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INSTRUCTIONS/PARTS LIST e 507-671
Rev D
ORACO
SUPERSEDES A
and PCN B
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
ULTRA@ 400
Hazard of Using Fluids Containing Halogenated Hydrocarbons
Never use l,l,l-tnchloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
I
such solvents in this eauimnent. Such use could result in a serious chemical reaction, with the possibility of explo-
I
.sion, which could cause d
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INDEX Microswitch Replacement ................................ 19 WARNINGS .................................................. 2 . 3 Bridge Rectifier Replacement ............................ 20 INTRODUCTION ................................................ 4 Choke Replacement ........................................ 21 SETUP ............................................................. 5 Varistor Replacement ...................................... 21 OPERATION; .............................
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HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals, tags, and warnings before operating equipment. FLUID INJECTION HAZARD Spray Gun Safety Devices General Safety This equipment generates very high fluid pressure. Spray from Be sure all gun safety devices are operating properly before the gun, leaks or ruptured components can inject fluid each use. Do not remove or modify any part of the gun
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EQUIPMENT MISUSE HAZARD FIRE OR EXPLOSION HAZARD General Safety Static electricity is created by the flow of fluid through the pump and hose. If every pan of the spray equipment is not Any misuse of the spray equipment or accessories, such as properly grounded, sparking may occur, and the system may overpressurizing, modifying parts, using incompatible become hazardous. Sparking may also occur when plugging chemicals and fluids, or using worn or damaged parts, can in or unplugging a powe
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Your new Ultra" 400 Sprayer functions and operates Displacement Pump differently than other airless paint sprayers. This section The positive displacement, volume-balanced pump pro- will help you become familiar with the sprayer before vides equal fluid delivery'on both the up and down operating it. pump strokes. The pump has a wet-cup which, when filled with Graco Throat Seal Liquid, helps prevent Pressure Control damage to the throat packings and piston rod. The pressure control includes
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SETUP 1. Connect Hose and Gun (Refer to Fig 1.) NOTE: When tightening fittings at the pressure con- trol, hold one wrench firmly on the hex of the pressure control fitting to keep it from rotating. Use another wrench to tighten the mating fitting. a. Remove the plastic cap plug from the filter outlet nipple and tightly screw the 15.2 m (50 ft) fluid hose onto the nipple. b. Tightly connect the whip hose between the fluid hose and the gun inlet connection. c. Don't use thread sealant
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OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, in- cluding 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 check- ing 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.
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4. Cleaning a Clogged Tip WARNING a fluid injection injury, DO NOT hold To avoid your hand, body, or a rag in front of the spray tip when cleaning or checking a clogged tip. Always point the gun toward .the ground or into a waste container when checking to see if the tup I S clear. DO NOT try to "blow back" paint; this is NOT an air spray sprayer. ENGAGETHE TRIGGER SAFETY LATCH BY TURNING a. Clean the front of the tip frequently during the LATCH PERPENDICUI AR day's operation. Fir
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FLUSHING GUIDELINES When to Flush 1. New Sprayer. Your new UltraQ 400 Sprayer was 5. Storage. Water-base paint: flush with water, then mineral factory tested in lightweight motor'oil which was left in to protect pump parts. spirits and leave the pump, hose and gun filled with Before using water-base paint, flush with mineral mineral spirits. Shutoff and unplug the sprayer, spirits, followed by soapy water, and then a clean open the drain valve to relieve pressure and leave water flush. o
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TROUBLESHOOTING GUIDE WARNING Pressure Relief Procedure 6. Engage the gun safety latch. To reduce the risk of serious .bodilv injury. in- ~~ cluding fluid injection, splashing fluid in ihe eyes 7. Ooen the drain valve. havina a container readv I or on the skin, or injury from moving parts or elec- to catch the drainage. tric shock, always follow this procedure whenever 8. Leave the drain valve open until you are ready you shut off the sprayer, when checkingor servic- to spray again.
