INSTRUCTIONS-PARTS LIST 308799

This manual contains important

Rev. E
warnings and information.
First choice when
READ AND KEEP FOR REFERENCE. quality counts.t
INSTRUCTIONS

120 VAC, 15A

ULTRArMAX 1095
AIRLESS PAINT SPRAYER
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure

Model 232150, Series A

Basic sprayer on Upright cart without
hose or gun
Model 232151 Series A
Complete sprayer on Upright cart with hose,
gun, RAC IVt DripLesst Tip Guard
and SwitchTipt
U.S. PATENT NO. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING

7690A

Related Manuals
Displacement Pump . . . . . . . . . . . . . . . . . . . . . 308798 .
Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307614
.
Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308644
..

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

ECOPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
 Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . Bearing Housing & Connecting Rod Replacement . 24
Component Function and Identification . . . . . . . . . . . .5 Drive Housing Replacement . . . . . . . . . . . . . . . . . . .25
.
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 27
..
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . Displacement Pump Repair . . . . . . . . . . . . . . . . . . . .29
.
Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . 9. .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
...
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 ..
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
..
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17...
General Repair Information . . . . . . . . . . . . . . . . . . . .16 . Parts Drawing – Sprayer . . . . . . . . . . . . . . . . . . . . . .32
.
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . .18 . Parts List – Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . 33
..
Power Supply Cord Replacement . . . . . . . . . . . . . . 19 . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
..
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . .19 . Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 36
..
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . .21 . Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
..

Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
his symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the
instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
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 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.

Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82
C (180
F) or below –40
C (–40
F).

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

2 308799
 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 7 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.



 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 7 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 SKIN INJECTION

EXPLOSION HAZARD HAZARD
Spray painting, flushing or cleaning equipment with flammable Liquids can be injected into the body by high pressure airless
liquids in confined areas can result in fire or explosion. spray or leaks – especially hose leaks.
Use outdoors or in extremely well ventilated areas. Ground Keep body clear of the nozzle. Never stop leaks with any part of the
equipment, hoses, containers and objects being sprayed. body. Drain all pressure before removing parts.Avoid accidental
Avoid all ignition sources such as static electricity from plastic triggering of gun by always setting safety latch when not spraying.
drop cloths, open flames such as pilot lights, hot objects such as Never spray without a tip guard.
cigarettes, arcs from connecting or disconnecting power cords In case of accidental skin injection, seek immediate
or turning light switches on and off. “Surgical Treatment”.
Failure to follow this warning can result in death or serious injury
. Failure to follow this warning can result in amputation or serious
injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

4 308799
 Component Identification and Function
V

S A

R
B
03008 U

L
C
K
J
H G
P N M D

F
E

7690A
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
outlet. Works with pressure adjusting knob.
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
allow more flexibility when spraying
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

308799 5
 Setup
2. Single gun hookup.
WARNING
Use 1/4 in. ID, 50 ft (minimum) main hose. For
If you supply your own hoses and spray gun, be more flexible gun movement, install 3/16 in. ID, 3
sure the hoses are electrically conductive, that the ft hose between main hose and gun.
gun has a tip guard, and that each part is rated for
at least 3000 psi (210 bar, 21 MPa) Working Pres- a. Connect gun, 3 ft hose and 50 ft hose.
sure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over- b. Connect gun and hose assembly to primary
pressurization and rupture of the hose or gun. fluid outlet (F). Do not use thread sealant.

c. Do not install spray tip.

CAUTION 3. Two gun hookup.
To avoid damaging the pressure control, which may
result in poor equipment performance and compo- Use 1/4 in. ID, 50 ft (minimum) main hose. For
nent damage, follow these precautions: more flexible gun movement, install 3/16 in. ID, 3
ft hose between main hose and gun.
Do not allow material to freeze in sprayer.
a. Connect gun, 3 ft hose and 50 ft hose.
Use nylon spray hose at least 50 ft (15 m) long.
b. Unscrew cap from 1/4 npsm(m) secondary
Do not use wire braid hose. fluid outlet (E).

