of correct voltage.
will not run if it is at minimum setting (fully motor starts.
Check pressure control knob setting. Motor
Slowly increase pressure setting to see if
counterclockwise).
separate gun or tip instruction manual.
Check for a clogged spray tip. Refer to
instruction manual for tip cleaning.
Relieve pressure. Refer to separate gun ortip
Check extension cord for visible damage. Use Replace extension cord.
a volt meter or test lamp at extension cord
outlet to check.
Check sprayer power supply cord for visible Replace power supply cord.
damage such as broken insulation or wires.
Check electrical supply with volt meter. Meter
Reset building circuit breaker; replace
should read 105-125VAC. building fuse.
Try another outlet.
Check for motor damage. Remove drive
housing assembly. See page 21, TI^ to rotate
Replace motor [l) if fan won't turn.
fan bv hand.
the pressure control, if damaged.
Sprayer will not run
Poor spray pattern Check for worn spray tip. Relieve pressure and then replace the tip.
See the separate gun or tip manual.
10 308-551

Troubleshooting
WPE OF PROBLEM WHAT TO DO
WHAT TO CHECK
If check is OK, go to nert check When check
is not OK refer to this column
Uotor runs and pump strokes, Check extension cord size and length.
Jutput.
type extension cord.
Jut output is low or there is no
Replace cord with a larger size, grounding
Check paint supply.
lighten; use thread sealant or sealing tape
Check for loose suction tube or loose fittings.
Remove and clean strainer and reinstall.
Check for clogged intake strainer.
Refill and reprime pump.
on threads, if necessary.
Check for worn spray tip. Follow Pressure
Rellef Procedure Warning,
then replace tip. See your separate gun or tip
manual.
Check motor brushes; check for loose leads
and terminals, minimum 112" brush length,
Replace parts as needed. See page 12.
broken or misaligned springs, or brushes
binding in holders. See page 12.
armature tester farowlerl.
Check motor armature for shorts by using an
Replace motor. See page 19.
. ...
.-
I
Check to see if pump continues to stroke Service pump. See page 13.
when gun trigger is released. With pump on
and primed, trigger gun momentarily, then
release and engage safely latch. Relieve
pressure, turn off and unplug sprayer.
Check to see if intake valve ball and piston Remove intake valve and clean. Check balls
ball are seating properly. and seats for nicks; replace
if necessary. See
particles that could clog the pump.
page 14. Strain paint before using to remove
Check for leaking around throat packing nut
Replace packings. See page 13. Also check
which may indicated worn or damaged
packings.
and replace ifnecessary. lighten the packing
piston valve seat for hardened paint or nicks
nut!wetcup.
lotor runs but pump does not
connectins rod. See Fio. 38. Daae 17.
spring (35) is fully in groove all around
pin (20). See page 17.
troke. . .
Replace pin, if missing. Be sure retainer
Check displacement pump connecting rod
-
Check for frozen or hardened paint in the
Thaw. See NOTE 1. Plug in sprayer and turn
- .. -
Pump (39).
on. Slowly increase pressure setting to see if
motor starts.
Be sure crank in drive housing rotates: plug in
and unplug sprayer.
and replace if necessary. See page 21.
sprayer and turn on briefly to check. Turn off
Check driie housing assembly for damage
lotor Is hot and runs
Rermittently. pressure with small tips, which causes low size.
Determine if sprayer was operated at high Decrease pressure setting or increase
tip
motor RPM and excessive heat build up.
Be sure ambienttemperature wheresprayer is Move sprayer
to shaded, cooler area, if
not located in direct sun.
located is no more than 90°F and sprayer is possible.
Determine in sprayer was turned on,
pressurized, but not operating for long
Turn off sprayer whenever you stop spraying
for a while and relieve fluid pressure.
periods of time.
NOTE 1: Thaw the sprayer if water or water-based paint has frozen in it, by placing it in a warm area. Do not try to
staft the sprayer until it has thawed completely. If paint hardened (dried) in the sprayer, replace the pump pack-
ings. See page 15.
"_ ". ..

