INSTRUCTIONS-PARTS LIST
308801
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
ELECTRIC, 120 VAC
ULTRA MAX 695
Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Models 232133 and 232131, Series A
Complete sprayer with hoses, gun, RAC IV DripLess
Tip Guard and SwitchTip
Model 232132 and 232130, Series A
Basic sprayer only
Rev. E
First choice when
quality counts.
Model 232133
Related Manuals
Displacement Pump 308815. . . . . . . . . . . . . . . . .
Fluid Filter 308249. . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Model 232131
7727A7728A
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 19. . . . . . . . . . . . . . . . . . . . .
Motor Test 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brushes 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Board 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Power Supply Cord 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 26. . . . . .
Pressure Transducer 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Seal 28. . . . . . . . . . . . . . . . . . . . . .
Suction Hose 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts 32. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phone Number 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
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 your distributor.
Do not alter or modify this equipment. Use only genuine Graco parts.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 31 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
2 308801
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
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.
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 “blow 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.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten 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
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
308801 3
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 spray-
ing 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.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Use only with a grounded outlet that matches the grounded plug of this equipment.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 8 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 31 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in
confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as cigarettes,
arcs from connecting or disconnecting power cords or turning light
switches on and off.
Failure to follow this warning can result in death or serious injury.
SKIN INJECTION
HAZARD
Liquids can be injected into the body by high pressure airless spray or
leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious injury.
4 308801
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Component Function and Identification
03008
S
K
J
B
A
C
D
E
F
G
H
R
L
P
N
Fig. 1
M
A Motor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch Power switch that controls 120 VAC main power to sprayer
D Drive Assembly Transfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Fluid Outlet Main hose to spray gun is connected here
G Pail Hanger Container for fluid to be sprayed may be hung here
H Displacement Pump Transfers fluid to be sprayed from source through spray gun
J 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
K RAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury
L Contractor Gun High pressure spray gun with gun safety latch
M RAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip
without removing tip from spray gun
N 3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun
to allow more flexibility when spraying
P Pressure Drain Valve Relieves fluid outlet pressure when open; diverts fluid to drain line
R Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement
pump outlet. Works with pressure adjusting knob.
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
7727A
308801 5
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Working Pres-
sure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over–
pressurization and rupture of the hose or gun.
CAUTION
Setup
2. Fill packing nut (D). Fill packing nut full with
Graco Throat Seal Liquid (TSL) (64) supplied.
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. Read FIRE OR EX-
PLOSION HAZARD on page 4 and
Grounding, page 7.
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions:
Do not allow material to freeze in sprayer.
Use nylon spray hose at least 50 ft (15 m) long.
Do not use wire braid hose.
Do not install shutoff device between sprayer and
gun. See Fig. 2.
1. Connect hose (B) and gun (C) and screw it onto
outlet nipple (A). Don’t use thread sealant, and
don’t install spray tip yet!
1
Do not install any shutoff device here.
2
Fill full with TSL
3
Shown in closed, or spray position.
3. Plug in sprayer. Be sure ON/OFF switch (E) is
OFF. Plug cord into grounded outlet at least 20 ft
(6 m) away from spray area.
4. Flush pump to remove oil installed to protect
pump parts after factory testing. See page 12.
5. Prepare paint according to manufacturer’s recommendations. Remove any paint skin. Stir paint to
mix pigments. Strain paint through a fine nylon
mesh bag (available at most paint dealers) to
remove particles that could clog gun filter or spray
tip. This is an important step toward trouble-free
paint spraying.
continued on next page
Fig. 2
6 308801
1
A
E
C
3
D
2
B
Model 232133 Shown
7728A
Setup
Grounding
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire or
explosion that could cause serious injury or death.
1. This equipment requires a 120 Vac, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
Grounded
Outlets
Grounding Prong
Fig. 3
2. Do not alter the ground prong or use an adapter.
3. A 12 AWG, 3-wire, grounded 150 ft extension cord
may be used with this equipment.
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully
counterclockwise to obtain the minimum setting. Turn
the knob clockwise to increase pressure. See Fig. 6.
1
Engaged
1
Disengaged
2
Fig. 4
2
03008
NOTE: Long extension cords affect sprayer perfor-
mance.
How to use the gun safety latch
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 4.
WARNING
If the gun still sprays when the gun safety latch is
engaged, adjust the gun. See manual 307614,
supplied.
How to use the pressure drain valve
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over-pressure condition, it opens automatically to relieve fluid pressure. If this happens, stop
spraying immediately, shut off and unplug the sprayer.
Determine the cause of the problem and correct it
before operating the sprayer again. Refer also to the
Troubleshooting Guide, page 14. See Fig. 5.
Fig. 5
1
Rotate to increase (+)
or decrease (–)
pressure
Fig. 6
Closed, or
1
spray position
Open, or
2
drain position
–
1
1
2
7731A
+
7732A
308801 7
Setup
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, 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,
install or clean the spray tip.
1. Engage gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
The tip guard alerts you to the risk of injection and
helps prevent placing any part of the body close to the
spray tip. The tip guard also adjusts the vertical or
horizontal spray pattern. See page 10. The tip guard
holds a reversing spray tip. The tip is in the spraying
position when the tip handle points forward. See Fig. 7.
Clean front of tip frequently during day’s operation.
First, follow preceding Pressure Relief Procedure.
1 2
Tip handle shown in
1
spraying position.
Turn handle 180,
2
trigger gun to clear clog
Fig. 7
03008
4. Disengage gun safety latch. Hold a metal part of
gun against a grounded metal pail and trigger gun
into pail to relieve pressure.
5. Engage gun safety latch.
6. Open any fluid drain valves in system. Leave drain
valve open until you are ready to dispense again.
How to use the RAC IV tip guard
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
preceding Pressure Relief Procedure.
How to remove a tip clog
7. Release gun trigger. Engage safety latch. Rotate
RAC IV tip handle 180
8. Disengage safety latch. Trigger gun into a pail or
onto ground to remove clog.
9. Engage safety latch. Rotate tip handle to spraying
position.
10. If tip is still clogged, engage safety latch, shut off
and unplug sprayer, and open pressure drain valve
to relieve pressure. Clean spray tip as shown in
manual 308644, supplied.
. See Fig. 7.
8 308801
Startup
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely.
NOTE: If this is a first–time startup, flush the sprayer.
See page 12.
1. Open pressure drain valve (A). See Fig. 8.
2. Don’t install spray tip until pump is primed!
3. Put suction hose or tube (C) into paint. If you
are pumping from a 1 gallon (5 liter) pail, push
drain hose (D) down below top of pail to avoid
splashing paint when drain valve is opened.