Do not install shutoff device between sprayer and c. Connect gun and hose assembly to secondary
gun. See Fig. 1. fluid outlet.

NOTE: See Fig. 1, except where noted.

WARNING
1. Fill packing nut full with Graco Throat Seal Liquid FIRE AND EXPLOSION HAZARD
(TSL), supplied. Fig. 2. 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 10.

6. Prepare paint according to manufacturer’s recom-

mendations. Remove any paint skin. Stir paint
thoroughly. Strain paint through fine nylon mesh




Fig. 2 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 308799
 Setup
Grounding
Grounded
Outlets
WARNING
Improper installation or alteration of the grounding Grounding Prong
plug will result in a risk of electric shock, fire or Fig. 3
explosion that could cause serious injury or death.
2. Do not alter ground prong or use adapter.

3. A 12 AWG, 3 wires with grounding prong, 300 ft

1. This equipment requires a 120 VAC, 60 Hz, 15A (90 m) extension cord may be used. Long lengths
circuit with a grounding receptacle. See Fig. 3. reduce sprayer performance.

Startup
NOTE: See Fig. 4 except where noted.
WARNING 1. Put suction tube (39) into paint container.
INJECTION HAZARD 2. Turn pressure adjusting knob (J) fully counter-
The system pressure must be manually clockwise to zero pressure.
relieved to prevent the system from
starting or spraying accidentally. Fluid 3. Plug in sprayer power cord.
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
CAUTION
parts, follow the Pressure Relief Procedure Do not run pump without fluid in it for more than 30
whenever you: seconds to avoid damaging pump packings.
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment, WARNING
or install or clean the spray tip.
FIRE AND EXPLOSION HAZARD
Pressure Relief Procedure To reduce risk of static sparking and
splashing when priming or flushing
1. Engage gun safety latch. system, hold metal part of gun firmly to
2. Turn ON/OFF switch to OFF. side of grounded metal pail before triggering gun.
3. Unplug power supply cord.
4. Prime pump.
4. Disengage gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve a. Open (handle down) pressure drain valve (G).
pressure. If no secondary hose is installed, be sure sec-
5. Engage gun safety latch. ondary outlet cap is installed. Turn ON/OFF
6. Open pressure drain valve. Leave pressure drain (L) switch ON. Slowly turn pressure adjusting
valve open until ready to spray again. knob clockwise until sprayer starts. When fluid
comes from drain hose, close pressure drain
If you suspect that the spray tip or hose is completely
valve (handle forward).
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loos- b. Fig. 5. Disengage gun safety latch. Following
en tip guard retaining nut or hose end coupling to warning, above, trigger gun until all air is
relieve pressure gradually, then loosen completely. forced out of system and paint flows freely
Now clear tip or hose obstruction. from gun.
c. Release trigger. Engage gun safety latch.
Use this procedure each time you start sprayer to en-
sure sprayer is ready to operate safely. 5. Check all fluid connections for leaks. Relieve fluid
Startup Procedure pressure before tightening connections.
NOTE: Flush sprayer if first-time startup. 6. Fig. 5. Engage gun safety latch. Install spray tip.
See page 10. Install tip guard. See manual 308644, supplied.

 
 Startup
7. Adjust spray pattern. RAC IV RETAINING
HANDLE NUT
GUN SAFETY
LATCH ENGAGED
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. Use larger tip for more coverage rather than

increasing pressure.
GUN SAFETY
c. Test spray pattern. To adjust pattern, engage LATCH DISENGAGED 03008
gun safety latch, loosen retaining nut. Position Fig. 5
tip guard horizontally for horizontal pattern or
vertically for vertical pattern. Then tighten re- Cleaning a Clogged Tip
taining nut. Fig. 5.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.

