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Graco 230-963 - page 1
INSTRUCTIONS/PARTS LIST e 507-671 ORACO Rev D SUPERSEDES A and PCN B This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE ULTRA@ 400 I Hazard of Using Fluids Containing Halogenated Hydrocarbons such solvents in this eauimnent. Such use could result in a serious chemical reaction, with the possibility of explo- Neve ...
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Graco 230-963 - page 2
INDEX WARNINGS .................................................. 2 . 3 SETUP ............................................................. 5 INTRODUCTION ................................................ 4 OPERATION; ................................................. 6. 7 SHUTDOWN 8 CARE ......................................... 7 TROUBLESHOOTING GU ...
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Graco 230-963 - page 3
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 General Safety This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject flui ...
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Graco 230-963 - page 4
EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection or other serious bodily injury, fire, explosion or property damage. could cause it to mal ...
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Graco 230-963 - page 5
Your new Ultra " 400 Sprayer functions and operates differently than other airless paint sprayers. This section will help you become familiar with the sprayer before operating it. Pressure Control The pressure control includes an ONlOFF switch for the sprayer, the pressure adjusting control knob, and a pressure sensing device. Its function is ...
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Graco 230-963 - page 6
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) flui ...
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Graco 230-963 - page 7
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 whenever you shut off the sprayer, when check- or electric shock, always follow this procedure when installing, cleaning or changing spray tips, ing or ...
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Graco 230-963 - page 8
4. Cleaning a Clogged Tip WARNING To avoid a fluid injection injury, DO NOT hold 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 spr ...
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Graco 230-963 - page 9
FLUSHING GUIDELINES When to Flush 1. New Sprayer. Your new UltraQ 400 Sprayer was factory tested in lightweight motor'oil which was 5. Storage. left in to protect pump parts. spirits and leave the pump, hose and gun filled with Water - base paint: flush with water, then mineral Before using water - base paint, flush with mineral spirits, follo ...
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Graco 230-963 - page 10
TROUBLESHOOTING GUIDE WARNING To reduce the risk of serious .bodilv injury. in- Pressure Relief Procedure 6. Engage the gun safety latch. cluding fluid injection, splashing fluid in ihe eyes 7. Ooen the drain valve. havina a container readv ~~ or on the skin, or injury from moving parts or elec - to catch the drainage. tric shock, always follow thi ...
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Graco 230-963 - page 11
TYPE OF PROBLEM MOTOR WON7 OPERATE Diagnosing circuit board in - dicator lamps. The normal condition is red lamp on, clear lamp on when board is telling pump to run. cedure Warning. Remove Follow Pressure Relief Pro- gun from hose. Remove pressure control cover and check for faulty condition of circuit board lamps. Condition A both lamps on; pump w ...
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Graco 230-963 - page 12
YPE OF PROBLEM Condition B (continued) Condition C Red lamp on, clear lamp off Unplug sprayer1 WHAT TO CHECK f check is OK, go to next check i. Check microswitch 1306). With no fluid pressure in the pressure control discon - nect wires TP18 and TP19. Check con - tinuity across switch terminals with an ohmmeter. Switch contact should be closed. Depr ...
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Graco 230-963 - page 13
~~ TYPE OF PROBLEM LOW OUTPUT NO OUTPUT Motor runs and pump stroke: 307-671 WHAT TO CHECK If check is OK. go to next check 1. Check for worn spray tip. 2. Check to see that pump does not con - 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 latch ...
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Graco 230-963 - page 14
TYPE OF PROBLEM NO OUTPUT (Continued) Motor runs but pump does not stroke EXCESSIVE PRESSURE FLUCTUATIONS Spray panern variations. MOTOR IS HOT e RUNS INTERMllTENTLY WHAT TO CHECK If check is OK, go to next check , Check to see if intake valve ball and piston ball are seating properly. See manual 307-793. . Check for leaking around throat packing n ...
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Graco 230-963 - page 15
TYPE OF PROBLEM ELECTRICAL SHORT Buildino circuit breaker ooens as sooi as sprayer switch is turned on. CAUTION Any short in any part of thf motor power circuit, which i$ connected to the output sidc of the bridge, will cause thf bridge to burn out immediate ly. Correctly diagnose anc ing and replacing bridge repair all shorts before check, as soon ...
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Graco 230-963 - page 16
~ ~_____~ SPIN TEST WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing fluids Relief Procedure Warning on page 17 to reduce 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 ...
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Graco 230-963 - page 17
BRIDGE TEST Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional. continuity tester, such as multi - meter set on the X1 See Bridge Rectifier Replacement, page 20. Use a ohms scale ( n ). the bridge fails even one test, it must be replaced. Eight individual checks, or tests, must be performe ...
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Graco 230-963 - page 18
GENERAL REPAIR NOTES WARNING Pressure Relief Procedure To'reduce the risk of serious bodily injury, in - cluding fluid injection, splashing fluid in the eyes or on the skin, or injury from moving parts or elec - tric shock, always follow this procedure whenever you shut off the sprayer, when checking or servic: ing any part of the spray system ...
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Graco 230-963 - page 19
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 sock ...
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Graco 230-963 - page 20
ON/OFF SWITCH REPLACEMENT (See Figs 14 Et WARNING Before doing this procedure, 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. Remove the pressure control cover and screws. 2. Remove the wires attached to the ...
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Graco 230-963 - page 21
BRIDGE RECTIFIER REPLACEMENT (See Fig 161 WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts or electric shock. 1 ~ ~~~ ~~ ~~ 1. Remove the pressure control cover and screws. 2. Disconnect all wire ...