Shown in closed, or spray position.
1
2
Open, or drain position
+
–
E
D
4. Turn pressure knob (E) to minimum setting.
5. Disengage gun safety latch. See Fig. 4.
CAUTION
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in it
for more than 30 seconds.
6. To prime pump, turn sprayer ON/OFF switch (F)
ON. Slowly increase pressure until sprayer starts.
When fluid comes from pressure drain valve, close
valve.
Fig. 8
C
B
F
1
A
2
Model 232133 Shown
7728A
308801 9
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing
when priming, be sure the spray tip is
not installed on the gun, and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
Startup
NOTE: Spray patterns will change as tips wear.
Change spray tip if adjusting pressure will not improve
spray pattern.
1
7. To prime hose, lower pressure to reduce splashing. Holding gun against pail, trigger gun and
slowly increase pressure until pump starts. Keep
gun triggered until all air is forced out of system
and fluid flows freely from gun. Release trigger and
engage gun safety latch.
8. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
9. Install spray tip. Engage gun safety latch first!
See manual 308644 for how to install tip.
10. Adjust spray pattern
a. Increase pressure just until spray from gun is
completely atomized. To avoid excessive
overspray and fogging, and to extend tip and
sprayer life, always use lowest pressure
needed to get desired results.
b. If more coverage is needed, use a larger tip
rather than increasing pressure.
c. Test spray pattern. To adjust direction of spray
pattern, engage gun safety latch and loosen
retaining nut (B). Position tip guard horizontally
for a horizontal pattern or vertically for a vertical pattern. Hold tip guard in place while tightening retaining nut. See Fig. 9.
1
2
Fig. 9
For a vertical
spray pattern
For a horizontal
spray pattern
B
2
03008
10 308801
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
6. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 12.
7. For very short shutoff periods, leave suction
hose in paint, relieve pressure, and clean spray tip.
1. Relieve pressure.
2. Check packing nut daily. Keep packing nut full of
TSL at all times to help prevent fluid buildup on
piston rod and premature wear of packings.
3. If pump begins to leak, loosen packing nut and
remove throat nut spacer (228). Tighten packing
nut just snug. Over tightening causes binding and
excessive packing wear. Use a round punch or
brass rod and light hammer to adjust nut. Refer to
Fig. 10. When leakage occurs again, repack pump.
4. Clean gun’s fluid filter often and whenever gun
is stored. Relieve pressure first. Refer to manual
307614.
5. Lubricate bearing housing after every 100 hours
of operation. Remove front cover. Apply several
drops of SAE 10 non-detergent oil in bearing
housing cavity (B). See Fig. 10.
CAUTION
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
8. Coil hose when storing it, even for overnight, to
help protect hose from kinking, abrasion, coupling
damage, etc.
Turn packing
1
nut clockwise to
tighten
B
1
228
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold weather,
never leave water or any type of paint in the sprayer
when it is not in use. Freezing can seriously damage
the sprayer or result in a loss of pressure or stalling.
Fig. 10
7734A
308801 11
Flushing
When to flush
Determine material to spray from column 1. Flush with
material in column 2. Then follow recommendations in
one of next three columns.
If you are going to: Flush with: Prime with: Clean with: Store unit with:
Do not leave water or water-based fluids in sprayer if
it could freeze. Push water out with mineral spirits.
Frozen fluid in sprayer prevents starting and may
cause serious damage.
CAUTION
Spray latex paint Warm, soapy water,
then clean water
Spray oil paint Mineral spirits Oil–base paint Mineral spirits Mineral spirits
Change latex to oil paint Warm, soapy water,
then clean water
Change oil to latex paint Mineral spirits,
soapy water, and
clean water.
Change colors, same base Compatible solvent
such as water or
mineral spirits
Latex-base paint Warm soapy water,
then clean water
Mineral spirits Mineral spirits Mineral spirits
Latex Warm, soapy water,
then clean water
Mineral spirits
Mineral spirits
How to flush
3. Remove filter screen and then reinstall bowl, hand
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
tight, without screen. Clean screen separately. See
manual 308249.
4. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal flushing pail. Put suction
hose in pail.
5. Open pressure drain valve. See Fig.11.
1. Relieve pressure.
2. Remove spray tip and clean it separately. If you
are changing from water-based to oil-based paints
or solvents, be sure that tip is cleaned thoroughly.
12 308801
6. To save paint still in pump and hose, follow
Step 7, except put drain hose in paint pail. When
solvent appears, close drain valve. Put drain hose
in flushing pail. Trigger gun into paint pail. When
solvent appears, release trigger. Continue with
Step 7.
WARNING
Flushing
10. Reinstall clean filter screen.
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
7. Lower pressure setting. Turn on sprayer. Maintaining metal-to-metal contact, trigger gun into flushing
pail. Slowly increase sprayer pressure just until
pump starts. Keep gun triggered until solvent flows
freely from gun. Circulate solvent to thoroughly
clean sprayer. Release gun trigger. Engage gun
safety latch.
8. Open drain valve and circulate solvent through
drain hose to thoroughly clean it. Close drain
valve.
9. Remove suction hose from pail. Disengage gun
safety latch. Trigger gun and run pump a few
seconds to push air into hose. Do not run pump
dry for more than 30 seconds to avoid damaging
pump packings! Relieve pressure.
11. Remove and clean inlet strainer. Wipe paint off
suction hose and drain hose.
12. Leave drain valve open until you use sprayer
again.
Open or
1
drain position
1
Fig. 11
7731A
308801 13
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
Check everything in the troubleshooting tables before disassembling the sprayer.
Thaw sprayer if water or water-based paint has
frozen in it, due to exposure to low temperatures, by
placing it in a warm area. Do not try to start sprayer
until it has thawed completely or damage to motor
and/or control board may occur. If paint hardened
(dried) in sprayer, the pump packings and/or pressure transducer must be replaced. See page 22
(pump) or 28 (pressure transducer).
Basic Problem Solving
TYPE OF
PROBLEM
Fluid Pressure 1. Check pressure transducer knob setting. The
Mechanical 1. Check for frozen or hardened paint in pump (18).
WHAT TO CHECK
If check is OK, go to next check
pump won’t develop much pressure if it is at minimum setting (fully counterclockwise).
2. Check for a clogged spray tip or fluid filter, if used.
See page 8.
Using a screwdriver, carefully try to rotate fan at
back of motor by hand. See page 23.
WHAT TO DO
When check is not OK, refer to this column
1. Slowly increase pressure setting to see if
motor starts.
2. If tip is still clogged, relieve pressure;
refer to separate gun or tip instruction
manual for tip cleaning. Clean or replace
filter element. See manual 308249.