1. Relieve pressure.

2. Clean front of tip frequently during operation.

3. If spray tip clogs, release gun trigger, engage gun

L safety latch, and rotate RAC IV handle 180 .
See Fig. 5.
J
G 4. Disengage gun safety latch and trigger gun into
waste container. Engage gun safety latch again.
F
E 5. Rotate RAC IV handle 180 to original position,
39 7691A disengage gun safety latch, and resume spraying.

6. If tip is still clogged, engage gun safety latch, shut

Fig. 4 off and unplug the sprayer, and open pressure
drain valve to relieve pressure. Clean spray tip as
shown in manual 308644.



 Shutdown and Care
6. Coil hose and hang it on hose rack when storing it,
WARNING even for overnight, to help protect hose from kink-
ing, abrasion, coupling damage, etc.
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.

1. Check packing nut (A) daily. First relieve pressure.

Keep packing nut full of TSL at all times to help
A
prevent fluid buildup on piston rod and premature
wear of packings. 228

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 TIGHTEN
brass rod and light hammer to adjust nut. Refer to
Fig. 6. When leakage occurs again, repack the
pump.

2. Clean fluid filter often and whenever sprayer is 7692A

stored. Follow Flushing Guidelines on page 10 for Fig. 6
cleaning procedure.
B
3. Lubricate bearing housing after every 100 hours of
operation. First relieve pressure. Remove front
cover (49). Fill bearing housing cavity (B) with SAE
10 non-detergent oil. See Fig. 7.
49
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 10.

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. 7 7693A

 
 Flushing
When to flush
Determine material to spray from column 1. Flush with CAUTION
material in column 2. Then follow recommendations in Do not leave water or water-based fluids in sprayer if
one of next three columns. it could freeze. Push water out with mineral spirits.
Frozen fluid in sprayer prevents starting and may
cause serious damage.

If you are going to: Flush with: Prime with: Clean with: Store unit with:

Spray with new sprayer or Mineral spirits, then Compatible paint, Compatible solvent Mineral spirits
sprayer that has been compatible solvent such as latex or such as water or
stored such as water or oil-base mineral spirits
mineral spirits
Spray latex paint Warm, soapy water, Latex paint Warm soapy water, Mineral spirits
then clean water then clean water
Spray oil paint Mineral spirits Oil-base paint Mineral spirits Mineral spirits
Change latex to oil paint Warm, soapy water, Mineral spirits Mineral spirits Mineral spirits
then clean water
Change oil to latex paint Mineral spirits, then Latex Warm, soapy water, Mineral spirits
soapy water, and fi- then clean water
nally, clean water
Change colors, same base Compatible solvent
such as water or
mineral spirits

How to flush
6. Do not run pump dry for more than 30 seconds to
WARNING avoid damaging pump packings!

FIRE AND EXPLOSION HAZARD 7. Follow Pressure Relief Procedure on page 7.

To reduce static sparking and splashing, Engage gun safety latch.
always remove the spray tip from the
8. Unscrew filter bowl and reinstall clean screen.
gun, and hold a metal part of the gun
Install bowl and hand tighten.
firmly to the side of a grounded metal pail when
flushing. 9. Remove suction tube and screen and clean them
separately.
1. Follow Pressure Relief Procedure on page 7.
Engage gun safety latch. FILTER
BOWL
2. Turn pressure adjusting knob (J) fully counter-
clockwise to zero pressure.
J SCREEN
3. Remove spray tip from gun. See Fig. 8. Remove
filter bowl, filter support and screen. Clean screen
separately and install bowl without screen or
support to flush it.
4. Put suction tube into a grounded metal pail with
FILTER
1/2 gallon of compatible solvent. Close pressure SUPPORT
drain valve (G).
G
5. Start sprayer. See page 7. To save fluid still in
sprayer, trigger gun into another container until
next fluid appears, then trigger gun back into 7694A

compatible solvent container. Circulate flushing

fluid a few minutes to thoroughly clean system. Fig. 8

10 308799
 Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 7.

