Page 1
INSTRUCTIONS-PARTS LIST
308802
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
120 VAC
ULTRAMAX 1595
AIRLESS PAINT SPRAYER
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
Model 232160, Series A
Basic sprayer on Upright cart without
hose or gun
Model 232161 Series A
Complete sprayer on Upright cart with hose,
gun, RAC IV DripLess Tip Guard
and SwitchTip
Model 232162, Series A
Basic CSA/UL sprayer on Upright cart without
hose or gun
Rev. E
First choice when
quality counts.
Model 232163 Series A
Complete CSA/UL sprayer on Upright cart with hose,
gun, RAC IV DripLess Tip Guard
and SwitchTip
U.S. PATENT NO. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
Related Manuals
Displacement Pump 308798. . . . . . . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7952A
MODEL 232161
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Page 2
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 14. . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 15. . . . . . . . . . . . . . . . . . . . .
Pressure Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 18. . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Wiring 20. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Motor Replacement 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement 23.
Drive Housing Replacement 24. . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 26. . . . . . . . . . . . . . . . . . . . .
Accessories 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 36. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 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 Graco 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 35 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.
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.
2 308802
Page 3
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.
3308802
Page 4
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 35 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.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
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 308802
Page 5
Component Identification and Function
V
T
S
R
03008
W
K
J
Fig. 1
A Motor DC motor, permanent magnet, totally enclosed, fan cooled
B Drive Assembly Transfers power from DC motor to the displacement pump
C Pail Hanger Container for fluid to be sprayed may be hung here
D Displacement Pump Transfers fluid to be sprayed from source through spray gun
E Primary Fluid Outlet Single spray gun operation is connected here
F Secondary Fluid Outlet Second spray gun operation is connected here
G Pressure Drain Valve Relieves fluid outlet pressure when open
H Fluid Filter Final filter of fluid between source and spray gun
J Pressure Adjusting Knob Controls fluid outlet pressure
K Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
L ON/OFF Switch Power switch that controls 120 VAC main power to sprayer
M 3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun to
N 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
P Contractor Gun High pressure spray gun with gun safety latch
R RAC IV Switch Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
S RAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
T Spray Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun
U Power Cord Rack Holds wrapped power cord for storage
V Spray Hose Rack Holds wrapped spray hose for storage
W 15/20 Amp Switch Allows sprayer to operate on 15A service with reduced performance
L
7148B
A
U
H
F
G
E
outlet. Works with pressure adjusting knob.
allow more flexibility when spraying
P
B
C
D
M
N
7952A
5308802
Page 6
Setup
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 overpressurization and rupture of the hose or gun.
CAUTION
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.
2. Single gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Connect gun and hose assembly to primary
fluid outlet (F). Do not use thread sealant.
c. Do not install spray tip.
3. Two gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For
more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Unscrew cap from 1/4 npsm(m) secondary
fluid outlet (E).
Do not install shutoff device between sprayer and
gun. See Fig. 1.
NOTE: See Fig. 1, except where noted.
1. Fill packing nut full with Graco Throat Seal Liquid
(TSL), supplied. Fig. 2.
Fig. 2
7677A
c. Connect gun and hose assembly to secondary
fluid outlet.
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 and
Grounding, page 7.
4. Turn ON/OFF (L) switch OFF. Plug sprayer power
cord into grounded electrical outlet at least 20 ft
(6 m) from spray area.
5. Flush pump to remove oil. See Flushing,
page 11.
6. Prepare paint according to manufacturer’s recommendations. Remove any paint skin. Stir paint
thoroughly. Strain paint through fine nylon mesh
bag (available at most paint dealers) to remove
particles that could clog filter or spray tip. This is
an important step for trouble-free paint spraying.
6 308802
Page 7
Grounding
Setup
Grounded
Outlets
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. All models require a 120 VAC, 60 Hz, 15A circuit
with a grounding receptacle. See Fig. 3.
Fig. 3
Grounding Prong
2. Do not alter ground prong or use adapter.
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
9248A
7308802
Page 8
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,
or install or clean the spray tip.
Pressure Relief Procedure
Startup
Startup Procedure
NOTE: Flush sprayer if first-time startup.
See page 11.
NOTE: See Fig. 4 except where noted.
1. Close pressure drain valve (G).
2. Don’t install spray tip until pump is primed!
3. Put suction tube (M) into paint container.
4. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
5. Plug in sprayer power cord.
CAUTION
Do not run pump without fluid in it for more than 30
seconds to avoid damaging pump packings.
WARNING
1. Engage gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Disengage gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Engage gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loos-
en tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose obstruction.
Use this procedure each time you start sprayer to ensure sprayer is ready to operate safely.
FIRE AND EXPLOSION HAZARD
To reduce risk of static sparking and
splashing when priming or flushing
system, hold metal part of gun firmly to
side of grounded metal pail before triggering gun.
6. Prime pump.
a. Open (handle down) pressure drain valve (G).
If no secondary hose is installed, be sure secondary outlet cap is installed. Turn ON/OFF
(L) switch ON. Slowly turn pressure adjusting
knob clockwise until sprayer starts. When fluid
comes from drain hose, close pressure drain
valve (handle forward).
b. Fig. 5. Disengage gun safety latch. Following
warning, above, trigger gun until all air is
forced out of system and paint flows freely
from gun.
c. Release trigger. Engage gun safety latch.
