OWNER’S MANUAL 824–033 Rev A This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE U.S. PATENT NO. 4,323,741, 4,397,610 PATENTED 1983, CANADA AND OTHER PATENTS PENDING ELECTRIC, 120 VAC ULTIMATE Plus+ 1500 Airless Paint Sprayer 3000 psi (21.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Motor Brush Replacement . . . . . . . . . . . . . . . . . . . .
WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely 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.
WARNING 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.
Major Components A S D K 0137 E M T F G H J U P R L B 7148A 7387A C N Fig.
Setup 1. Connect gun, 3 ft. hose (78) and 50 ft. hose (79). Don’t install spray tip yet. WARNING 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. 2. Two gun hookup. Remove cap (12) from 1/4 npsm(m) secondary hose outlet and attach minimum 50 ft. long hose. For more flexible gun movement, install 3/16 in. ID, 3 ft.
Operation Pressure Relief Procedure WARNING WARNING PRESSURIZED EQUIPMENT HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray nozzle.
Operation 7. To prime pump, hold a metal part of gun firmly against into a metal waste container. See Fig. 4. Squeeze trigger and hold it open, turn ON/OFF switch to ON, and slowly increase pressure setting until sprayer starts. Keep gun triggered until all air is forced out of system and paint flows freely from gun. Release trigger and engage gun safety latch. 11. Adjust pressure. a. Turn pressure adjusting knob clockwise until spray from gun is just completely atomized.
Operation Cleaning a Clogged Tip Shutdown and Care 1. Check packing nut/wet–cup daily. Relieve pressure. Keep packing nut/wet–cup (A) 1/3 full with TSL at all times to help prevent fluid buildup on piston rod and premature wear of packings. Tighten packing nut just enough to stop leakage. Overtightening may cause binding and excessive packing wear. Use screwdriver and light hammer to adjust nut. See Fig. 6.
Flushing When to Flush 1. New Sprayer. The sprayer is factory tested with lightweight oil which is left to protect pump parts. C A 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 spirits. 7148A B D 2. Changing Colors. Flush with compatible solvent. 3. Changing from water–base to oil–base paint. Flush with warm, soapy water, then mineral spirits. E 4. Changing from oil–base to water–base paint.
Troubleshooting WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. Check everything in the guide before disassembling the sprayer. TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO 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.
Troubleshooting TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK refer to this column Motor runs and pump strokes, but output is low or there is no output. Check extension cord size and length. Replace cord with a larger size, grounding type extension cord. Check paint supply. Refill and reprime pump. Check for clogged intake strainer. Remove and clean strainer and reinstall. Check for loose suction tube or loose fittings.
- Motor Brush Replacement WARNING ELECTRIC SHOCK HAZARD To reduce the risk of Electric Shock: wait 5 minutes after turning sprayer off before servicing to allow stored current to discharge. NOTE: Replace the brushes when they have worn to less than 0.4 in. See Fig. 10. Always replace both brushes at the same time. A Brush Repair Kit, p/n 220–853, and spring clip, p/n 110–816, are available.
- Motor Brush Replacement H B B C D C Order part no. 110–816 Hook of spring clip D Fig. 9 Fig. 11 D B C 0.4 in. minimum 14 E G Fig.
Removing and Installing Pump WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. Removal See Fig. 12. CAUTION If the locknut (38) loosens during operation, the threads of the bearing housing (27) will be damaged. Be sure to tighten the locknut firmly. 3. Tighten packing nut/ wet-cup just enough to stop leakage, but no tighter. Fill wet–cup/packing nut 1/3 full with Graco TSL. 1.
Pressure Control CAUTION Do not install the pressure control until motor is checked. A defective motor may damage the pressure control. Make sure to test the motor prior to pressure control installation. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of Electric Shock: wait 5 minutes after turning sprayer off before servicing to allow stored current to discharge. 8. Install pump pin and fan cover.
Pressure Control 37 64 14 1 116 22,93 47 120 7399A 1 Seals (93) located inside conduit (22) 119 121 47 7394A Fig 15 Pressure Control Repair General Repair and Replacement WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. 1. Relieve pressure. 2. Remove power cord (23) and plug retainer (23a) by removing screws (230) and washers (229). 3. Remove screws (213) and lockwashers (214).