Motor Brush
about 0.4 in (10
mm). Always
check both brushes
NOTE Replace
the brushes
when they have worn to
9. Reinstall the remaining parts.
and replace them together.
A Brush Repair Kit, p/n
220-853, and the spring clip, p/n 110-816, are avail-
able. Order separately.
NOTE Replacement brushes may last only half as
long
as the original ones. To maximize brush life,
break in new brushes by operating the sprayer for at
connecting rod pin).
least
one hour with no load (remove the pump
k
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
01891
Procedure on page 10.
1. Remove the motor cover (14) and both inspection
covers
(A). See Fig 8.
2. Push in the spring clip (D) to unhook it, and then
pull
it out See Fig 9.
3. Loosen the terminal screw (F). Pull the brush lead
(G) away, leaving the motor lead in place. Re-
move the brush (C) and spring (B). See Fig 10.
4. Inspect the commutator for excessive pitting,
burning or gouging.
A black color on the commu-
tator
is normal. Have the commutator resurfaced
by a qualified motor repair shop
if the brushes
seem
to wear too fast.
5. Install the new brush (C) so its lead is in the long
slot
(K) of the holder (H). Slide the terminal (E)
under the terminal screw (FJ washer. Make sure
the motor lead terminal
(G) is still connected at
the screw. Tighten the screw.
See Fig 11.
6. Place the spring (6) on the brush (C) as shown in
Fig
11.
7. Push in and hook the spring clip (D). See Fig 11.
8.
Repeat for the other side.
I
A CAUTION
Do not run the sprayer dry for more than 30 sec-
onds while checking the brushes to avoid damag-
ing the displacement pump.
Fig.
9
D
Fig. 10
G
A in this dlredo
LA 0.4 in. go mm
Note: S ring must coil
Minimum brush lengm:
Fig. 11

Displacement Pump
Removing the Pump
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
1. Flush the pump, if possible, and relieve pressure
again. Stop the pump with the piston rod in
its
lowest position, if possible.
2. Remove the hose (47). clips and drain tube (101).
Remove the suction tube (42); hold the wrench
on the pump intake valve
(223) to keep the pump
from loosening.
See Fig. 12.
3. Push the retaining spring (35) up. See Fig. 13.
4. Push out the pin (20). See Fig. 14.
5. Loosenthe locknut (38) and unscrew the pump
from the bearing housing
(27). See Fig. 15.
Tools Needed for Pump Repair
Repair Kit, P/N 220-877
Sleeve Removal Tool, P/N 220-991
Heavy duty vise
1-1/16' open end wrench for Pump 220-872
2-1/4"
adjustable, bpen-end wrench
Plastic mallet
Small screwdriver
Throat
Seal Liquid
Thread Sealant
NOTE Soak leather packings in oil before installing.
Cleaning and Inspecting Parts
to the ball seat in the intake valve, which should have
Clean and inspect the parts. Pay particular attention
the outside
of thepiston rod, which should not be
no nicks or wear, and to the inside of the sleeve and
worn
or scratched. Replace worn or damaged parts.
Remove and clean the sleeve when
you are
repacking the pump.
A special sleeve removal tool is
available. See the chart, above, for the tool number
for your pump.
INJECTION HAZARD
Always use the special sleeve removal
tool to remove the sleeve. Other remov-
rupture, resulting in serious bodily injury.
If the
al methods could cause the pump to
sleeve cannot be removed easily using the tool,
tributor for removal.
return the sleeve and cylinder to your Graco dis-
Fig. 12
II I I
Fig. 14 I I ms55
Fig. 15

- Displacement Pump
Disassembly
220-877, are marked with an asterisk (*) in the text
NOTE Parts included in the Packing Repair Kit, P/N
and drawings. Use all the new parts in the kt.
1. Loosen the packing nut (21 6) and remove the
valve. See Fig.
16.
plug (205). Unscrew the cylinder from the intake
2. Disassemble the intake valve. Use a pick
to
remove the old gasket (202). Clean and inspect
the parts. See Fig. .17.
3. Reassemble the intake valve using a new gasket
(202*), ball (204*) and pin (221*). See Fig. 17.
4. Tap the piston rod (224) out of the cylinder. See
Fig. 18.
5. Screw the sleeve removal tool's large nut
(A) into
the top of the cylinder. Screw down the rod to
push the sleeve out. See Fig. 19. Remove the
tool. Clean and inspect the parts.
6. Clamp the piston rod (224) in a vise. Loosen the
retaining nut (21
1). Unscrew the piston valve
(222). See Fig. 20.
7. Disassemble the piston and discard the packings
and glands. See Fig. 21.
8. Remove and discard the throat packings and
glands from pump cylinder. See Fig. 22.
205
21 6
Fig. 16 n- E558
Fig. 17 m559
14 308-551
224
Fig.
18 U mYI1
222
21 1
0
A
Fig. 21
Fig. 22 m565