7. Check all fluid connections for leaks. Relieve fluid
pressure before tightening connections.
8. Fig. 5. Engage gun safety latch. Install spray tip.
Install tip guard. See manual 308644, supplied.
8 308802
Page 9
Startup
9. Adjust spray pattern.
a. Increase pressure just until spray from gun is
completely atomized. Use lowest pressure
necessary to get desired results. This reduces
overspray and fogging, decreases tip wear and
extends the life of the sprayer.
b. For more coverage, use larger tip rather than
increasing pressure.
c. Test spray pattern. To adjust pattern, engage
gun safety latch, loosen retaining nut. Position
tip guard horizontally for horizontal pattern or
vertically for vertical pattern. Then tighten
retaining nut. Fig. 5.
RAC IV
HANDLE
RETAINING
NUT
GUN SAFETY
LATCH ENGAGED
GUN SAFETY
LATCH DISENGAGED
Fig. 5
Cleaning a Clogged Tip
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 8.
03008
G
Fig. 4
1. Relieve pressure.
2. Clean front of tip frequently during operation.
L
3. If spray tip clogs, release gun trigger, engage gun
safety latch, and rotate RAC IV handle 180.
See Fig. 5.
4. Disengage gun safety latch and trigger gun into
waste container. Engage gun safety latch again.
5. Rotate RAC IV handle 180 to original position,
F
E
J
M
7954A
disengage gun safety latch, and resume spraying.
6. If tip is still clogged, engage gun safety latch, shut
off and unplug the sprayer, and open pressure
drain valve to relieve pressure. Clean spray tip as
shown in manual 308644.
9308802
Page 10
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 8.
1. Check packing nut (A) daily. First relieve pressure.
Keep packing nut full of TSL at all times to help
prevent fluid buildup on piston rod and premature
wear of packings. See Fig. 6.
If pump begins to leak, loosen packing nut and
remove throat nut spacer (B). 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. When leakage
occurs again, repack the pump.
6. Coil hose and hang it on hose rack when storing it,
even for overnight, to help protect hose from kinking, abrasion, coupling damage, etc.
A
B
TIGHTEN
2. Clean fluid filter often and whenever sprayer is
stored. Follow Flushing Guidelines on page 11 for
cleaning procedure.
3. Lubricate bearing housing after every 100 hours of
operation. First relieve pressure. Remove front
cover (C). Fill bearing housing cavity (D) with SAE
10 non-detergent oil. See Fig. 7.
4. For very short shutoff periods, leave suction tube
in paint, relieve pressure, and clean spray tip.
5. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 11.
CAUTION
To prevent pump corrosion, never leave water or any
type of paint in the sprayer when it is not in use.
Pump water or paint out with mineral spirits.
Fig. 6
Fig. 7
7692A
D
C
7693A
10 308802
Page 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 with new sprayer or
sprayer that has been
stored
Spray latex paint Warm, soapy water,
Spray oil paint Mineral spirits Oil-base paint Mineral spirits Mineral spirits
Change latex to oil paint Warm, soapy water,
Change oil to latex paint Mineral spirits, then
Change colors, same base Compatible solvent
Mineral spirits, then
compatible solvent
such as water or
mineral spirits
then clean water
then clean water
soapy water, and finally, clean water
such as water or
mineral spirits
Compatible paint,
such as latex or
oil-base
Latex paint Warm soapy water,
Mineral spirits Mineral spirits Mineral spirits
Latex Warm, soapy water,
Compatible solvent
such as water or
mineral spirits
then clean water
then clean water
Mineral spirits
Mineral spirits
Mineral spirits
How to flush
6. Do not run pump dry for more than 30 seconds to
WARNING
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.
1. Follow Pressure Relief Procedure on page 8.
Engage gun safety latch. See Fig. 8.
2. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
3. Remove spray tip from gun. Remove filter bowl,
filter support and screen. Clean screen separately
and install bowl without screen or support to flush
it.
avoid damaging pump packings!
7. Follow Pressure Relief Procedure on page 8.
Engage gun safety latch.
8. Unscrew filter bowl and reinstall clean screen.
Install bowl and hand tighten.
9. Remove suction tube and screen and clean them
separately.
FILTER
BOWL
SCREEN
J
4. Put suction tube into a grounded metal pail with
1/2 gallon of compatible solvent. Close pressure
drain valve (G).
5. Start sprayer. See page 8. To save fluid still in
sprayer, trigger gun into another container until
next fluid appears, then trigger gun back into fluid
compatible solvent container. Circulate flushing
fluid a few minutes to thoroughly clean system.
G
Fig. 8
FILTER
SUPPORT
8193B
11308802
Page 12
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 8.
Check everything in the guide before disassembling the sprayer.
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Building circuit breaker opens Check all electrical wiring for damaged
insulation.
Check for other electrical appliances on
circuit.
Check position of 15–20 (LO–HIGH) amp
switch.
Sprayer will not run Check pressure control knob setting. Motor
will not run if it is at minimum setting (fully
counterclockwise).