MOTOR WON’T OPERATE

TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Basic Fluid Pressure Problems 1. Check pressure control knob setting. The mo- 1. Slowly increase pressure setting to see if
tor will not run if it is at the minimum setting motor starts.
(fully counterclockwise).
2. Check for a clogged spray tip or fluid filter. Re- 2. Relieve pressure, refer to separate gun, tip,
fer to separate gun, tip, or fluid filter instruction or fluid filter instruction manual for cleaning.
manual.
Basic Mechanical Problems 1. Check for frozen or hardened paint in pump 1. Thaw. Plug in sprayer and turn on. Slowly
(64). Using a screwdriver,carefully try to rotate increase pressure setting to see if motor
fan at back of motor by hand. See page 17. starts. If it doesn’t, see NOTE 1, below.
2. Check displacement pump connecting rod pin 2. Push pin into place and secure with spring
(66). It must be completely pushed into con- retainer.
necting rod (63) and retaining spring (68) must
be firmly in groove ofconnecting rod. See Fig.
25.
3. Check for motor damage. Remove drive 3. Replace motor (73) if fan won’t turn. See
housing assembly (67). See page 25. T ry to page 27.
rotate fan by hand.

Basic Electrical Problems 1. Check pressure control safety circuit. 2. Turn pressure control ON/OFF switch to
OFF to RESET. If pressure control safety
continues to trip, see ELECTRICAL
SHORT on page 15.
2. Check electrical supply with volt meter. Meter 2. Reset building circuit breaker; replace
must read 105–125 VAC. building fuse. Try another outlet.
3. Check extension cord for damage. Check ex- 3. Replace extension cord.
tension cord continuity with a volt meter.
4. Check sprayer power supply cord (79) for 4. Replace power supply cord. See page 19.
damage such as broken insulation or wires.

NOTE 1: 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
. If paint hardened (dried) in sprayer, pump packings must be replaced.
See page 29 (Displacement Pump Repair).

308799 11
 Troubleshooting
MOTOR WON’T OPERATE (Continued)
TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Basic Electrical Problems 1. Check leads from motor to be sure they are 1. Replace loose terminals; crimp to leads. Be
(continued) securely fastened and properly mated. sure terminals are firmly connected.
Follow Pressure Relief Pro- Clean circuit board terminals. Securely re-
cedure on page 7. Remove connect leads.
gun from hose. Remove pres-
sure control cover.
2. Check for loose motor brush lead connections 2. Tighten terminal screws. Replace brushes
and terminals. See page 18. if leads are damaged. See page 18.
3. Check brush length which must be 1/2” mini- 3. Replace brushes. See page 18.
mum. See page 18.

NOTE: The brushes do not wear at the same

rate on both sides of the motor . Check both
brushes.
4. Check for broken or misaligned motor brush 4. Replace spring if broken. Realign spring
springs. Rolled portion of spring must rest with brush. See page 18.
squarely on top of brush. See page 18.
5. Check motor brushes for binding in brush 5. Clean brush holders. Remove carbon with
holders. See page 18. small cleaning brush. Align brush leads
with slot in brush holder to assure free verti-
cal brush movement.
6. Check motor armature commutator for burn 6. Remove motor and havemotor shop resur-
spots, gouges and extreme roughness. face commutator if possible. See page 27.
See page 18.
7. Check motor armature for shorts using arma- 7. Replace motor. See page 27.
ture tester (growler) or perform spin test. See
page 17.
8. Check motor control board (104) by perform- 8. Replace with new pressure control board
ing motor control board diagnostics on page (104). See page 21.
21. 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.
Refer to wiring diagram on 1. Check power supply cord (79). Connect volt 1. Replace power supply cord. See page 19.
page 35 to identify test points meter between TP1 (neutral) and TP2. Plugin
(TP). sprayer. Meter must read 105 to 125 AC.
V Un-
plug sprayer.
2. Check ON/OFF switch (80). Connect volt me- 2. Replace ON/OFF switch. See page 19.
ter between TP1 and TP3 terminal on ON/
OFF switch. Plug in sprayer and turn ON.Me-
ter must read 105 to 125 V
AC. Turn off and un-
plug sprayer. Reconnect TP3.
3. Check motor thermal cutof f switch. Turn 3. If thermal switch is open (no continuity), al-
sprayer OFF. Check for continuity between low motor to cool. If switch remains open af-
TP4 and TP5 with ohmmeter. ter motor cools, replace motor. If thermal
switch closes after motor cools, correct
cause of overheating.
4. Check all terminals for damage or loose fit. 4. Replace damaged terminals and recon-
nect securely.