1. Thaw. After thawing, plug in sprayer and
turn it on. Slowly increase pressure setting to see if motor starts. If it doesn’t
start, see CAUTION above.
CAUTION
2. Check pump connecting rod pin (14). It must be
completely pushed into connecting rod (12), and
retaining spring (15) must be firmly in connecting
rod groove. See Fig. 18, page 22.
3. Check for motor damage. Remove drive housing
assembly (2). See page 26. Try to rotate motor
fan by hand.
Electrical 1. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
2. Check extension cord for visible damage. Use a
voltmeter or test lamp at extension cord outlet to
check.
3. Check sprayer power supply cord (30) for visible
damage such as broken insulation or wires.
2. Push pin into place and secure with
spring retainer.
3. Replace motor (85) if fan won’t turn. See
page 23.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Replace extension cord.
3. Replace power supply cord. See page
25.
14 308801
Basic Problem Solving
TYPE OF
PROBLEM
Electrical
(continued)
WHAT TO CHECK
If check is OK, go to next check
4. Check motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
d. Broken leads.
e. Worn brushes.
f. Brush leads snagged on spring clip.
NOTE: The brushes do not wear at same
rate on both sides of motor. Check both
brushes.
5. Check motor armature commutator for burn spots,
gouges and extreme roughness. Remove motor
cover and brush inspection plates to check. See
page 21.
6. Check motor armature for shorts using armature
tester (growler) or perform motor test.
See page 20.
7. Check leads from pressure transducer and motor
to motor control board (22a) to be sure they are
securely fastened and properly mated.
WHAT TO DO
When check is not OK, refer to this column
4. Refer to page 21.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
(12.5 mm) long.
f. Correctly route the wires.
See page 21.
5. Remove motor and have motor shop
resurface commutator if possible.
See page 23.
6. Replace motor. See page 23.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
9. Check power supply cord (30). Disconnect black
and white power cord terminals; connect volt
meter to these leads. Plug in sprayer. Meter should
read 105–125 VAC. Unplug sprayer.
10. Check ON/OFF switch (80). Disconnect black wire
(96) between motor control board (22a) and switch
and connect volt meter between exposed terminal
switch and power cord’s white wire. Plug in
sprayer and turn ON. Meter should read 105–125
VAC. Turn off and unplug sprayer.
11. Check motor thermal cutout switch. Connect ohmmeter between motor’s red leads. Meter should
read 1 ohm maximum.
12. Check the transducer (67) by replacing it with a
new one.
13. Check pressure adjustment potentiometer (77) by
replacing it with a new one.
8. Replace board. See page 24.
9. Replace power supply cord.
See page 25.
10. Replace ON/OFF switch. See page 25.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12. Replace pressure transducer.
See page 28.
13. Replace potentiometer.
308801 15
Intermediate Problem Solving
TYPE OF
PROBLEM
Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure
WHAT TO CHECK
If check is OK, go to next check
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and
turn on sprayer. Prime with paint. Trigger gun momentarily, then release and engage safety latch.
Relieve pressure, turn off and unplug sprayer.
3. Release gun trigger. Observe resting position of
pump rod (222).
4. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
5. Check extension cord size and length. 5. Replace with a correct, grounded exten-
6. Check motor brushes. See Electrical – What To
Check, item 4, on page 15.
WHAT TO DO
When check is not OK refer to this column
Warning on page 8, then replace tip.
See your separate gun or tip manual.
2. Service pump. See page 22.
3. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 22.
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
sion cord. Note that long lengths and/or
smaller gauges reduce performance.
6. See page 21.
16 308801
Intermediate Problem Solving
TYPE OF
PROBLEM
Low Output
(continued)
Drain Valve Leaks 1. Check drain valve for correct torque and/or worn
No Output: Motor
Runs And Pump
Strokes
WHAT TO CHECK
If check is OK, go to next check
7. Check motor control board (22a) by substituting
with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
8. Check motor armature for shorts by using an armature tester (growler) or perform motor test. See
page 20.
parts. Check for debris trapped on seat.
1. Check paint supply. 1. Refill and reprime pump.
2. Check for clogged intake strainer. 2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. See
page 29.
4. Check to see if intake valve ball and piston ball are
seating properly. See page 22.
WHAT TO DO
When check is not OK, refer to this column
7. Replace board. See page 24.
8. Replace motor. See page 23
.
1. Tighten to 185 in-lb (21 Nm). Clean
valve and replace with new gasket (55)
and sealant 110–110. See page 30.
3. Tighten; use thread sealant on
npt threads of suction tube (43). Check
for damaged o–ring (45).
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as needed. See page 22. Strain paint before using to remove particles that could clog
pump.
No Output: Motor
Runs But Pump
Does Not Stroke
Spray Pattern
Variations
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 22.
6. Release gun trigger. Observe resting position of
pump rod (222).
1. Check displacement pump connecting rod pin (14).
See Fig. 18, page 22.
2. Check connecting rod assembly (12) for damage.
See page 26.
3. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off and
unplug sprayer. See page 26.
1. Spray tip worn beyond sprayer pressure capability. 1. Replace spray tip.
2. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
5. Replace packings. See page 22. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut/wet-cup.
6. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 22.
1. Replace pin if missing. Be sure retainer
spring (15) is fully in groove all around
connecting rod.
2. Replace connecting rod assembly. See
page 26.
3. Check drive housing assembly for damage and replace if necessary. See
page 26.
NOTE: A smaller size tip will provide
longer life.
2. Replace board. See page 24.
308801 17
Intermediate Problem Solving
TYPE OF
PROBLEM
Spray Pattern
Variations
(continued)
Motor Is Hot and
Runs Intermittently
Building Circuit
Breaker Opens As
Soon As Sprayer
Switch Is Turned
On.
WHAT TO CHECK
If check is OK, go to next check
3. Check pressure adjustment potentiometer (77) by
replacing it with a new one.
4. Check Low Output section, page 16.
1. Determine if sprayer was operated at high pressure
with small tips, which causes excessive heat build
up.
2. Be sure ambient temperature where sprayer is located is no more than 90
not located in direct sun.
3. Check motor. 3. Replace motor. See page 23.
1. Check all electrical wiring for damaged insulation,
and all terminals for loose fit or damage.
Also check wires between pressure transducer
and motor. See page 23.
2. Check for missing motor brush inspection plate
gasket (see page 21), bent terminal forks or other
metal to metal contact points which could cause a
short.
3. Check motor armature for shorts. Use an
armature tester (growler) or perform motor test.
See page 18. Inspect windings for burns.
F (32C) and sprayer is
WHAT TO DO
When check is not OK, refer to this column
1. Decrease pressure setting or increase tip
size.