Check for a clogged spray tip. Refer to
separate gun or tip instruction manual.
Check extension cord for visible damage.
Use a volt meter or test lamp at extension
cord outlet to check.
Check sprayer power supply cord for visible
damage such as broken insulation or wires.
Check electrical supply with volt meter. Meter
must read 105–125 VAC.
Check for motor damage. Remove drive
housing assembly. See page 24. Try to rotate
fan by hand.
WHAT TO DO
When check is not OK refer to this column
Replace any damaged wiring.
Shutdown other electrical appliances on
circuit.
Put switch in 15 amp (LO) position.
Slowly increase pressure setting to see if
motor starts.
Relieve pressure. Refer to separate gun or
tip instruction manual for tip cleaning.
Replace extension cord.
Replace power supply cord.
Reset building circuit breaker; replace
building fuse. Try another outlet.
Replace motor (1) if fan won’t turn.
Check for locked motor rotor. Unplug cord
and try to turn fan blades with a screwdriver.
Check for shorted motor. Use ohmmeter to
check for shorts between motor leads or
between motor leads and motor frame.
Defective pressure control transducer. Replace pressure control transducer. See
Poor spray pattern Check for worn spray tip. Relieve pressure and then replace the tip.
Repair gear train or pump, if damaged. Thaw
the sprayer, if frozen; See NOTE 1. Replace
the pressure control, if damaged.
Inspect for damage to motor brush leads.
Replace motor, if necessary.
page 18.
See the separate gun or tip manual.
12 308802
Page 13
Troubleshooting
TYPE OF PROBLEM WHAT TO CHECK
Motor runs and pump strokes,
but output is low or there is no
output.
If check is OK, go to next check
Check extension cord size and length. Replace cord with a larger size, grounding
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. Tighten; use thread sealant or sealing tape on
Check for worn spray tip. Follow Pressure Relief Procedure
Check motor brushes; check for loose leads
and terminals, minimum 1/2 in. brush length,
broken or misaligned springs, or brushes
binding in holders. See page 15.
Check motor armature for shorts by using an
armature tester (growler).
Check to see if pump continues to stroke
when gun trigger is released. With pump on
and primed, trigger gun momentarily, then
release and engage safety latch. Relieve
pressure, turn off and unplug sprayer.
WHAT TO DO
When check is not OK refer to this column
type extension cord.
threads, if necessary.
Warning, then replace tip. See your
separate gun or tip manual.
Replace parts as needed. See page 15.
Replace motor. See page 21.
Service pump. See manual 308798.
Motor runs but pump does not
stroke.
Motor is hot and runs
intermittently.
Check to see if intake valve ball and piston
ball are seating properly.
Check for leaking around throat packing nut
which may indicated worn or damaged
packings.
Defective pressure control transducer. Replace pressure control transducer. See
Check displacement pump connecting rod
pin (20). See page 26.
Check for frozen or hardened paint in the
pump (39).
Be sure crank in drive housing rotates; plug
in sprayer and turn on briefly to check. Turn
off and unplug sprayer.
Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
Be sure ambient temperature where sprayer
is located is no more than 90F and sprayer
is not located in direct sun.
Remove intake valve and clean. Check balls
and seats for nicks; replace if necessary.
See manual 308798. Strain paint before
using to remove particles that could clog the
pump.
Replace packings. See manual 308798.
Also check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten the packing nut/wetcup.
page 18.
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. See page 26.
Thaw. See NOTE 1. Plug in sprayer and turn
on. Slowly increase pressure setting to see if
motor starts.
Check drive housing assembly for damage
and replace if necessary. See page 27.
Decrease pressure setting or increase tip
size.
Move sprayer to shaded, cooler area, if
possible.
NOTE 1: Thaw the sprayer if water or water-based paint has frozen in it, by placing it in a warm area. Do not try to
start the sprayer until it has thawed completely. If paint hardened (dried) in the sprayer, replace the pump packings.
See manual 308798.
Determine in sprayer was turned on,
pressurized, but not operating for long
periods of time.
Turn off sprayer whenever you stop spraying
for a while and relieve fluid pressure.
13308802
Page 14
General Repair Information
CAUTION
To reduce the risk of a pressure control malfunction:
Always use needle nose pliers to disconnect a
wire. Never pull on the wire, pull on the connector.
Mate wire connectors properly. Be sure flat blade
of insulated male connector is centered in wraparound blade of female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Be sure
wires are not pinched between cover and control
box.
Tool List
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. adjustable wrench
Adjustable, open-end
wrench
Torque wrench
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure again to verify that everything
was done correctly. If necessary, see Troubleshooting on page 12, to help identify other possible
problems and solutions.
WARNING
EXPLOSION 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. Always have the motor shield in place
during regular operation to reduce the risk of burns,
fire or explosion.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
4. Reinstall motor shield before regular operation
of sprayer and replace if damaged. The cover
directs cooling air around the motor to help prevent
overheating. It can also help reduce the risk of
burns, fire or explosion; see preceding WARNING.
WARNING
ELECTRIC SHOCK 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 repair.
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.
14 308802
Page 15
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in. Note
that brushes wear differently on each side of motor, so check both. Brush Repair Kit 220853 is
available. A new spring clip, 110816, may be
purchased separately.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 8.