12 308799
 Troubleshooting
LOW OUTPUT
TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warn-
ing, then replace tip. See your separate
gun or tip manual.
2. Check to see that pump does not continue to 2. Service pump. See page 29.
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, turnoff and un-
plug sprayer.
3. Check electrical supply with volt meter. Meter 3. Reset building circuit breaker; replace
must read 105–125 VAC. building fuse. Repair electrical outlet or try
another outlet.
4. Check extension cord size and length; must 4. Replace with a correct, grounded exten-
be at least 12 gauge wire and no longer than sion cord.
300 ft.
5. Check leads from motor to pressure control 5. Be sure male terminal blades are centered
circuit board (104) for damaged or loosewires and firmly connected to female terminals.
or connectors. Inspect wiring insulation and Replace any loose terminal or damaged
terminals for signs of overheating. wiring. Securely reconnect terminals.
6. Check for loose motor brush leads andtermi- 6. Tighten terminal screws. Replace brushes
nals. See page 18. if leads are damaged. See page 18.
7. Check for worn motor brushes which must be 7. Replace brushes. See page 18.
1/2” minimum. See page 18.
8. Check for broken and misaligned motor brush 8. Replace spring if broken. Realign spring
springs. Rolled portion of spring must rest with brush. See page 18.
squarely on top of brush.
9. Check motor brushes for binding in brush 9. Clean brush holders, remove carbon dust
holders. See page 18. with small cleaning brush. Align brush lead
with slot in brush holder to assure free verti-
cal brush movement.
10.Check stall pressure. 10.Replace with new pressure control board
(104). See page 21.
11. Check motor armature for shorts by using an 12.Replace motor. See page 27.
armature tester (growler) or perform spin test.
See page 17.
12.Check motor control board (104) by perform- 11. Replace with new pressure control board
ing motor control board diagnostics on page (104). See page 21.
21. 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.

308799 13
 Troubleshooting
NO OUTPUT
TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Motor runs and pump strokes 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. 3. Tighten; use thread sealant or sealingtape
on threads if necessary.
4. Check to see if intake valve ball and piston ball4. Remove intake valve and clean. Check
are seating properly. See page 29. balls and seats for nicks; replace if neces-
sary. See page 29. Strain paint before us-
ing to remove particles that could clog
pump.
5. Check for leaking around throat packing nut 5. Replace packings. See pages 29–30.Also
which may indicate worn or damaged pack- check piston valve seat for hardenedpaint
ings. See page 29. or nicks and replace if necessary. Tighten
packing nut/wet-cup.

Motor runs but pump does not 1. Check displacement pump connecting rod pin 1. Replace pin if missing. Be sure retainer
stroke (66). See page 30. spring (68) is fully in grooveall around con-
necting rod. See page 30.
2. Check connecting rod assembly (63) for dam- 2. Replace connecting rod assembly . See
age. See page 24. page 24.
3. Be sure crank in drive housing rotates; plug in 3. Check drive housing assembly for damage
sprayer and turn on briefly to check. Turn off and replace if necessary. See page 25.
and unplug sprayer. See page 25.

EXCESSIVE PRESSURE FLUCTUATIONS

TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Spray pattern variations. 1. Be sure leads to motor control board are firmly 1. Reconnect securely. See Fig. 29.
connected. Be sure all male terminals blades
are centered and firmly connected to female
terminals. See Fig. 29.
2. Check maximum working pressure. 2. Replace pressure control board (104).
See page 21.
3. Check motor control board (104) by perform- 3. Replace with a newpressure control board
ing motor control board diagnostics on page (104). See page 21.
21. 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.
4. Check LOW OUTPUT section, page 13.