2. Move sprayer to shaded, cooler area if
possible.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Correct faulty conditions.
3. Replace motor. See page 23.
Circuit breaker
opens after sprayer
operates for 5 to 10
minutes.
Building circuit
breaker opens as
soon as sprayer is
plugged into outlet
and sprayer is NOT
turned on.
Unit will not run on
generator but does
run on AC power
4. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board
1. Check ‘Basic Problems – Electrical’ on page 14.
1. Check ON/OFF switch (80). Be sure sprayer is
unplugged! Disconnect wires from switch. Check
switch with ohmmeter. The reading should be
infinity with ON/OFF switch OFF, and zero with
switch ON.
CAUTION: A short in motor circuit can damage
switch and or motor control board (22a).
2. Check for damaged or pinched wires in junction
box (20).
1. Check the generator’s “peak” voltage. This sprayer
will not run if the peak voltage is above 190V or
below 100V.
4. Replace board. See page 24.
1. Replace ON/OFF switch. See page 25.
2. Replace damaged parts.
1. Use AC power or a different generator.
18 308801
General Repair Information
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
Tool List
These service tools are required.
12” adjustable wrench: pump
1/4” Allen wrench: filter plug
3/8” Allen wrench: pump manifold
3/16” Allen wrench: gear housing, legs, handle
5/64” Allen wrench: pressure adjustment knob
Phillips screwdriver: junction box, front cover, motor
shield
3/8” socket wrench: motor mount
5/8” socket wrench: drain valve, on/off switch boot,
piston
5/8” open end wrench: outlet fittings
13/16” socket wrench: drain valve
1-1/4” socket wrench: pump inlet valve
1/2” open end wrench: pump rod
11/16” open end wrench: piston jam nut
15/16” open end wrench: flats of inlet tube
1-3/4” open end wrench: pump jam nut
5/64” drive pin: drain valve pin
3” needle nose pliers: wiring, on/off switch
Hammer & punch: packing nut
Torque wrenches: various fasteners
Pipe wrench: suction tube
CAUTION
3. Route wires carefully and avoid pinching any
wires between covers.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure transducer.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures.
5. Test your repair before regular operation to be
sure problem is corrected.
6. If sprayer does not operate properly, verify that
everything was done correctly. Also refer to Troubleshooting Guide, page 14, to help identify other
possible problems and solutions.
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury, including electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the sprayer.
Shut off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
To reduce the risk of a pressure transducer malfunction, properly mate connectors and never pull on a
wire to disconnect it.
1. When disconnecting wires, use needle nose
pliers to separate mating connectors.
2. When reconnecting wires, center flat blade of
male connector in blade of female connector.
WARNING
FIRE HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire
or explosion.
308801 19
Motor Test
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
For checking armature, motor winding and brush
electrical continuity.
Armature Short Circuit Test
1. Remove fan cover (B). See Fig.12.
2. Spin motor fan by hand. If there are no shorts, the
motor will coast two or three revolutions before
coming to a complete stop. If the motor does not
spin freely, the armature is shorted and the motor
must be replaced. See page 23.
Setup
1. Unplug sprayer.
2. Remove drive housing. See page 26. This is to
ensure that any resistance you notice in armature
test is due to motor and not to worn gears in drive
housing.
3. Remove motor brush inspection covers (A). See
Fig. 12.
4. Remove screws (25, 26). Lower control board
(22a). Disconnect two leads (C) from motor to
board. See Fig.13.
B
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Connect red and black motor leads (C) together
with a test lead. Turn motor fan by hand at about
two revolutions per second. See Fig. 13.
80
black
green
30
white
Fig. 13
67
78
E
96
D
yellow
black red
C
22a
77
107
108
7869B
Fig. 12
20 308801
2. When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is
irregular turning resistance, or no turning resis-
A
02991
tance, check and repair the following as needed:
broken brush springs, brush leads, motor leads;
loose brush terminal screws or motor lead terminals; worn brushes. See page 21.
3. If there is still uneven or no turning resistance,
replace motor. See page 23.
Motor Brushes
NOTE: Replace brushes when worn to about 12.5 mm
(0.5 in.). Always check both brushes. Brush Repair Kit
236967 is available for motor brush repair.
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 with no load
as instructed in this procedure.
NOTE: To minimize down time, and for best sprayer
performance, check motor brushes and clean transducer (see page 28) whenever pump is repacked.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Unplug sprayer.
2. Remove both inspection covers (A) and their
gaskets. See Fig.14.
9. Test brushes.
a. Remove pump connecting rod pin (14).
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
d. Inspect brush and commutator contact area for
excessive arcing. Arcs should not trail or circle
around commutator surface.
10. Install brush inspection covers and gaskets.
11. Break in brushes. Operate sprayer for at least
one hour with no load. Install pump connecting rod
pin.
A
Fig. 14
3. Push in spring clip (F) and release hooks (G) from
brush holder (B). Pull out spring clip. See Fig. 15.
4. Inspect commutator for excessive pitting, burning or
gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes seem to wear too fast or arc
excessively. See Step 9.d., also.
5. Repeat for other side.
6. Place a new brush (C) in holder (B) so ramp (H)
faces spring. See Fig. 15.
7. Holding spring clip (F) at a slight angle, slide spring
clip into brush holder and hook it over end of
holder. See Fig. 16. Pull on spring clip to be sure it
stays in place. Connect brush lead to blade connector (E).
8. Repeat for other side.
7735A
Fig. 15
Fig. 16
Motor lead; do not disconnect
1
2 Minimum 12.5 mm (.5 in.)
2
C
G
F
H
E
D
1
F
C
E
1
B
G
03881
308801 21
Displacement Pump
A
NOTE: Packing Repair Kit 235703 is available. Reference numbers of parts included in the kit are marked
with an asterisk, i.e., (223*).
Removing pump (See Fig.17)
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow
Pressure Relief Procedure on page 8.
Torque to
1
50 ft-lb (68 Nm)
Apply pipe
2
sealant (110110
1
Fig. 17
12
11
48
17
47
45
43
)
14
15
222
18
36
213
50
2
232132, 232133 shown
215
*214
*227
7736
6. Use a screwdriver to push retaining spring (15) up
and push out pin (14).
7. Loosen screws (17). Remove pump (18).
Repairing pump
See manual 308815 for displacement pump repair
instructions and parts.
Installing pump (See Fig. 17 and 18)
15
201
14
202
Fig. 18
1. Lightly grease or oil transducer (67). See Fig. 24.
Guide pump over alignment pins and pressure
transducer. Tap it into position with a soft hammer.