NOTE: Read General Repair Information on page 14
before doing this procedure.
1. Relieve pressure.
2. Remove motor shield (54). Remove inspection
covers (B) and gaskets on each side of motor.
See Fig. 9.
54
5. 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.
CAUTION
When installing the brushes, follow all steps carefully
to avoid damaging the parts.
6. Install new brush so lead is in long slot of holder.
See Fig. 11.
BRUSH HOLDER
SHORT SLOT
LONG SLOT
BRUSH
SPRING
CLIP
Fig. 9
B
7703B
3. Push in spring clip to release hooks from brush
holder. Pull out spring clip. See Fig. 10.
SPRING
Fig. 10
HOOK
BRUSH
SPRING CLIP
110816
01227
4. Loosen brush lead terminal screw. Pull brush lead
away, leaving motor lead terminal in place. Remove brush and spring. See Fig. 12.
Fig. 11
NOTE: SPRING MUST COIL
IN THIS DIRECTION
01227
7. Slide terminal under terminal screw washer and
tighten screw. Be sure motor lead is still connected
at screw. See Fig. 12.
SPRING
BRUSH
Fig. 12
TERMINAL SCREW
MOTOR LEAD
TERMINAL
SPRING CLIP
BRUSH LEAD
01227
8. Place spring on brush as shown in Fig. 11.
9. Install spring clip and push it down to hook short
slots in housing. See Fig. 11.
10. Repeat for other side.
15308802
Page 16
Motor Brush Replacement
11. Test brushes.
a. Remove pump connecting rod pin.
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 must not trail or circle
around commutator surface.
CAUTION
Do not run the sprayer dry for more than 30 seconds
while checking the brushes to avoid damaging the
displacement pump packings.
12. Install brush inspection covers and gaskets.
13. Break in brushes.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch brushes, leads, springs or
brush holders when sprayer is plugged
in to reduce risk of electric shock and
serious bodily injury.
a. Operate sprayer for one hour with no load.
b. Install connecting rod pin.
16 308802
Page 17
Pressure Control
CAUTION
Pressure Control Replacement
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 dis-
charge.
Motor Test
With motor shield off and four motor leads disconnected:
1. Check continuity with multimeter from each black
motor lead to ground (one at a time). Any reading
less than infinite resistance – even very high resistance – means motor is shorted to ground. Replace 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 8.
1. Relieve pressure.
2. Remove two screws (19) holding filter
assembly (A). See Fig. 14 and parts list, except as
noted.
3. Remove filter assembly by unthreading swivel
union (15) from hex nipple (103). Unthread nipple
from pressure control (5)
4. Remove 8 screws (64) and motor shield (14).
5. Remove outlet cover (221) on pressure control
wiring box. Disconnect motor leads. See Fig 13.
6. Loosen electrical tubing (22) from pressure control
fitting and pull out wires
CAUTION
A motor that is shorted to ground will damage the
pressure control.
2. Remove fan cover from motor.
3. Remove pump pin ( See page 26 for instructions to
remove pin).
4. With black motor leads not connected, use motor
fan to spin motor quickly. Motor should spin freely
in both directions. If not, replace motor.
5. Connect black motor leads together.
6. Use motor fan to turn motor. It should be much
harder to turn than in step 4. If there is uneven or
no resistance to turning, check brushes and replace if necessary.
7. Remove hose (28) from rear of pressure
control swivel union (15).
8. Support pressure control (5) and carefully remove
motor mount screws (37). Remove pressure
control.
9. Install new pressure control (5) with screws (37).
10. Continue to assemble sprayer.
Black
Black/White
Black
7. If there is still uneven or no resistance to turning,
replace motor.
8. Install pump pin and fan cover.
Fig 13
Red
7145A
Yellow
17308802
Page 18
Pressure Control
Fig 14
37
19
A
64
14
5
221
15
103
22,85
1
28
15
06964A
1 Seals (85) located inside conduit (22)
7957A
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 8.
1. Relieve pressure.
2. Remove power cord (90) and plug retainer (89) by
removing screws (230) and washers (229).
3. Remove screws (213) and lockwashers (214).
Carefully remove control housing (202) from
control motor board (201) so internal wiring is not
damaged. Lay housing on side next to control
motor board. See Fig. 15 and parts list.
4. Remove and replace only those components and
wires necessary for repair. Make a diagram showing wire hook-ups for items removed to insure
correct wiring when reinstalling. See Fig 16 for
wiring information.
18 308802
5. Install control housing (202) to motor control
board (201) using screws (213) and
lockwashers (214).
Pressure Control Transducer and O-Ring
Replacement
WARNING
FIRE AND EXPLOSION HAZARD
Proper o-ring replacement is essential to
reduce the risk of fire or explosion which
can result in serious injury and property
damage. Also read FIRE OR EXPLO-
SION HAZARD on page 4.
NOTE: Do not replace o-ring unless damaged or if
leakage is seen around weep hole, o-ring or
transducer.
1. See Fig. 15 and pressure control part list. Disassemble pressure control as in steps 1 through 4 on
page 18 and remove old transducer (219) and, if
necessary, old o-ring (220).