14 308799
 Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Motor is hot and runs intermit- 1. Determine if sprayer was operated at high 1. Decrease pressure setting or increase tip
tently. pressure with small tips, which causes low size.
motor RPM and excessive heat build up.
2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if pos-
is located is no more than 90 F and sprayer sible.
is not located in direct sun.
3. Determine if sprayer was turned on, pressur- 3 Turn off sprayer whenever you stop spray-
ized, but not operating for long periods of time. ing for a while and relieve fluid pressure.

ELECTRICAL SHORT
TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO
If check is OK, go to next check When check is not OK refer to this column
Building circuit breaker opens 1. Check all electrical wiring for damaged insula- 1. Repair or replace any damaged wiring or
as soon as sprayer switch is tion, and all terminals for loose fit or damage. terminals. Securely reconnect all wires.
turned on. Also check wires between pressure control
and motor. See page 27.
CAUTION 2. Check for missing inspection plate gasket 2. Correct faulty conditions.
Any short in any part of the (see page 27), bent terminal forks or other
motor power circuit will cause metal to metal contact points which could
the control circuit to inhibit cause a short.
sprayer operation. Correctly
diagnose and repair all shorts 3. Check motor armature for shorts. Use an ar- 3. Replace motor. See page 27.
before checking and replac- mature tester (growler) or perform spin test.
ing control board. See page 17. Inspect windings for burns.
4. Check motor control board (104) by perform- 4. Replace with a newpressure control board
ing motor control board diagnostics on page (104). See page 21.
21. 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.

Building circuit breaker opens 1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
as soon as sprayer is plugged
into outlet and sprayeris NOT 2. Check ON/OFF switch (80) See page 19. Be 2. Replace ON/OFF switch. See page 19.
turned on. sure sprayer is unplugged! Disconnect wires
from switch. Check switch with ohmmeter .
The reading must be infinitywith the ON/OFF
switch OFF, and zero with the switch ON.
3. Check for damaged or pinched wires in the 3. Replace damaged parts. See page 21.
pressure control. See page 21.
Sprayer quits after sprayer op- 1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
erates for 5 to 10 minutes.
2. Check electrical supply with volt meter. Meter 2. If voltage is too high, do not operate
must read 105 to 125 VAC. sprayer until corrected.
3. Check tightness of pump packing nut. Over 3. Loosen packing nut. Check for leaking
tightening tightens packings on rod, restricts around throat. Replace pump packings, if
pump action, and damages packings. necessary. See page 29.

308799 15
 General Repair Information
CAUTION WARNING
To reduce the risk of a pressure control malfunction: ELECTRIC SHOCK HAZARD
To reduce the risk of serious injury,
Always use needle nose pliers to disconnect a
wire. Never pull on the wire, pull on the connector. including electric shock, DO NOT touch
any moving parts or electrical parts with
Mate wire connectors properly. Be sure flat blade your fingers or a tool while inspecting the repair.
of insulated male connector is centered in wrap- Shut off the sprayer and unplug it as soon as you
around blade of female connector. complete the inspection. Reinstall all covers,
Route wires carefully to avoid interference with gaskets, screws and washers before operating the
other connections of pressure control. Be sure sprayer.
wires are not pinched between cover and control
box. 3. If sprayer does not operate properly, review
repair procedure again to verify that everything
was done correctly. If necessary, see Trouble-
shooting Guide, pages 11 – 15, to help identify
other possible problems and solutions.
Tool List
Phillips screwdriver 1/4 in. hex key wrench WARNING
Small flat blade 3/16 in. hex key wrench
screwdriver 5/8 in. socket wrench EXPLOSION HAZARD
Needle nose pliers 3/8 in. open end wrench During operation, the motor and drive
Plastic mallet or 20 oz housing become very hot and could burn
1/2 in. open end wrench
(max) hammer your skin if touched. Flammable materi-
12 in. adjustable wrench 3/4 in. open end wrench
als spilled on the hot, bare motor could cause a fire
Adjustable, open-end 7/8 in. open end wrench
or explosion. Always have the motor shield in place
wrench High quality motor oil during regular operation to reduce the risk of burns,
Torque wrench Bearing grease fire or explosion.