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Graco 230-963 - page 22
CHOKE REPLACEMENT (See Fig 17) 1. Remove the pressure control cover and screws. 2. Remove the grounding screw (312) and remove the lead. Loosen the appropriate screw on the terminal lead. strip (336) and discornect the yellow/green choke 3. Use the M8 wrench to remove the upper nut and lockwasher (337, US) on the outside of the pressure control box ...
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Graco 230-963 - page 23
CIRCUIT BOARD REPLACEMENT (See Figs 20 8 21) WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts, or electric shock. Be sure to unolua rhe soraverl rClRCUlT BOARD r PRESSURE CONTROL KNOB 1. Remove t ...
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Graco 230-963 - page 24
PRESSURE CONTROL REPLACEMENT the risk of a fluid injection injury, splashing in the 1. Disconnect the main fluid hose (72) and the secon - dary fluid hose, if used, from the sprayer. 2. Disconnect the fluid hose (23) from between the displacement pump outlet nipple (22) and pressure control inlet elbow (314). 3. Loosen the filter bracket nut (63) a ...
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Graco 230-963 - page 25
~ ~~ STALL PRESSURE CALIBRATION I WA RNlNG I USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from splashing, component rupture, electric shock, fire, explosion, or moving parts. This procedure sets the sprayer to 192 bar (2750 psi) MAXIMUM ...
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Graco 230-963 - page 26
CONNECTING ROD, DRIVE HOUSING, or CRANKSHAFT REPLACEMENT (See Fig 25) WARNING Before doing this procedure, follow the Pressure the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts or NOTE: Stop the sprayer at the bottom of its stroke to get the crank (81) ...
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Graco 230-963 - page 27
19. Install the connecting rod (9). 20. Screw the displacement pump about 3/4 of the way into the bearing housing (6). Hold the pin (20) up to the pin hole in the connecting rod assembly (9) and continue screwing in the pump until the pin slides easily into the hole. Back off the pump until the top threads of the pump cylinder are flush with the fa ...
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Graco 230-963 - page 28
MOTOR BRUSH REPLACEMENT (See Figs 27 8 28) NOTE: New motor brushes are included with each 11. Reinstall the brush inspection covers, gaskets, and Packing Repair Kit. Replace them when screws. Reinstall the motor shield and screws. replacing the packings, and/or when they the longest side. have been worn to a minimum of 9/16 on Before doing this pro ...
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Graco 230-963 - page 29
MOTOR CAPACITOR REPLACEMENT (See Figs 29 & 30) WARNING the risk of a fluid injection injury, splashing in the Relief Procedure Warning on page 17 to reduce eyes or on the skin, injury from moving parts or 1. Remove the control box cover (48). Disconnect the motor leads. 2. Remove the fan cover IF) and screws (G) from the rear of the motor. See ...
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Graco 230-963 - page 30
MOTOR REPLACEMENT (See Fig 31 8 32) 1 WARNING Before doing this procedure, follow the Pressure 6. Loosen the connector nut (39) at the motor and pull the conduit (41 away from the motor, then pull the Relief Procedure Warning on page 17to reduce the risk of a fluid injection injury, splashmg in the leads through the conduit, one at a time. See Fig ...
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Graco 230-963 - page 31
13. Use a plastic mallet to gently tap the displacement pump (19) from the rear to loosen the drive housing ing away from the front end bell. (6) from the front end bell. Then pull the drive hous- CAUTION ~ DO NOT allow the gear cluster (26) to fall when removing the drive housing (6). It is easily damag- ed if dropped. The cluster may stay engaged ...
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Graco 230-963 - page 32
PART DRAWINGS AND PARTS LISTS 307 - 671 31 ...
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Graco 230-963 - page 33
PARTS DRAWING Model 230-963 Ultra " 400. Series D Includes items 1 - 112 11 ...
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Graco 230-963 - page 34
Includes items 1 - 112 REF PART NO. NO. 1 2 4 3 5 6 7 8 9 11 13 14 19 x) 22 21 23 24 26 27 33 34 35 39 40 41 42 43 44 45 48 50 51 52 53 218-415 181-612 107 - 267 107 - 264 220-270 107-219 105 - 510 107445 218-359 218-363 107 - 209 180-192 220 - 647 176-818 176-817 218-083 162 - 453 100-069 218-364 '178-934 218 - 361 104-008 107 - 212 102-932 2 ...
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Graco 230-963 - page 35
Ref No. 40 Includes items 301 to 340 PRESSURE CONTROL ASSEMBLY 313 PARTS LIST REF PART NO. NO. 301 218-351 302 107-437 303 105659 304 107 - 255 306 107-435 3B 218-400 309 218-366 310 107427 311 065-140 312 100-035 DES C RIPTION BARE PR E SSURE CONTROL BOX Includes items 302 to 306 .ON/OFF SWITCH .BOOT, ONIOFF switch .GUARD, locking .MICROSWITCH BRI ...
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Graco 230-963 - page 36
WIRING DIAGRAM TO TWO TERMINALS ON THE OTHER THESE WIRES ARE CONNECTED SIDE OF THE ONlOFF SWITCH SERVICE INFORMATION Listed below by the assembly changed are OLD and NEW parts. NOTE: This manual now includes complete service procedures. The parts list has new reference numbers. ASSEMBLY PART REF PART CHANGED STATUS NO. NO. NAME Sprayer, Series OLD ...
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Graco 230-963 - page 37
ULTRA@ 400 TECHNICAL DATA Power Requirements : 230 VAC, 50 Hz, 1 Phase, 3.7 AMP minimum CyclesILiter (gallon) : 124 (470) Operating Range : 0 - 192 bar (0-2750 psi) Power Cord : 2.5 mm 0 (13 ga.), 3 wire, 6 m (20 ft) long Inlet Paint Strainer : 16 mesh, 1190 micron, Outlet Paint Filter : 60 mesh, 250 micron, Stainless Steel Screen, reusable Stainle ...
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