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~~~~~~ WHAT TO DO TYPE OF PROBLEM WHAT TO CHECK If check is NOT OK refer to this column If check Is OK, go to next check MOTOR WON7 OPERATE 1. Replace any loose terminals and crimp I. Check leads from bridge 1308) to motor Diagnosing circuit board in- to leads. Be sure male terminal blades to be sure they are securely fastened dicator lamps. The normal are straight and firmly connected to and properly mated. condition is red lamp on, mating part. clear lamp on when board is tell
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WHAT TO DO YPE OF PROBLEM WHAT TO CHECK If check is NOT OK refer to this colurn f check is OK, go to next check 5. Replace microswitch. See page 19. i. Check microswitch 1306). With no fluid Condition B pressure in the pressure control discon- (continued) nect wires TP18 and TP19. Check con- tinuity across switch terminals with an ohmmeter. Switch contact should be closed. Depress actuator bunon. An audible "click" indicates the contacts have opened. Ohmmeter should read in- finit
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~~ TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK. go to next check If check is NOT OK refer to this column LOW OUTPUT 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warning then replace tip. See your separate gun or tip manual. 2. Check to see that pump does not con- 2. Service pump. See manual 307-793. tinue to stroke when gun trigger is released. Plug in and turn on sprayer. Prime with paint. Trigger gun momen- tarily, then release and engage safety latc
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WHAT TO DO TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check If check is NOT OK refer to this column NO OUTPUT , Check to see if intake valve ball and ,. Remove intake valve and clean. Check balls and seats for nicks; replace if (Continued) piston ball are seating properly. See necessary. See manual 307-793. manual 307-793. #. Replace packings. See manual 307-793. . Check for leaking around throat packing Also check piston valve seat for harden- nut which may indicate wor
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WHAT TO DO TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check If check Is NOT OK refer to this col- umn ELECTRICAL SHORT Buildino circuit breaker ooens Check all electrical wiring for damaged 1. Repair or replace any damaged wiring or as sooi as sprayer switch is insulation, and all terminals for loose fit terminals. Securelv reconnect all wires. turned on. or damage. Be sure to check wires bet- ween pressure control and motor which CAUTION are encased in conduit 141 I. See
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~ ~_____~ SPIN TEST WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing fluids in the eyes or on the skin, injury from moving Darts. or electric shock. 1 ~~~ ~~ For checking armature, motor winding and brush elec- trical continuity. Setup Remove the drive housing from the sprayer as des- cribed in Steps 1-9, page 25. Remove the pressure control cover and screws, !he motor cover, the
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BRIDGE TEST Remove the bridge from the pressure control box and BRIDGE WIRES perform this test to determine if the bridge is functional. See Bridge Rectifier Replacement, page 20. Use a continuity tester, such as multi-meter set on the X1 ohms scale ( n ). Eight individual checks, or tests, must be performed. If the bridge fails even one test, it must be replaced. Fig 11 shows the position of the wires on the bridge. Us- ing the chart at the right, connect the meter wires as in- dicat
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GENERAL REPAIR NOTES 1. When disconnecting wires in the pressure control WARNING assembly, use needle nose pliers to separate mating Pressure Relief Procedure connectors. To'reduce the risk of serious bodily injury, in- cluding fluid injection, splashing fluid in the eyes When reconnecting the wires, be sure the flat blade or on the skin, or injury from moving parts or elec- of the insulated male connector is centered in the tric shock, always follow this procedure whenever wrap-arou
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POWER SUPPLY CORD REPLACEMENT (See Fig 12 Et 131 WARNING follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of a fluid injection injury, splashing in the eyes or on the skin, injury from moving parts, or electric shock. 1. Use the 19 mm open end wrench to remove the nut (337) from the filter stud (310). 2. Use the 13 mm socket wrench to remove the two screws (651 holding the pressure control to the frame. 3. Remove the pressure control mounting bracket (50) u
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ON/OFF SWITCH REPLACEMENT (See Figs 14 Et 15) WARNING Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce a fluid injection injury, splashing in the the risk of eyes or on the skin, injury from moving parts, or electric shock. 1. Remove the pressure control cover and screws. 2. Remove the wires attached to the switch (302) at TPl and TP2, using a screwdriver. See page 22, Fig 21. 3. Use a 16 mm socket wrench to loosen and remove the nut and