Displacement Pump
Pump Reassembly
1. Clean the piston valve threads. One at a time,
stack the backup washer
(203*), seal (215') (with
lips facing down), and female gland (214') on the
piston. Alternately stack the polyethylene
(212*)
the piston. Then install the male gland (210'). See
and leather (206*) packings (lips facing up) on
Fig. 23.
2. Place the flats of the piston valve in a vise. lighten
Fig. 25 02558
the packing retaining nut against the piston valve
to
4 in-lb (0.35 Nm). See Fig. 24.
tainer nut. Maintain this alignment through Steps 4
Note the alignment of the piston to the packing re
and
5.
3. Apply one drop of Locktiie to the threads. Place
the ball
(225') on the piston valve. See Fig. 25.
4. While maintaining the alignment, thread the
the piston valve nut contacts
the rod. See Fig. 26.
piston valve assembly into the piston
rod just until
5. Place the flats of the rod in a vise. Carefully Fig. 26 02569
tighten the piston valve nut (21 1) against the
piston rod to 19 ft-lb
(27 Nm). Use two wrenches
to maintain the alignment.
See Fig. 27.
6. Place the male gland (208*) in the cylinder. Alter-
nately stack
the polyethylene (213*) and leather
the female gland (209') in
the top of the cylinder.
packings
(207*) (lips facing down). Then place
Seat the packings. See Fig.
28.
*210
*212
*214
02570
Flg. 23
Torque to 4 in-lb /
(0.35 Nm) ( x

Displacement Pump
7. Loosely install the packing nut (216) and plug
(205). See Fig. 29.
8. Place a O-ring (217*) in the cylinder. Slide the
sleeve in to the cylinder to seat the O-ring. See
Fig.
30. Remove the sleeve.
9. Grease the piston packings and the top edge of
the sleeve. See Fig. 31.
10. Carefully slide the piston assembly into the top of
the sleeve. See Fig. 32.
11. Slide the sleevelpiston rod assembly into the
bottom
of the cylinder. See Fig. 33.
12. Grease the intake valve O-ring with non-silicon
grease. Screw the pump cylinder into the intake
valve. Torque to
70 ft-lb (95 Nm). See Fig. 34.
13.
Tighten the packing nut (216) hand tight. Screw
the cylinder locknut
(A) down to the bottom of the
external cylinder threads. See Fig.
35.
Fig. 29
I I
m512
n
217*
Fig. 30
U
Fig. 32
02575
t
Fig. 33
02576
Fig. 34
Fig. 35
mna

Displacement Pump
Installing the Pump
1. Screw the displacement pump into the bearing
housing
(27) until the pin holes align. See Fig. 36.
2. Install the pin (221*). See Fig. 37.
3.
Continue to screw the pump into the bearing
are flush with the face of the bearing housing and
housing until the top threads of the pump cylinder
the outlet nipple is straight back. Push the retain-
m580
the connecting rod to prevent it from working
ing spring
(35) into the groove all the way around
loose due to vibration. See Fig. 38.
Fig. 37
\\
a
MOVING PARTS HAZARD
If the pin works loose, it or other parts
pumping action. These parts could be
projected through the air and result in
serious
age to the pump, connecting rod or bearing hous-
bodily injury or property damage, including dam-
ing.
*.
could break off due to the force of the
4. lighten the locknut (38) to 70 ft-lb (97 N.m). See
Fig.
39.
A CAUTION
threads of the bearing housing (29) will be dam-
If the locknut (38) loosens during operation, the
aged. Be sure to tighten the locknut firmly.
5. Tighten the packing nut/ wetcup just enough to
ing nut
1/3 full with Graco TSL. See Fig. 40.
'- stop leakage, but no tighter. Fill the wet-cup/pack-
35
Fig. 38
I I
02581
Fig. 39 Ms82
Fig. 40 II myu