CAUTION
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce- Do not run the sprayer dry for more than 30 seconds
dures. These parts are not normally provided with to avoid damaging the pump packings.
replacement assemblies.
4. Reinstall motor shield before regular operation
of sprayer and replace if damaged. The cover
directs cooling air around the motor to help prevent
2. Test repair before regular operation of sprayer overheating. It can also help reduce the risk of
to be sure problem is corrected. burns, fire or explosion; see preceding WARNING.

16 308799
 Spin Test
Armature, Brushes, and Motor Wiring Open
WARNING Circuit Test (Continuity)
ELECTRIC SHOCK HAZARD 1. Relieve pressure. Connect red and black motor
Do not touch brushes, leads, springs or leads together with a test lead. Turn motor fan by
brush holders while the sprayer is hand at about two revolutions per second.
plugged in to reduce risk of electric 2. If there is uneven or no turning resistance, check
shock and serious bodily injury. following: broken brush springs, brush leads,
motor leads; loose brush terminal screws, motor
WARNING lead terminals; worn brushes. Repair parts as
needed. See page 18.
INJECTION HAZARD
3. If there is still uneven or no turning resistance,
To reduce the risk of serious injury,
replace motor. See page 27.
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 7.
F
For checking armature, motor winding and brush elec-
trical continuity.
Setup
1. Relieve pressure. Remove drive housing. See
page 25.
2. Remove motor shield (54), fan cover (A) and
inspection covers (82). See Fig. 9.
3. Remove pressure control cover (B). Disconnect
motor leads (F) and (G). See Fig. 10.
Armature Short Circuit Test
Relieve pressure. Quickly turn motor fan by hand. If 82 G
there are no shorts, the motor will coast two or three 7695A
Fig. 10
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 27.

54

B 7703B
Fig. 9

308799 17
 Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in. Note 5. Inspect commutator for excessive pitting, burning
that brushes wear differently on each side ofmo- or gouging. A black color on commutator is normal.
tor, so check both. Brush Repair Kit 220853 is Have commutator resurfaced by a qualified motor
available. A new spring clip, 1 10816, may be repair shop if brushes seem to wear too fast.
purchased separately.

WARNING CAUTION
INJECTION HAZARD When installing the brushes, follow all steps carefully
To reduce the risk of serious injury, to avoid damaging the parts.
whenever you are instructed to relieve
pressure, follow the Pressure Relief 6. Install new brush so lead is in long slot of holder.
Procedure on page 7. See Fig. 13.

BRUSH HOLDER
NOTE: Read General Repair Information on page 16
before doing this procedure. SHORT SLOT
LONG SLOT
1. Relieve pressure.
BRUSH
2. Remove motor shield (54). Remove inspection SPRING
CLIP
covers (B) and gaskets on each side of motor.
See Fig. 11.

54
NOTE: SPRING MUST COIL
IN THIS DIRECTION 01227
Fig. 13

7. Slide terminal under terminal screw washer and

tighten screw. Be sure motor lead is still connected
at screw. See Fig. 14.

Fig. 11 B 7703B
SPRING
SPRING CLIP

3. Push in spring clip to release hooks from brush

holder. Pull out spring clip. See Fig. 12.

SPRING HOOK
BRUSH

BRUSH LEAD
BRUSH
TERMINAL SCREW
MOTOR LEAD
TERMINAL
Fig. 14 01227
SPRING CLIP
110816
01227 8. Place spring on brush as shown in Fig. 13.
Fig. 12
9. Install spring clip and push it down to hook short
4. Loosen brush lead terminal screw. Pull brush lead slots in housing. See Fig. 13.
away, leaving motor lead terminal in place. Re-
move brush and spring. See Fig. 14. 10. Repeat for other side.