Page 19
Pressure Control Repair
229
202
214
216
218
217
219
220
A
213
215
230
90 REF
89 REF
1
213
B
Torque to 150 in–lb (17 N.m)
1
Fig 15
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.
NOTE: O-ring (220) is made of PTFE which is difficult
to install.
214
C
201
7202D
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.
6. When o-ring is correctly installed, reinstall transducer and tighten screws to 150 in–lb (17 N.m).
Install spacer (216) and C-clip (215). Connect
electrical lead and assemble sprayer.
3. Carefully slide new transducer and plastic
spacer (217) down bore. Loosely attach
bracket (218), screws (213), and washers (214).
4. Seat transducer into o-ring by drawing down
screws and washers until bracket is flush with
motor control surface.
7. Follow Operation Startup procedures for sprayer
on page 8 using compatible fluid.
8. Inspect weep hole (C) for any leakage.
9. If any leakage is present, replace o-ring repeating
steps 1 through 9.
19308802
Page 20
Pressure Control Wiring
GRN/YEL wire, E to housing ground
ON/Off sw
WHITE
wire ON/
OFF SW–5
to to L2 on
board
BLACK
wire ON/
OFF SW–2
to to L1 on
board
Twisted pair
Twisted pair
64
1253
To J3
Housing ground
L
E
N
BLACK wire, L to on/off sw–1
WHITE wire, N to on/off sw–4
Red wires to I1
and I2 on board
Twisted pair
7369A
From control housing,
one red wire to I1
From control housing,
one red wire to I2
Connector from
potentiometer to J3
Twisted pair
Wires J4/J5 to
15/20 switch
I1
I2
J3
J5 J4
J6
Connector from pressure
transducer to J6
L2
From control
housing, WHITE
wire to L2
From control
housing, BLACK
wire to L1
L1
J7
GND
Ground wire to
housing ground
7135B
Fig 16
20 308802
Page 21
Motor 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 8.
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 dis-
charge.
NOTE: Refer to Fig. 17 and parts list, except as
noted.
1. Relieve pressure.
2. Remove motor shield (14). Remove front cover
(31). Disconnect hose (28) at pump. Disconnect
drain hose (79) from pump (39).
3. Remove outlet cover on pressure control wiring
box. Disconnect four motor leads. See Fig 13.
4. Unscrew conduit connector (16) from motor and
pull motor leads from tubing (22).
5. Remove screws (33) from recess of drive housing.
6. Remove screws (21 and 30) from motor bell (F).
7. Use a plastic mallet to tap displacement pump (39)
from rear to loosen drive housing (18) from motor
bell (F). Pull off drive housing.
CAUTION
DO NOT drop gear cluster (9) when removing drive
housing (18). The gear cluster may stay engaged in
the motor front end bell or the drive housing.
DO NOT lose thrust balls (10) located at each end of
gear cluster (9) or drop them between gears. The
balls, which are heavily covered with grease, usually
stay in the shaft recesses, but could be dislodged. If
caught between gears and not removed, the balls will
seriously damage the drive housing. If the balls are
not in place, the bearings will wear prematurely.
8. Lower pressure control (5) by unscrewing motor
mounting screws (37).
9. Lift off motor (1).
10. Mount and center new motor on frame and attach
pressure control (5) with motor mounting screws
(37).
11. Insert motor leads through connector (16) and
tubing (22) to pressure control. Screw connector
(125) two or three threads into motor. Tighten
locknut up to motor. Connect four motor leads.
See Fig. 13.
12. Liberally grease gear cluster (9) and pinion gear
(G) and pack all bearings in motor bell. Be sure
thrust balls (10) are in place. (One ball is included
with a replacement drive housing.)
13. Align gears and push drive housing (18) straight
onto motor bell (F) and locating pins.
14. Continue to reassemble sprayer.
21308802
Page 22
37
Motor Replacement
1
Seals (93) located inside conduit (22)
Apply 6 ounces bearing grease
2
14
1
21
F
G
10
9
2
16
22
1
30
Fig. 17
28
10
18
33
31
5
39
79
7957A
22 308802
Page 23
Bearing Housing and Connecting Rod
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 8.
NOTE: Read General Repair Information on page 14
before doing this procedure. See Fig. 18.
NOTE: Stop sprayer at bottom of its stroke to get crank
(E) in its lowest position.To lower crank manually, carefully rotate blades of fan with a screwdriver.
1. Relieve pressure.
2. Remove front cover (31). Unclip drain hose (79)
from pump. Hold a wrench on pump intake valve
(H) and unscrew pump suction tube (42). Disconnect pump hose (28).
3. Push up retaining spring (35). Push pin (20) out
rear.
11. Align connecting rod (29) with crank (E) and drive
housing locating pins (G) with bearing housing (27)
holes. Push bearing housing onto drive housing or
tap it into place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screws (33) to try
to align or seat the bearing housing; the bearing and
drive housing will not align properly and will result in
premature bearing wear.
12. Install screws (33) and lockwashers (49). Tighten
screws evenly to 300 in-lb (34 N.m).
13. Install pump. See page 27.
14. Install remaining parts. See Fig. 18.
B
14
E
OIL
PACK WITH
C
BEARING GREASE
29
49
TORQUE TO
300 in-lb (34 N.m)
33
31
4. Loosen locknut (38). Unscrew displacement
pump (39).