Tighten screws (17) to 50 ft-lb (68 Nm).
2. Align hole in rod (222) with connecting rod assembly (12). Use screwdriver to push retaining spring
(15) up and push in pin (14). Push retaining spring
into place around connecting rod.
7840A
1. Relieve pressure.
2. Flush pump, if possible. Relieve pressure. Stop
pump with piston rod (222) in its lowest position, if
possible. To lower piston rod manually, rotate
motor fan blades.
3. Remove filter (48).
4. Models 232132 and 232133. While pulling upward
on suction hose (47), unscrew hose from inlet tube
(43). Unscrew drain hose (50) from displacement
pump nipple (36).
5. Models 232130 and 232131. Remove suction
tube (43). Unscrew drain tube (84) from displacement pump nipple (36).
22 308801
WARNING
MOVING PARTS HAZARD
Be sure retaining spring (18) is firmly in
groove all around, to prevent pin (14)
from working loose. See Fig. 18.
If pin works loose, parts (including pump connecting rod or bearing housing) could project into the air
and cause serious injury or property damage.
3. Replace o-ring (45) if worn or damaged. See page
29. Reconnect suction and drain hoses (47, 50).
Install front cover (11).
4. Tighten packing nut (202) enough to stop leakage,
but no tighter. Fill packing nut full with Graco TSL.
Push plug (201) into packing nut.
WARNING
Motor
9. Remove four screws (75) and lift motor off cart
(70).
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
NOTE: See Fig. 21 except where noted.
1. Try to stop pump with piston rod (222) in lowest
position. To lower piston rod manually, remove
shroud (32) and rotate motor fan blades. Use a
screwdriver to push retaining spring (15) up and
push out pin (14). See Fig. 19.
2. Relieve pressure.
3. Remove motor shield (32).
4. Lift connecting rod. Remove screws (25, 26) and
lower heat sink (22) and motor control board (22a).
Disconnect motor wires and pressure transducer
wire (A) from motor control board. Remove heat
sink (22) and motor control board (22a), screws
(23), and junction box (20). Refer to Fig. 21 and
13.
5. Remove drive housing cover (11).
6. Turn displacement pump rod (222) so pin hole
aligns with bottom drive housing screw (16). See
Fig. 20. Remove three drive housing screws and
lockwashers (16, 4). See Fig. 20 and 21.
7. Remove two motor screws and lockwashers (3, 4).
10. Align new motor with cart and reinstall screws (75).
11. Assemble drive housing to motor. Follow steps 9
to 15 on page 26. Install junction box.
12. Connect wires to motor control board (22a). Refer
to Fig. 13. Install motor control board.
13. Connect piston rod (222) to drive housing; see
page 22, Installing Pump, Step 2 and WARNING
following it.
14. Install shroud (32) and drive housing cover (11).
15
14
Fig. 19
4
16
12
Fig. 20
7840A
222
7840A
8. Tap lower rear of drive housing (2) with a plastic
mallet to loosen motor. Pull drive housing straight
off motor while guiding pressure transducer wire
(A) from motor. Do not allow gear (13) to fall. Read
CAUTION on page 26.
4
16
1
34
11
Torque to 80 in-lb (9 Nm)
1
Fig. 21
32
1
3
4
13
2
5
20
23
A
22a
22
25
75
26
308801 23
70
7741A
Motor Control Board
Motor control board removal
WARNING
5. Remove four screws and motor control board
(22a).
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Remove screws (25, 26) and lower heat sink (22)
and motor control board (22a). See Fig. 21.
3. Disconnect wires (C), (D), (96), (E) and 108 from
motor control board (22a). See Fig. 13.
4. Disconnect potentiometer (77) and transducer (67)
from motor control board (22a).
Motor control board diagnostics
1. Relieve pressure.
2. Remove screws (25, 26) and lower heat sink (22)
and motor control board (22a). See Fig. 21.
LED
BLINKS
SPRAYER OPERATION INDICATES WHAT TO DO
6. Install new motor control board (22a) with four
screws. Reconnect all wires and secure heat sink
(22) to junction box (20).
CAUTION
To reduce the risk of a malfunction:
Be sure the flat blade of the insulated male
connector is centered in the wrap–around blade of
the female connector when the connections are
made.
Route all wires carefully to avoid interference with
the motor control board or junction box.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
Once Sprayer runs Normal operation Do nothing
Twice Sprayer runs Normal operation Do nothing
Twice
repeatedly
Three times
repeatedly
Four times
repeatedly
Five times
repeatedly
Sprayer shuts down and LED continues
to blink twice repeatedly
Sprayer shuts down and LED continues
to blink three times repeatedly
Sprayer shuts down and LED continues
to blink four times repeatedly
Sprayer shuts down and LED continues
to blink five times repeatedly
Line voltage is too
high
Pressure transducer
is faulty or missing
Run away pressure.
Pressure greater than
4500 psi.
Locked rotor. Motor
can not turn because
of some mechanical
condition.
Lower line voltage to 120 VAC
Replace pressure transducer
Replace motor control board.
See preceding Motor control
board removal procedure.
Clear obstruction and replace
broken parts preventing motor
from turning
24 308801
Power Supply Cord
WARNING
3. Disconnect power supply cord leads (30), including
green wire to grounding screw (78). See Fig. 13.
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Remove screws (25, 26) and lower heat sink (22).
See Fig. 21.
On/Off Switch
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Remove screws (25, 26 ) and lower heat sink (22).
See Fig. 23.
4. Loosen strain relief bushing (29). Remove power
supply cord (30).
5. Install new cord (30) in reverse order of disassembly.
6. Install heat sink (22). Be sure no leads are pinched
between heat sink and junction box (20).
4. Disconnect black wires from ON/OFF switch (80)
and remove switch. See Fig. 13.
5. Install switch so internal tab of anti–rotation ring
(54) engages with vertical groove in threads of
switch, and external tab engages with slot of
junction box. See page 32.
6. Powder inside of rubber boot (82) with talcum,
then shake excess out of boot. Install nut and
rubber boot and tighten.
7. Reconnect ON/OFF switch black wires.
3. Remove rubber boot (82). See page 32.
8. Install control card. Be sure no leads are pinched
between motor control board or other components.
308801 25
Drive Housing, Connecting Rod, Crankshaft
7. Tap lower rear of drive housing (2) with a plastic
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
mallet to loosen motor. Pull drive housing straight
off motor.
8. Remove and inspect crankshaft (5) and connecting
rod (12). Replace all damaged or worn parts.
NOTE: Inspect parts as they are removed. Replace
parts that are worn or damaged.
