Graco ULTRA MAX 1595 Instructions-parts List Manual
INSTRUCTIONS-PARTS LIST
308854
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
Airless Paint Sprayers
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
ULTRAMAX 1595
230 VAC
Model Series Description
232164 A Hi-boy with RAC IV tip, gun and hose
120 VAC
Model Series Description
232160 A Hi-Boy
232161 A Hi-Boy with RAC IV tip, gun and hose
232162 A CSA/UL Hi-Boy
232163 A CSA/UL Hi-Boy with RAC IV tip, gun
and hose
Rev. F
First choice when
quality counts.
MARK V
100 VAC
Model Series Description
232166 A Hi-Boy
230 VAC
Model Series Description
232173 A Hi-boy with RAC IV tip, gun and hose
120 VAC
Model Series Description
232171 A Hi-Boy with RAC IV tip, gun and hose
All models are not available in all countries
Table of Contents
Component Function and Identification 3. . . . . . . . . . . .
Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 4. . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 7. . . . . . . . . . . . . . . . . . . . . .
Pressure Control 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 10. . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Wiring 12. . . . . . . . . . . . . . . . . . . . . . . .
Motor Replacement 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement 14.
8194A
Model 232164
Related Manuals
Operator 308855. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 308491. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing Replacement 15. . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 16. . . . . . . . . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Warnings and Cautions
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
Fire and explosion can occur when spraying or flushing
flammable fluid in an area where air circulation is poor and
flammable vapors can be ignited by an open flame or sparks.
To help prevent a fire and explosion:
Use outdoors or in an extremely well ventilated area.
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.
Remove, extinguish or unplug all ignition sources; tape wall
switches. Do not smoke in spray area.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of a grounded pail when triggering into pail.
Use a properly grounded outlet.
Use only conductive airless paint hose.
Do not modify this equipment.
Fluid injection is a serious injury! If high pressure fluid
pierces your skin, the injury might look like “just a cut”. But it is
a serious wound! Get immediate medical attention.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Point gun away from yourself or anyone else.
Relieve pressure before checking or repairing any leak.
Relieve pressure when you turn off the sprayer or stop
spraying
Keep drain hose outlet under fluid when opening drain valve.
Relieve pressure through the gun when you turn off the
sprayer or stop spraying.
Do not use components rated less than system Maximum
Working Pressure
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
2 308854
Never allow children to use this unit. If you are injured using this
equipment, get immediate medical treatment.
Component Identification and Function
V
T
S
R
03008
W
K
LJ
7148B
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 Adjust 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 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, (3/8 in. ID, MARK V) grounded, nylon hose, spring guards both ends
P Spray 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 10/12 Amp Switch Allows Models 232164, 232173 to operate on 10A service with reduced perfor-
15/20 Amp Switch Allows Models 232160 through 232163, 232166, 232171 to operate on 15A ser-
U
H
G
F
outlet. Works with pressure adjusting knob.
allow more flexibility when spraying
mance
vice with reduced performance
A
B
C
D
E
8194A
M
P
N
3308854
General Repair Information
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect a wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires 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
WARNING
ELECTRIC SHOCK HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting, page
5, for other possible solutions.
WARNING
EXPLOSION HAZARD
Motor and drive housing are very hot
during operation and could burn skin if
touched. Flammable materials spilled on
hot, bare motor could cause fire or explosion. Have
motor shield in place during operation to reduce
risk of burns, fire or explosion.
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
4 308854
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
Extension cord size and length. Replace cord with a larger size, grounding
Paint supply. Refill and reprime pump.
Clogged intake strainer. Remove and clean strainer and reinstall. Mark
Loose suction tube or loose fittings. Tighten; use thread sealant or sealing tape on
Worn spray tip. Follow Pressure Relief Procedure
Motor brushes, loose leads and terminals,
minimum 13 mm brush length, broken or
misaligned springs, or brushes binding in
holders. See page 7.
Motor armature for shorts. Use an armature
tester (growler).