5. Remove four screws (33) and lockwashers (49).
6. Lightly tap lower rear of bearing housing (27) with
a plastic mallet to loosen it from drive housing (14).
Pull bearing housing and connecting rod assembly
(29) straight off drive housing.
7. Remove pail bracket assembly (F) and install with
locknuts (13) on new bearing housing.
8. Inspect crank (E) for excessive wear and replace
parts as needed. Evenly lubricate inside of bronze
bearing (B) with high quality motor oil. Liberally
pack roller bearing (C) with bearing grease.
9. Assemble connecting rod (29) and bearing
housing (27).
10. Clean mating surfaces of bearing (27) and
drive (14) housings.
25
28
Fig. 18
13
27
G
35
38
20
F
101
39
H
86
79
42
7955A
23308802
Page 24
Drive Housing Replacement
3. Remove four bearing housing screws (33) and
WARNING
lockwashers (49).
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 8.
CAUTION
DO NOT drop gear cluster (9) when removing drive
housing (18). Gear cluster may stay engaged in the
motor front end bell or the drive housing.
DO NOT lose thrust balls (10) located at each end of
gear cluster (9) or drop them between gears. The
balls, which are heavily covered with grease, usually
stay in the shaft recesses, but could be dislodged. If
caught between gears and not removed, the balls will
seriously damage drive housing. If the balls are not
in place, the bearings will wear prematurely.
NOTE: Read General Repair Information on page 14
before doing this procedure. See Fig. 19.
1. Relieve pressure.
2. Remove front cover (31) and motor shield (14).
Unclip drain hose (79) from pump.
4. Lightly tap lower rear of bearing housing (27) with
a plastic mallet to loosen it from drive housing (18).
Pull assembled bearing housing and connecting
rod straight off drive housing.
5. Remove two drive housing screws (51) and
lockwashers (63).
6. Remove two lower screws (30) and lockwashers
(63) and then two upper screws (30) and lockwashers (63) from front of motor (1).
7. Tap drive housing (18) with a plastic mallet to
loosen it from front of motor (1), and then pull drive
housing straight off.
8. Liberally apply approximately 4 ounces of bearing
grease to gear cluster (9). Grease is supplied with
drive housing replacement kit. Be sure thrust balls
(10) are in place.
9. Align gears and push new drive housing straight
onto front of motor and locating pins.
10. Continue reassembling sprayer.
24 308802
Page 25
Drive Housing Replacement
64
21
2
63
1
14
10
9
3
18
49
27
33
10
30
2
63
1
31
63
2
51
Torque to 300 in-lb (34 N.m)
1
2
Torque to 90–100 in-lb (10.2–11.3 N.m)
3
Liberally apply grease
Fig. 19
79
7956A
25308802
Page 26
Removing pump
Displacement Pump Repair
1. Flush pump. Relieve pressure. Fig. 20. Cycle
pump with piston rod (222) in its lowest position.
2. Fig. 20. Unscrew suction tube and hose from
pump.
222
Fig. 20
3. Fig. 21. Use screwdriver to push retaining spring
(35) up and pin (20) out.
7672A
4. Fig. 21. Push out pin.
5. Fig. 22. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 22
7673A
Repairing Pump
See manual 308798 for pump repair instructions.
35
20
Fig. 21
26 308802
7675A
Page 27
Displacement Pump Repair
Installing pump
WARNING
If the pin works loose, it or other parts could break
off due to the force of the pumping action. These
parts could be projected through the air and result
in serious bodily injury or property damage, including damage to the pump, connecting rod or bearing
housing.
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
3. Fig. 25. Push retaining spring into groove all the
way around connecting rod.
1. Fig. 23. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
Fig. 23
2. Fig. 24. Push pin (21) into holes.
7676A
Fig. 25
Fig. 26. Screw jam nut down onto pump until stops.
Screw pump up into bearing housing until it is stopped
by jam nut. Back off pump and jam nut to align pump
outlet to back. Tighten jam nut by hand, then tap 1/8 to
1/4 turn with a 20 oz (maximum) hammer to approximately 75" 5 ft–lb (102 Nm).
Fig. 26
Fig. 27. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.