1. Relieve pressure.
2. Remove displacement pump. See page 22.
3. Remove shroud (32).
4. Lower heat sink (22) and remove pressure transducer (67). See page 28.
4
16
Fig. 22
7840A
9. Install connecting rod.
10. Lubricate inside of connecting rod bearing with
SAE non-detergent oil. Pack roller bearing and
gears with grease supplied.
NOTE: The gears and bearings between the drive
housing (2) and motor front end bell (C) should contain
a total of 3 fl oz (89 cc) of grease.
11. Place large washer (6) and then small washer (7)
on crankshaft (5).
12. Rotate crank to top of stroke and insert crankshaft
(5). Align gears and push drive housing (2) straight
onto motor and locating pins. Install screws (16, 3)
and their lockwashers (4). Torque to 80 in-lb (9
Nm).
13. Plug in pressure transducer. See page 28.
5. Remove three drive housing screws and lockwashers (16, 4). Also see Fig. 23.
6. Remove two motor screws and lockwashers (3, 4).
See Fig. 23.
CAUTION
Do not allow the gear (13) to fall; it may stay attached to the drive housing or to the motor.
Do not lose the thrust balls (2a or 41) or let them fall
between the gears, which will damage the drive
housing if not removed. The balls, which are heavily
covered with grease, usually stay in the gear recesses, but could be dislodged. If the balls are not in
place, the bearings will wear prematurely.
14. Install displacement pump. See page 22.
15. Install front cover (11).
16. Replace shroud (32).
17. Replace heat sink (22).
26 308801
Drive Housing, Connecting Rod, Crankshaft
4, 3
5
6
1
Note: Filter
not shown
Torque to 80 in-lb (9 Nm)
1
Fig. 23
16
12
4
B
7
13
C
2a
A
2
1
25
22
22a
26
7742A
308801 27
Pressure Transducer
NOTE: See Fig. 23 and 24 for this procedure.
NOTE: The pressure transducer (67) cannot be re-
paired or adjusted. If it malfunctions, replace it.
Removal
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Remove displacement pump (18). See page 22.
3. Remove front cover (11). Remove screws (25, 26).
Lower motor control card.
4. Disconnect harness connector from motor control
board (22a). Remove grommet (65).
5. Remove retaining ring (66). Pull pressure transducer down and out past drive housing (2).
2. Pass a spacer (68) over harness connector (A)
and down into position at bottom of transducer
(67).
3. Guide harness up through leg and notch of drive
housing (2). Secure guide wire over connector.
4. While pulling guide wire out through bottom of
motor, guide harness through drive housing and
motor castings.
5. Place grommet (65) over harness and push into
position in drive housing hole.
6. Feed excess harness cable through grommet and
fully seat transducer body into hole in drive
housing leg. Secure it with retaining ring (66).
7. Attach connector to motor control board (22a).
Replace cover (11) and heat sink (22). Ensure no
wires are pinched between components.
65
A
6. Guide harness (A) through motor and drive housing and remove pressure transducer.
7. Inspect spacer (68) and seal (69) for damage.
Replace seal (69) only if it is cut, nicked, or if
leakage occurred. See page 28.
Installation
1. Using a small piece of solid copper or mild steel
wire (approximately 12 in.), form a small hook and
place it in the passage of bottom of the motor.
Guide it up and out the hole in the drive housing.
Pressure Transducer Seal
NOTE: PTFE seal is unaffected by most solvents and
materials. Replace seal only when leakage occurs.
Removal
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
28 308801
66
67
68
69
Fig. 24
1. Relieve pressure.
2. Remove displacement pump (18). See page 22.
3. Remove seal (69) from recess in manifold (229).
4. Clean manifold recess with solvent and cloth or
cotton swabs. Inspect for nicks or scratches.
02996A
Pressure Transducer Seal
Installation
1. Lightly coat cleaned packing recess in manifold
with a light grease or oil.
2. Heat seal (69) in hot water for several minutes.
CAUTION
Excess pressure from the probes or fingernails will
damage the packing and cause subsequent leakage.
3. Use a blunt wooden or plastic probe and install
seal (69) into recess in manifold (229). Be careful
not to cause kinks or bends in packing during
installation.
Suction Hose (Models 232132 and 232133)
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
4. Lightly grease or oil transducer (67) and install
pump (18). See page 22.
69
229
Fig. 25
CAUTION
Misalignment or cross-threading will damage the
parts and/or create shavings which can cause the
o-ring (45) to leak.
7743A
1. Relieve pressure.
2. Remove drain hose (50) from clip.
3. Pull upward on suction hose (47) while unscrewing
it from inlet tube (43). The hose coupling (A)
threads will engage and the hose will separate
from the tube.
4. Replace o-ring (45) if it is worn or damaged.
5. Lubricate o-ring (45) and inlet tube (43) threads
with light grease.
6. Align suction hose coupling (A) with threads of
inlet tube (43). Tighten hose onto tube at least 4
turns to ensure that threads have disengaged and
can function as a swivel joint.
Fig. 26
50
47
1
45
1
A
43
1
Lubricate with
light grease.
7744A
308801 29
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
Drain Valve
Repair
1. Unscrew spring retainer from valve body. Remove
spring, washers and stem/ball. Clean any debris
from ball or seat area.
2. If replacing gasket (55) or seat (56), pry out gasket.
2. Turn handle (54) to closed position. Drive out pin
(53). Remove handle.
3. Remove base (52).
4. Unscrew drain valve assembly (51). gasket (55)
and seat (56) will stay in valve.
55
56
2
51
52
3
1
Torque into pump manifold to
1
185 in-lb (21 Nm)
Apply thread sealant
2
3
Apply grease to face of base
4
Handle shown in closed position
Fig. 27
53
54
4
7839A
NOTE: Whenever gasket (55) is removed, replace it
with a new one.
3. Place seat (56) in drain valve assembly (51) so
lapped side is toward ball. Apply a small amount of
grease to new gasket (55) and install it in drain
valve assembly.
NOTE: The gasket will protrude from the end of the
valve until the valve is tightened into pump, which
correctly seats the gasket.
Replacement
1. Apply a small amount of thread sealant (110110)
onto drain valve assembly (51) threads. Tighten
the valve into the pump manifold (229) to 185 in-lb
(21 Nm).
2. Lightly grease face of base (52) and install base.
Turn stem so pin hole is vertical.
3. Securely install handle (54) and drive pin (53).
30 308801
Technical Data
Power Requirements 120 VAC, 60 Hz,. . . . . . . . . . . . .
1 phase, 15A minimum
Generator 3000W minimum. . . . . . . . . . . . . . . . . . . . . . .
Working Pressure Range 0–3000 psi. . . . . . . . . . . . . . .