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.
V models 232171 and 232173 strainer is for
use in paint only.
threads, if necessary.
Warning, then replace tip. See your
separate gun or tip manual.
Replace parts as needed. See page 7.
Replace motor. See page 13.
Service pump. See manual 308798.
If intake valve ball and piston ball are seating
properly.
Intake valve ball is packed with material. Remove and clean intake valve. Do not
Leaking around throat packing nut which may
indicated worn or damaged packings.
Defective pressure control transducer. Replace pressure control transducer. See
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.
leave Mark V models 232171 and 232173
sprayers under pressure for more than 5
minutes when pumping texture material and
not actively spraying.
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 10.
(Continued on page 6)
5308854
Troubleshooting
Motor runs but pump does not
stroke.
Motor is hot and runs
intermittently.
Displacement pump connecting rod pin (20).
See page 16.
Frozen or hardened paint in the pump (39). Thaw. See NOTE 1. Plug in sprayer and turn
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 90
is not located in direct sun.
Determine if sprayer was turned on,
pressurized, but not operating for long
periods of time.
F and sprayer
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. See page 16.
on. Slowly increase pressure setting to see if
motor starts.
Check drive housing assembly for damage
and replace if necessary. See page 17.
Decrease pressure setting or increase tip
size.
Move sprayer to shaded, cooler area, if
possible.
Turn off sprayer whenever you stop spraying
for a while and relieve fluid pressure.
NOTE 1: Thaw sprayer in a warm area if water or water-based paint has frozen in it. Do not start sprayer until it has
thawed completely. If paint hardened (dried) in sprayer, replace pump packings. See manual 308798.
6 308854
Grounding
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. Models 232160 through 233163, 232171 require a
120 Vac, 60 Hz, 10A circuit with a grounding
receptacle. Models 232164, 232173 requires a 230
Vac, 50 Hz, 10A circuit with a grounding receptacle. Model 232166 requires a 100 Vac, 50 Hz,
15A circuit with a grounding receptacle. See Fig. 2.
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in.
Brushes wear differently on each side of motor, check both sides. Brush Repair Kit 222157
is available for Models 232164, 232173 and
Brush Repair Kit 220853 is available for Models 232160 through 232163, 232166, 232171.
Spring clip, 110816, may be purchased separately.
Motor Brush Removal
Grounded
Outlet
Fig. 2
2. Do not alter ground prong or use adapter.
3. A 1.5 mm
with this equipment.
4. Fig. 4. Push in 110816 spring clip (A) to release
hooks (B) from brush holder (C). Pull out spring
clip.
5. Fig. 4. Loosen terminal screw (D). Pull brush lead
(E) away, leaving motor lead (F) in place. Remove
brush (G) and spring (H).
Model 232164
2
by 90 m extension cord may be used
9286A
1. Read General Repair Information; page 4.
2.
3. Fig. 3. Remove motor shield (14). Remove inspection covers (B) and gaskets on each side of
motor.
14
Fig. 3
Relieve pressure; page 4.
(Continued on page 8)
A
B
7703B
H
G
Fig. 4
6. 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 wear too fast.
A
E
D
F
BC
01227
7308854
Motor Brush Replacement
Motor Brush Installation
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
7. Fig. 5. Install new brush (G) with lead in long slot
(J) of brush holder (C).
8. Fig. 4. Slide brush lead (E) under washer of terminal screw (D) and tighten screw. Be sure motor
lead (F) is connected at terminal screw.
9. Fig. 5.Place spring (H) on brush (G).
10. Fig. 5. Install spring clip (A). Push down to hook
short slots (K) in brush holder (C).
C
K
J
G
A
11. Repeat for other side.
12. 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.
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displacement pump packings.
13. Install brush inspection covers and gaskets.
14. Break in brushes.
Fig. 5
H
NOTE SPRING COIL DIRECTION
E
01227
a. Operate sprayer 1 hour with no load.
b. Install connecting rod pin.
8 308854
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