Pressure Control Repair 229 230 23 23a 202 214 216 217 213 1 215 218 219 220 A 201 B 7202B 214 213 1 C Torque to 150 in. lbs (17 N–m) Fig 16 2. Carefully slide new o–ring (220) down bore (A) of motor control (201) into o–ring groove (B). Make sure o–ring is in groove around its entire circumference. 5. Carefully remove transducer and verify that o–ring is seated correctly and not pushed out of groove. If not seated correctly use new o–ring and repeat steps 2 through 5.
Pressure Control Wiring GRN/YEL wire, E to housing ground BLACK wire, L to on/off sw–1 E L WHITE wire, N to on/off sw–4 N Twisted pair Housing ground 4 5 6 1 2 3 On/off sw WHITE wire on/off SW–5 to to L2 on board Red wires to I1 and I2 on board Twisted pair 7369A BLACK wire on/off SW–2 to to L1 on board To J3 Twisted pair From control housing, WHITE wire to L2 From control housing, one red wire to I1 From control housing, one red wire to I2 From control housing, BLACK wire to L1 L2 I1
Motor WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of Electric Shock: wait 5 minutes after turning sprayer off before servicing to allow stored current to discharge. NOTE: Refer to Fig. 18 and parts list, except as noted.
14 1 Seals (93) located inside conduit (22) 2 Bronze colored washer 3 Apply 6 ounces bearing grease 4 Silver colored washer 1 37 21 F 4 2 18b 18a 10 G 3 9 18 125 22 10 31 101 1 7395A 39 51 47 30 Fig.
Bearing Housing and Connecting Rod WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. 1 Torque to 300 in–lb (34 N.m) 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 pump. See page 15. 2. Remove front cover (31). Remove bearing housing screws (33). 3.
Drive Housing Replacement 6. Remove screws (30 and 21) from motor bell (F). WARNING 7. Tap drive housing (18) with a plastic mallet to loosen from motor bell, then pull straight off. INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7. NOTE: 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.
Sprayer Parts Drawing 10 18 18b 9 18a 10 3,98 61 1 2 1 (both sides) 134 29 2 31 32 49 33 27 64 1 21 63 2 14 37 63 51 64 81 82 64 91 69 Ref 61 35 4 19 2 22 20 38 1 30 63 97 62 17 83 52 39 75 100 119 47 121 102 134 1 60 119 1 Safety label 2 Identification label 3 Information label 4 Caution label 80 Ref 6 37 116 42 6 7 85 125 58 26 53 11 34 46 23a 23 121 37 48 46 REF 47 7398A 101 122 120 118 12 126 95 54 7399A 4 7364A
Sprayer Parts List Models 824–030, Series A; 824–031, Series A; and 824–032, Series A (items 1–134) NOTE: Models 824–031 and 824–032 do not include: Items 25, 55, 78, and 79 shown on page 26. Ref No. 1 6 7 9 10 11 12 14 17 18 Part No.
Hose and Gun Parts Drawing and List Ref No. Part No. Description 25 220–955 SPRAY GUN 55 237–859 78 238–358 79 238–361 TIP GUARD, RAC IV (included with 220–955) see manual 308–644 HOSE, grounded, nylon; 3/16” ID; cpld 1/4 npsm(f); 3 ft.
Notes
Pressure Control Parts List 229 207 230 23 228 205 23a 204 208 209 202 234 211 203 210 206 212 214 3 213 1 215 218 216 217 220 219 4 201 225 224 236 235 214 232 233 213 2 54 227 226 221 231 222 1 Torque to 150 in. lbs (17 N–m) 2 To housing ground, Fig. 17. 3 Located this point, inside housing 4 WARNING! See Pressure Control Transducer and O–Ring Replacement on page 17 for correct replacement procedure.
Pressure Control Parts List Part Number 239–750 Pressure Control Includes items 201 – 327 Ref No. Part No. Description 239–750 PRESSURE CONTROL Qty Ref No. Part No. Description 1 220 104–319 1 PACKING, o–ring WARNING! See Pressure Control Transducer and O–Ring Replacement on page 17 for correct replacement procedure.
Accessories Use Only Genuine Graco Parts and Accessories 5 6 DANGER LABELS 170–957 181–072 The English language DANGER label shown on page 1 is also on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing below shows the best placement of these labels for good visibility. TUBE, suction STRAINER 1 1 1 Order the labels directly from your Graco Apply other distributor.
Technical Data Power Requirements (full output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Vac, 60Hz, 1 phase, 18 Amp minimum Working Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–3000 psi (0–21.0 MPa, 0–210 bar) Cycles/Gallon (Liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sherwin-Williams Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