Pressure Control
1.
2.
3.
4.
5.
6.
7.
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow
the Pressure Relief
Procedure on page
10.
NOTE: Refer to Fig. 41 except where noted.
Disconnect the hose
(47).
valve.
Disconnect the drain tube (101) from the drain
1.
2.
3.
4.
5.
Loosen the outside filter bracket nut (2Ej.
Unscrew the swivel fitting (E) and remove the filter.
Remove the pressure control cover (36). Dkcon-
nect the four motor leads.
See Fig. 42.
the pressure control.
Unscrew the connector
(54). Pull the wires out of
Remove the pressure control mounting screws
(37). Remove the pressure control. Install the con.
nector
(54) on the new pressure control.
Install the new pressure control. Place the seal
(103) around the motor leads and push the seal
into the connector
(54). See Fig. 42.
, Fig. 41
Power Supply Cord
BACK VIEW OF PRESSURE CONTROL
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page
10.
NO= Refer to Fig. 41 except where noted.
Relieve pressure.
FRONT VIEW OF PRESSURE CONTROL
Remove the back pressure control plate (16).
Remove the pressure control cover. Disconnect
the power supply cord leads.
See Fig. 42.
power supply cord (23).
Loosen the strain relief bushing (B). Remove the
Install the new cord.
01897
18 308-551

Motor
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you
are instructed to relieve
pressure, follow the
Pressure Relief
A CAUTION
To avoid damage to the drive housing:
Do not drop the gear cluster (9), which may
stay engaged in the motor bell or in the drive
housing.
Do not lose the thrust balls (1 0) or drop them
between gears.
The balls usually stay in the
shaft recesses, but could be dislodged.
If the
balls are not in place, the bearings will wear
prematurely.
1. Remove the motor shield (14). Remove the front
cover
(31). Disconnect the hose (47).
2. Remove the pressure control cover (36). Discon-
nect the four motor leads.
3. Unscrew the connector (54) from the pressure
control. Pull the wires through the connector.
4. Unscrew the connector (54) from the motor and
remove the conduit
(22).
5. Remove the screws (51) from the recess of the
drive housing.
6. Remove the screws (21 and 30) from the the mo-
tor end bell
(F).
Fig.
7. Use a plastic mallet to tap the displacement pump
from the motor end bell
(F). Pull off the drive
(39) from the rear to loosen the drive housing (18)
housing.
8. Remove the screws (37) holding the motor to the
frame.
Lift off the motor.
9. Mount the new motor on the frame.
10. Slide a connector
(54) over the conduit (22) of the
new motor and screw two or three threads of
it
into the motor. Tighten the locknut (44) up to the
motor.
gear
(G) and pack all bearings in the motor end
bell.
Be sure the thrust balls (IO) are in place.
housing.)
(One ball
is included with a replacement drive
12. Place the bronze-colored washer
(18b) and THEN
the silver-colored washer (18a) on the shaft pro-
truding from the’big gear in the drive housing
13. Align the gears and push the drive housing (18)
14.
Continue to reassemble the sprayer.
11. Liberally grease the gear cluster (9) and pinion
(18).
straight onto the motor bell (F) and locating pins.

Bearing Housing & Connecting Rod
INJECTION HAZARD
To reduce the risk of serious injuiy,
: pressure, follow the Pressure Relief
whenever you are instructed to relieve
Procedure on page
10.
A Toque to 175 ln-lb (19 N.m)
A Lubricate with motor 011
A Liberally pack roller bearing with beating grease
Fig. 44
maw
NOTE Stop the sprayer at the bottom of its stroke to
get the crank
(H) in its lowest position.To lower the
crank manually, rotate the blades of the motor fan
with a screwdriver.
1. Remove the pump. See page 13.
2. Remove the front cover (31). Remove the bearing
housing screw (33).
3. Tap 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 off the drive housing.
4. Remove the pail bracket assembly (L) and rein-
stall it on the new bearing housing.
5. Inspect the crank
(H) for excessive wear and re
place parts as needed.
6. Evenly lubricate the inside of the bronze bearing
(J) with bearing grease.
(I<) with motor oil. Liberally pack the roller bearing
7. Slide the connecting rod
(29) into the bearing
housing
(27).
8. Clean the mating surfaces of the bearing and
drive housings.
9. Align the connecting rod with the crank (H) and
the holes in the bearing housing
(27). Push the
align the locating pins in the drive housing with
bean’ng housing onto the drive housing or tap it
into place with a plastic mallet.
10. Install the bearing housing screws (33). Torque
evenly to 175 in-lb
(19 Nm).
11. Reinstall all parts. See page 17 to install the
pump.
20 308-551