(0–210 bar, 21 MPa)
Motor 0.9 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with latex at 2000 psi (138 bar, 13.8 MPa)
Cycles/Gallon (liter) 566 (150). . . . . . . . . . . . . . . . . . . . .
Maximum Delivery Rating 0.6 gpm (2.3 lpm). . . . . . . .
Tip Size one gun to 0.026 new tip. . . . . . . . . . . . . . . . . .
with latex at 2000 psi (138 bar, 13.8 MPa)
Power Cord 14 AWG, 3 wire, 15 ft (4.5 m). . . . . . . . . . .
Inlet Paint Strainer 16 mesh (975 micron). . . . . . . . . . . .
Stainless Steel Screen, reusable
Outlet Filter 60 mesh (238 micron). . . . . . . . . . . . . . . . . .
Pump Inlet Size 3/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Outlet Size 1/4 npsm. . . . . . . . . . . . . . . . . . . . . . . .
Wetted Parts: Zinc-plated carbon steel,. . . . . . . . . . . . .
Aluminum, Stainless steel,
Polyethylene, Delrin, Leather
Tungsten carbide, Chrome plating, Polyurethane
NOTE: Delrin
re trademarks of the DuPont Company.
Dimensions
Models 232132 and 232133 Models 232130 and 232131
Weight (dry w/o packaging) 61 lb (27.7 kg). . . . . . . . . .
Length 25.5 in. (648 mm). . . . . . . . . . . . . . . . . . . . . . . . .
Width 15 in. (381 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height 20 in. (508 mm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (dry w/o packaging) 73 lb (33.1 kg). . . . . . . . . .
Length 21 in. (533 mm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 20.5 in. (521 mm). . . . . . . . . . . . . . . . . . . . . . . . . .
Height (Handle Down) 28.5 in. (711 mm)
Accessories
DANGER LABELS
The English language DANGER label shown on page 4
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.
Order the labels directly from Graco, free of charge:
1–800–328–0211
French 187784
Spanish 185956
German 185961
Greek 186041
Korean 186045
English 187791
Apply other
language here
7728A
308801 31
Complete Sprayer Parts
Model 232132 and 232133, Series A
99
70 Ref
71
74
73 Ref
72
73 Ref
34
35
11
48
49
47
12
14
65
15
50
16
2
4
66
44
19
97
57
33
9
3
4
85
7
51
2a
20
24
22a
22
41
13
23
25
26
42
21
75
95
73
9
8
5
6
68
67
69
55
56
101
60
40
32
31
37
70
39
38
64
10
46
Pressure Control Box
(Bottom View)
30
29
45
43
18
28
36
52
53
54
103
27
7745A
17
78 82
76
77
80
81
102
30 Ref
80 Ref
67 Ref
78
96
22a
100
7730A
107
108
77 Ref
7869B
32 308801
Complete Sprayer Parts
Model 232132 and 232133, Series A
Ref.
No. Part No. Description Qty.
2 240057 KIT, housing, drive, U–695 1
2a 100069 BALL, thrust 1
3 101682 SCREW, sch, 1/4–20 x .625 2
4 105510 LOCKWASHER, 1/4 hi–collar 5
5 239979 CRANKSHAFT, U–695 1
6 180131 BEARING, thrust, front 1
7 107434 BEARING, thrust, rear 1
8 189270 BRACKET, shield 1
9 108865 SCREW, panh 5
10 193718 NIPPLE, 1/4 npt x 14 npsm 1
11 236366 KIT, cover, front, U–695 1
12 240519 CONNECTING, rod assy 1
13 218364 GEAR, assy, 2nd stage 1
14 176818 PIN, straight 1
15 176817 SPRING, retaining 1
16 103345 SCREW, sch, 1/4–20 x 1.25 3
17 111706 SCREW, mach, sch, 7/16 x 1.75 2
18 239769 KIT, pump, displacement 1
see manual 308815
19 112620 SCREW, 6–32 x 0.187 4
20 189105 HOUSING, junction box 1
21 112158 GASKET, motor 1
22 192844 HEAT SINK, does not include 22a 1
22a 240168 KIT, board, control, motor 1
see manual 308816
23 112379 SCREW, filh, 10–24 x 0.75 2
24 112159 GASKET, heatsink 1
25 112381 SCREW, panh, 10–24 x 3.5 2
26 114417 SCREW, panh, 8–32 x 0.5 2
27 114273 KNOB, potentiometer 1
28 193056 LABEL, pressure adjust 1
29 108295 BUSHING, strain relief 1
30 239995 CORD, power set 1
31 114053 SCREW, trusshead, 8–32 2
32 240318 KIT, shield, motor, U–695 1
includes 9, 31, & 37; 33 & 57
33 187784 LABEL, DANGER, French 2
34 114406 SCREW, filh, 8–32 x 1.0 4
35 192617 LABEL, cover, front 1
36 111612 ADAPTER, tube 1
37 114052 NUT, self–retaining 2
38 112612 CAP, hub 2
39 112607 WHEEL, semi–pneumatic 2
40 109570 WASHER, plain 2
41 100069 BALL, thrust 1
42 112759 PLUG, tube 2
43 192808 TUBE, suction 1
44 235004 STRAINER, 1/2 npsm 1
45
104938 PACKING, o-ring 1
46 192644 NIPPLE, long, 1/4 npt x 1/4 npt 1
47 187624 HOSE, suction, swivel 1
Ref.
No. Part No. Description Qty.
48 240038 FILTER, fluid 1
see manual 308249
49 114026 CLIP, spring 1
50 187652 HOSE, drain assy 1
51
235014 ASSEMBLY, drain valve 1
includes 55 and 56
52 224807 VALVE, base 1
53 111600 PIN, grooved 1
54 187625 HANDLE, drain valve 1
55 111699 GASKET, seat valve 1
56 187615 SEAT, valve, lapped 1
57 187791 LABEL, DANGER, English 2
60 187975 LABEL, WARNING, elec shock 1
64 206994 LIQUID, throat seal 1
65 114296 GROMMET, cable 1
66 112396 RING, external retaining 1
67 240514 TRANSDUCER, pressure control 1
68 189269 SPACER, transducer 1
69 104319 PACKING, o-ring, PTFE
70 239999 FRAME,cart, U–695 1
71 109567 PIN, spring, straight 2
72 178565 BUTTON, spring 1
73 189934 HANDLE, cart 1
74 280290 BUSHING, sleeve, molded 2
75 110997 SCREWS, 1/4–20 x .625 4
76 112382 NUT, shaft sealing 1
77 236352 POTENTIOMETER, pressure adj 1
78 110037 SCREW, sltd hex hd, 10–24 x .3751
80 111930 SWITCH, toggle 1
81 105658 RING, locking 1
82 105659 BOOT, toggle 1
85 240035 KIT, motor, electric, DC 1
95 114420 SCREW 4
96 240495 WIRE, electrical, 5”, (F),18 AWG 1
97 192838 LABEL, warning 2
99 114271 STRAP, hose 1
100* 214701 HOSE, whip, 3/16” x 3’ 1
101* 220955 SPRAY GUN, contractor 1
see manual 307614
102* 223541 HOSE, 1/4” x 50’ 1
103 193072 LABEL, pressure 1
107 114422 SCREW, pnhd 1
108 240498 WIRE, ground 1
*Not supplied with sprayer Model 232132
Extra Warning Labels available free
Replace Ref. No. 45 with 114048 and o-ring 169110 in Ref.
