307671D ULTRA 400 AIRLESS PAINT SPRAYER - Graco Inc.

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~ 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 replacing the packings, and/or when they screws. Reinstall the motor shield and screws. have been worn to a minimum of 9/16 on the longest side. Before doing this procedure, follow the Pressure Relief Procedure Warning on page 17 to reduce the risk of fluid injection injury, splashing in the eyes or on the skin, injury from moving parts or electric shock. Be sure to unplug the sprayer1 1. Remove the four short screws (110) and the two long screws (112) and spacers (111) from the motor shield (1). Remove the shield. See Fig 27. 2. Remove the screws (HI, inspection covers (JI and gaskets (K) on each side of the motor. See Fig 27. 3. Loosen the brush lead terminal screw and remove the lead. 4. .Push down on the spring clip slightly then pull the clip away from and out of the brush holder. Refer to Fig 28. Keep the spring clip. 5. Remove and discard the brush. 6. Inspect the commutator for excessive pitting, burning or gouging. NOTE: A black color on the commutator is normal. Fig n SPRING CLIP 107-398 J.K 7. 8. 9. Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to be wearing too fast. Place a new brush in the holder so the beveled edges are as shown in the first part of Fig 28, and the brush lead is routed as shown in the second part of Fig 28. Slowly push.the tabbed end of the spring clip into the brush holder until the clip tab engages in the holder and the rolled portion of the tension spring rests squarely on the brush. Route the brush lead to the terminal and tighten the terminal screws. Be sure the brush lead does not touch any part of the armature or motor housing. COMMUTATOR SIDEVIEW OFMOTOR BRUSH INSTALLATION CAPACITOR 10. Test the brushes: TERMINALSCREW a. With the ON/OFF switch OFF, turn the pressure control knob all the way counterclockwise to minimum pressure. Plug in the sprayer. b. Turn the ON/OFF switch ON and slowly increase the pressure until the motor comes up to full speed. c. Inspect the brush and commutator contact area for excessive arcing. Arcs should not "trail" or circle around the commutator surface. WARNING Do not touch the brushes, leads, springs or brush holders while the sprayer is plugged in to avoid electric shock and possible serious bodily injury. BRUSH LEAD SPRING CLIP BRUSH HOLDER MOTOR END BELL I -BRUSH CAUTION Do not run the sprayer dry for more than 30 seconds while checking the brushes to avoid damaging the displacement pump. Fig 28 DETAIL OF MOTOR BRUSH SHOWN WITH MOTOR LEAD FACING BACK OF MOTOR 307-671 27
MOTOR CAPACITOR REPLACEMENT (See Figs 29 & 30) WARNING 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 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 Fig 29. 3. Use a screwdriver to gently lift the fan tab out of the motor shaft groove and remove the fan (El. 4. Remove the inspection cover (J), screws (H), and gasket (K) from each side of the motor (2). See Fig 29. 5. Push down slightly on the spring clip and pull the clip out of the brush holder. See Fig 30. 6. Gently push the brushes out of the brush holder and inspect. Replace if necessary. See page 27. 7. Make a matchmark between the front end bell (L) and the motor housing and the rear end bell (M) and the motor housing to use as alignment marks during reassembly. Also make a mark on the front of the motor housing. Refer to Fig 29. Fig 29 8. Use a 11 mm (7/16) socket wrench to remove the nuts from the rear end bell (MI. 9. Gently tap alternate ears of the rear end bell with a plastic mallet to loosen it, then pull it straight off. Do not pull the motor armature out. Retain any washers that fall out when the bell is removed. 10. To replace the capacitor, remove the brush lead terminal screws (Y) and the screw (Z) going into the insulation plate of the rear end bell. Install a new capacitor (X), making sure the ceramic case of the capacitor is not cracked. Maintain a 3 mm (1/8") clearance'between the capacitor and any grounded metal parts. Always replace both capacitors at the same time. 11. Position the rear end bell (MI over the tie bolts and push it onto the motor housing. Align the metchmarks carefully and install the lockwashers and nuts. 12. Position the fan (E) over the motor shaft and push it into place, making sure the fan tabs engage in the motor shaft groove. 13. Install the fan cover and screws. 14. Reconnect the motor leads in the pressure control box and reinstall the conduit (41).Push conduit seal (105) into conduit elbow, around the motor lead. Reinstall the pressure control cover (48) and screws (51). Fig 30 ' BRUSH HOLDER 4 1 I DETAIL OF MOTOR BRUSH SHOWN WITH MOTOR LEAD FACING BACK OF MOTOR Ll 28 307-671
Page 1 and 2: INSTRUCTIONS/PARTS LIST e 507-671 T
Page 3 and 4: ~~ ~ HIGH PRESSURE SPRAY CAN CAUSE
Page 5 and 6: Your new Ultra" 400 Sprayer functio
Page 7 and 8: OPERATION WARNING Pressure Relief P
Page 9 and 10: FLUSHING GUIDELINES When to Flush 1
Page 11 and 12: ~~~~~~ TYPE OF PROBLEM MOTOR WON7 O
Page 13 and 14: ~~ TYPE OF PROBLEM WHAT TO CHECK If
Page 15 and 16: TYPE OF PROBLEM ELECTRICAL SHORT WH
Page 17 and 18: BRIDGE TEST Remove the bridge from
Page 19 and 20: POWER SUPPLY CORD REPLACEMENT (See
Page 21 and 22: ~ ~~~ ~~ ~~ ~~ BRIDGE RECTIFIER REP
Page 23 and 24: Step 2 is essential to reduce the r
Page 25 and 26: ~ ~~ STALL PRESSURE CALIBRATION I I
Page 27: 19. Install the connecting rod (9).
Page 31 and 32: 13. Use a plastic mallet to gently
Page 33 and 34: PARTS DRAWING Model 230-963 Ultra"
Page 35 and 36: Ref No. 40 PRESSURE CONTROL ASSEMBL
Page 37: ULTRA@ 400 TECHNICAL DATA Power Req

307671D ULTRA 400 AIRLESS PAINT SPRAYER - Graco Inc.

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