7674A
7673A
Fig. 24
21
7675A
Fig. 27
7677A
27308802
Page 28
Notes
28 308802
Page 29
Notes
29308802
Page 30
Parts Drawing - Sprayer
Ultra MAX 1595 Sprayers
Model 232160, Series A
Model 232162, Series A
Includes items 1 – 104
Basic Sprayer
61
14
82
74
90
REF
61
62
17
83
52
80
REF
6
89
81
64
78
55
104
84
A
A
88
108
Detail B
37
30
19
48
44
64
10
77
63
9
21
18
10
63
1
5
79 REF
237 REF
25
28
51
35
13
101
29
Ultra MAX 1595 Sprayers
Model 232161, Series A
Model 232163, Series A
Includes items 1 –107
Complete Sprayer
27
49
33
38
20
39
86
42
31
32
73
59
72
19
75
34
60
36
93
94
56
57
103
41
79
11
58
26
92
95
47
30 308802
15
71
69
53
102
43
15
Detail A–A
6
16
105
22
54,85
28 REF
50
107
106
8
24
Detail B
7951A
Page 31
Ultra MAX 1595 Sprayers
Model 232160 Series A
Model 232162 Series A
Includes items 1 – 104
Basic Sprayer
Parts List - Sprayer
Model 232161, Series A
Model 232163, Series A
Includes items 1 –107
Complete Sprayer
REF
NO. PART NO. DESCRIPTION QTY
1 220854* MOTOR, ELECTRIC 1
includes 41 and 73a
5 239750 PRESSURE CONTROL
see parts list on page 34 1
6 240143 FRAME, cart 1
8 107266 TERMINAL 2
9 220637 GEAR REDUCER 1
10 100069 BALL 2
11 104811 CAP, hub 2
13 112746 LOCKNUT, 5/16 –18 2
14 240483 SHIELD, motor 1
(includes item 77)
15 155494 UNION, swivel, 90 2
16 110138 CONNECTOR, conduct 1
17 112827 BUTTON, snap 2
18 220879 DRIVE HOUSING 1
includes 67a and 67b
19 114402 SCREW, hex hd, flanged 4
20 183210 PIN, straight, hdls 1
21 100644 SCREW, cap 2
22 065312 TUBING, electrical, flexible, 5.5 in. 1
24 107264 TERMINAL 2
25 161889 UNION, swivel 1
26 154636 WASHER 2
27 240701 BEARING HOUSING (includes
items 13 and 73) 1
28 240246 HOSE, coupled, 3/8 in. by 20 in. 1
29 220640 ROD CONNECTING KIT 1
30 100643 SCREW, cap 2
31 188423 COVER, housing 1
32 108850 SCREW, mach, filh 4
33 110141 SCREW, cap, sch 4
34 193081 BRACKET, manifold, filter 1
35 183169 SPRING, retaining 1
36 111699 GASKET, seat, valve 1
37 110963 SCREW, flange, hex hd 4
38 193031 NUT, retaining 1
39 240291 KIT, pump, displacement 1
see manual 308798 for parts
41 112538 ELBOW, 90, street, reducing 1
42 193097 TUBE, suction 1
43 240131 PLUG, packless 1
44 114271 STRAP, retaining 1
47 206994 THROAT SEAL LIQUID, 8 OZ 1
48 240315 BOWL, filter (includes 71) 1
49 106115 WASHER, lock, spring 4
50 181072 STRAINER, inlet 1
51 108849 SCREW, cap, sch 2
52 110243 RING, retaining 2
53 108691 PLUG, tubing 2
54 108460 CONNECTOR, conduit, 45 1
55 192839 LABEL, caution 1
REF
NO. PART NO. DESCRIPTION QTY
56 104361 PACKING, o-ring 1
57 164672 ADAPTER 2
58 101242 RING, retaining, ext. 2
59 167025 STRAINER, 60 mesh 1
60 179811 WHEEL, semi-pneumatic 2
61 240136 HANDLE, cart 1
62 192027 SLEEVE, cart 2
63 105510 WASHER, lock, spring 6
64 108865 SCREW, machine, pan hd 10
69 111482 RIVET, snap 1
71 171941 SPRING, compression 1
72 186075 SUPPORT, filter 1
73 192719 HANGER, pail 1
74 100020 CONNECTOR, tube, female 2
75 187615 VALVE, seat 1
77 187791 LABEL, danger, English 1
79 240144 HOSE, drain 1
80 109032 SCREW, machine, pan hd 4
81 185384 BRACKET 2
82 110240 NUT, self-retaining 2
83 183350 WASHER 2
85 107447 SEAL, conduit 2
86 192691 CLIP, spring 1
87 290447 LABEL, warning
(on brush covers–not shown) 3
88 187784 LABEL, danger, French 1
89 114426 RETAINER, plug 1
90 114514 CORD SET (used on 232160, 232161) 1
114515 CORD SET, CSA
(used on 232162, 232163) 1
92 235014 DRAIN VALVE ASSEMBLY 1
93 224807 CAM, drain valve 1
94 111600 PIN, grooved 1
95 187625 HANDLE, valve, drain 1
101 162485 NIPPLE, adapter 1
102 193024 NIPPLE, hex 1
103 240700 HOUSING KIT, filter 1
104 187975 LABEL, warning, English 1
105 238361 HOSE, grounded, nylon, 1/4” ID, 1
cpld 1/4 npsm(f), 50 ft (15 m)
spring guards both ends
106 238358 HOSE, grounded, nylon, 3/16” ID, 1
cpld 1/4 npsm(f), 3 ft (.9 m),
spring guards both ends
107 220955 SPRAY GUN 1
see manual 307614 for parts
108 192838 LABEL, warning. French 1
(used on 232162, 232163)
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available.
Order separately.
31308802
Page 32
Notes
32 308802
Page 33
Pressure Control Drawing
209
210
208
204
203
205
214
218
217
212
213
207
229
90 REF
230
228
90a REF
234
211
202
3
206
1
215
216
238
220
4
219
201
225
224
236
235
214
213
227
237
226
221
Torque to 150 in–lb (17 N.m)
1
To housing ground, Fig. 16.