No. 51 assembly 235014 with 112319 if using severe
solvents such as lacquer thinner and acetone.
1
308801 33
Complete Sprayer Parts
Model 232130 and 232131, Series A
9
8
2
4
16
65
12
11
34
66
35
73
99
60
105
57
33
9
3
4
85
21
7
41
5
68
67
69
6
2a 13
23
20
24
22a
2622
75
95
32
31
37
74
72
79
71
19
70
14
15
48
46
Pressure Control Box
(Bottom View)
49
98
47
17
45
18
43
44
55
28
84
52
53
54
27
56
51
103
25
102
76
77
42
82 Ref
67 Ref
78
39
101
96
40 38
100
22a
64
7729A
107
108
30 29 78
34 308801
80
81
82
7745A
30 Ref
77 Ref
7869B
Complete Sprayer Parts
Model 232130 and 232131, Series A
Ref.
No. Part No. Description Qty.
2 240057 KIT, housing, drive, U–695 1
2a 100069 BALL, thrust 1
3 101682 SCREW, sch, 1/4–20 x .625 2
4 105510 LOCKWASHER, 1/4 hi–collar 5
5 239979 CRANKSHAFT, U–695 1
6 180131 BEARING, thrust, front 1
7 107434 BEARING, thrust, rear 1
8 189270 BRACKET, shield 1
9 108865 SCREW, panh 5
11 236366 KIT, cover, front, U–695 1
12 240519 CONNECTING, rod assy 1
13 218364 GEAR, assy, 2nd stage 1
14 176818 PIN, straight 1
15 176817 SPRING, retaining 1
16 103345 SCREW, sch, 1/4–20 x 1.25 3
17 111706 SCREW, mach, sch, 7/16 x 1.75 2
18 239769 KIT, pump, displacement 1
Manual 308815
19 109032 SCREW, 10–24 x 0.250 4
20 189105 HOUSING, junction box 1
21 112158 GASKET, motor 1
22 192844 HEAT SINK, does not include 22a 1
22a 240168 KIT, board, control, motor 1
23 112379 SCREW, filh, 10–24 x 0.75 2
24 112159 GASKET, heatsink 1
25 112381 SCREW, panh, 10–24 x 3.5 2
26 114417 SCREW, panh, 8–32 x 0.5 2
27 114273 KNOB, potentiometer 1
28 193056 LABEL, pressure adjust 1
29 108295 BUSHING, strain relief 1
30 239995 CORD, power set 1
31 114053 SCREW, trusshead, 8–32 2
32 240318 KIT, shield, motor, U–695 1
includes 9, 31, & 37; 33 & 57
33 187784 LABEL, DANGER, French 2
34 114406 SCREW, filh, 8–32 x 1.0 4
35 192617 LABEL, cover, front 1
37 114052 NUT, self–retaining 2
38 104811 CAP, hub 2
39 106062 WHEEL, semi–pneumatic 2
40 101242 RING, retaining, wheel 2
41 100069 BALL, thrust 1
42 108691 PLUG, tube 2
43 192809 TUBE, suction 1
44 187190 STRAINER, 1/2 npsm 1
45 112777 SCREW, 8–32 x 38 2
46 193718 NIPPLE, 1/4 npt x 1/4 npsm 2
47 190321 HANGER, pail 1
48 240038 FILTER, fluid 1
Manual 308249
Ref.
No. Part No. Description Qty.
49 192648 CLIP, spring 1
51
235014 ASSEMBLY, drain valve 1
includes 55 and 56
52 224807 VALVE, base 1
53 111600 PIN, grooved 1
54 187625 HANDLE, drain valve 1
55 111699 GASKET, seat valve 1
56 187615 SEAT, valve, lapped 1
57 187791 LABEL, DANGER, English 2
60 187975 LABEL, WARNING, elec shock 1
64 206994 LIQUID, throat seal 1
65 114296 GROMMET, cable 1
66 112396 RING, external retaining 1
67 240514 TRANSDUCER, pressure control 1
68 189269 SPACER, transducer 1
69 104319 PACKING, o-ring, PTFE
70 240007 FRAME,cart, U–695 1
71 110243 RING, retaining, handle 2
72 111590 BUTTON, spring 2
73 239998 HANDLE, cart 1
74 192027 SLEEVE, cart 2
75 110997 SCREWS, 1/4–20 x .625 4
76 112382 NUT, shaft sealing 1
77 236352 POTENTIOMETER, pressure adj 1
78 110037 SCREW, sltd hex hd, 10–24 x .3751
79 183350 WASHER, flat 2
80 111930 SWITCH, toggle 1
81 105658 RING, locking 1
82 105659 BOOT, toggle 1
84 240017 TUBE, drain 1
85 240035 KIT, motor, electric, DC 1
95 114420 SCREW 4
96 240495 WIRE, electrical, 5”, (F),18 AWG 1
98 192840 LABEL, WARNING, finger pinch 1
99 114271 STRAP, hose 1
100* 214701 HOSE, whip, 3/16” x 3’ 1
101* 220955 SPRAY GUN, contractor 1
Manual 307614
102* 223541 HOSE, 1/4” x 50’ 1
103 193072 LABEL, pressure 1
105 192838 LABEL, WARNING, French 1
107 114422 SCREW, pnhd 1
108 240498 WIRE, ground 1
*Not supplied with sprayer Model 232130
Extra Warning Labels available free
Replace o-ring 168110 in Ref. No. 51 assembly 235014
with 112319 if using severe solvents such as lacquer thinner
and acetone.
1
308801 35
Graco Standard Warranty
Graco warrants all equipment referenced in this document 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. This warranty applies only when the equipment
is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–690–2894 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Foreign Offices: Belgium, Korea, Hong Kong, Japan
Sales Offices: Minneapolis, Detroit
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
PRINTED IN U.S.A. 308801 December 1997, Revised August 1999
36 308801
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