2
Located this point, inside housing
3
WARNING! See Pressure Control Transducer and O-Ring Replacement on page 18 for correct replacement procedure.
4
222
Fig 28
232
233
231
2
54 REF
7202D
33308802
Page 34
Pressure Control Parts List
Part Number 239750
Pressure Control
Includes items 201 – 327
Ref
No. Part No. Description Qty
239750 PRESSURE CONTROL 1
See Ref. No. 5 on page 31 for
location on Sprayer
201 239751 MOTOR CONTROL BOARD 1
202 239752 CONTROL HOUSING 1
For complete assembly, order part
number 239442.
203 111930 . SWITCH, toggle (15/20) 1
204 105658 . RING, locking 1
205 105659 . BOOT, toggle 1
206 111961 . SWITCH, rocker (on/off) 1
207 236352 . POTENTIOMETER (pressure adjust) 1
208 112382 . NUT, shaft sealing 1
209 114273 . KNOB, control 1
210 193072 . LABEL, control knob 1
211 192226 . SPACER, switch 1
212 112788 . SCREW, cap hd 2
213 100644 SCREW, cap 5
214 100016 WASHER, lock 5
215 114031 CLIP, cee 1
216 192223 SPACER, transducer 1
217 192144 SPACER, transducer 1
218 192145 BRACKET, transducer 1
219 236353 TRANSDUCER, pressure control 1
220 104319 PACKING, o-ring
Pressure Control Transducer and O-Ring
Replacement on page 18 for correct
replacement procedure.
Replacement Danger and Warning labels, tags and cards are available at no cost.
These parts are included on all sprayers as shipped, but not on replacement pressure control 239750.
* These parts are included with replacement pressure control 239750, but are not on all sprayers as shipped.
WARNING! See 1
Ref
No. Part No. Description Qty
221 192050 ELECTRICAL ENCLOSURE KIT 1
222 M71503 SCREW 2
224 192142 PLUG 1
225 104836 SCREW 4
226 110637 SCREW 2
227 192155 COVER 1
228 113799 INLET, ac power 1
229 114027 WASHER, flat 2
230 111714 SCREW, machine, phillips, pan hd 2
231 189930 LABEL, caution 1
232 157021 WASHER, lock, internal 1
233 111593 SCREW, grounding 1
234 186620 LABEL, ground 1
235 111710 O-RING 1
236 111711 RING, backup 1
237 101754 PLUG, pipe 1
238 192212 PAD, foam 1
323* 235009 SWITCH TRANSDUCER (not shown) 1
324* 192150 BLOCK, transducer (not shown) 1
325* 108850 SCREW, machine, fil hd (not shown) 4
326* 111704 SCREW, machine, fil hd (not shown) 2
327* 239530 SWITCH (not shown) 1
34 308802
Page 35
Accessories
Technical Data
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 shows the best placement of these labels for
good visibility.
Order the labels from your Graco distributor.
Apply other
language here
French 187784
Spanish 185962
German 186042
Greek 186046
Korean 186050
7954A
Power Requirements 120 VAC, 60 Hz,. . . . . . . . . . . . . . . . . . . .
Working Pressure Range 0–3000 psi (0–210 bar, 0–21 MPa)
Cycles/Gallon (liter) 118 (31). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Delivery Rating 1.25 gpm (4.75 lpm). . . . . . . . . . . . .
Tip Size: one gun – 0.035; two guns – 0.023; three guns – 0.018
Power Cord 12 AWG, 3 wire, 15 ft (4.5 m). . . . . . . . . . . . . . . . .
Inlet Paint Strainer 16 mesh (975 micron). . . . . . . . . . . . . . . . .
Outlet Paint Filter 60 mesh (238 micron). . . . . . . . . . . . . . . . . .
Pump Inlet Size 3/4 npt(m). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Outlet Size
Filter 3/8 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter with standard 3/8 npt(f) to 1/4 npsm adapter 1/4 npsm
Sound Data
Sound pressure level at one meter 85.3 db(A). . . . . . . . . . .
Sound power level 95.2 db(A). . . . . . . . . . . . . . . . . . . . . . . . .
Measured under maximum operating conditions per
ISO–3744
Basic Sprayer Wetted Parts: zinc-plated carbon steel,. . . . . .
NOTE: Delrin
1 phase, 15A minimum or 5000W generator
(with latex at 2000 psi (138 bar, 13.8 MPa)
(with latex at 2000 psi (138 bar, 13.8 MPa)
stainless steel screen, reusable
stainless steel screen, reusable
polyurethane, polyethylene, stainless steel,
PTFE,
is a registered trademark of the
Delrin ,chrome plating, leather,
V-Max
stainless steel, tungsten carbide
UHMWPE, aluminum,
DuPont Co.
6.1 rotoM HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions
Weight (dry w/o packaging) 140 lb (63.5 kg). . . . . . . . . . . . . . .
Height 30.5 in. (775 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length 25.5 in. (648 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 22.5 in. (572 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35308802
Page 36
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”.
Graco 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
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN USA 308802 March 1998, Revised 03/2000
36 308802
Sales Offices: Minneapolis, Detroit
www.graco.com
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