18 308799
 Motor Brush Replacement
11. Test brushes.
a. Remove pump connecting rod pin.
CAUTION
Do not run the sprayer dry for more than 30 seconds
b. With sprayer OFF, turn pressure control knob
while checking the brushes to avoid damaging the
fully counterclockwise to minimum pressure.
displacement pump packings.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed. 12. Install brush inspection covers and gaskets.
d. Inspect brush and commutator contact area for
excessive arcing. Arcs must not trail or circle 13. Break in brushes.
around commutator surface.

a. Operate sprayer for one hour with no load.

WARNING
ELECTRIC SHOCK HAZARD b. Install connecting rod pin.
Do not touch brushes, leads, springs or
brush holders when sprayer is plugged
in to reduce risk of electric shock and
serious bodily injury.

Power Supply Cord On/Off Switch

Replacement Replacement
WARNING WARNING
INJECTION HAZARD INJECTION HAZARD
To reduce the risk of serious injury, To reduce the risk of serious injury,
whenever you are instructed to relieve whenever you are instructed to relieve
pressure, follow the Pressure Relief pressure, follow the Pressure Relief
Procedure on page 7. Procedure on page 7.

NOTE: Read General Repair Information on page 16

before doing this procedure. See Fig. 15. NOTE: Read General Repair Information on page 16
before doing this procedure. See Fig. 15.
1. Relieve pressure.
1. Relieve pressure.
2. Remove pressure control cover (82).
2. Remove pressure control cover (82).
3. Disconnect power supply cord black (J) lead from
ON/OFF switch (80),the white wire (D) going to
3. Disconnect two wires (B) and (J) from ON/OFF
circuit board, and green wire (E) to grounding
switch (80).
screw (107).

4. Loosen strain relief bushing (G) and remove power 4. Press in on two retaining tabs on each side of
supply cord (79). ON/OFF switch (80) and remove.

5. Install power supply cord (79) and tighten strain 5. Install new ON/OFF switch (80) so tabs of switch
relief bushing (G). snap into place on inside of pressure control
housing.
6. Connect power supply cord black (J) lead to
ON/OFF switch (80), white wire to circuit board
(D), and green wire (E) to grounding screw (107). 6. Connect two wires (B) and (J) to ON/OFF switch.

7. Install pressure control cover (82). 7. Install pressure control cover (82).

308799 19
 Power Supply Cord and On/Off Switch
Replacement
80 B J

79 G 107 E

82

Fig. 15
 

20 308799
 Pressure Control Repair
Motor Control Board Installation
WARNING
INJECTION HAZARD 1. Relieve pressure.
To reduce the risk of serious injury,
whenever you are instructed to relieve
2. Fig. 16. Install motor control board (104) with four
pressure, follow the Pressure Relief
screws (102) and washers (103).
Procedure on page 7.

Motor Control Board Removal 3. Connect to motor control board:

1. Relieve pressure.

2. Fig. 16. Remove five screws (28) and cover (82). Lead (E) to transducer.

3. Disconnect from motor control board:

Lead (D) to potentiometer.
Six motor leads (B).

Lead (C) from power cord. Lead (111) to ON/OFF switch.

Lead (111) from ON/OFF switch.

Lead (C) to power cord.
Lead (D) from potentiometer.

Lead (E) from transducer. Six motor leads (B).

4. Remove four screws (102), washers (103) and

circuit board (104). 4. Install cover (82) with five screws (28).

Motor control board diagnostics

1. Relieve pressure. 3. Turn ON/OFF switch ON.

2. Remove five screws (28) and cover (82). 4. Observe LED operation and reference following
See Fig. 16. table:

LED SPRAYER OPERATION INDICATES WHAT TO DO

BLINKS
Once Sprayer runs Normal operation Do nothing
Twice Sprayer runs Normal operation Do nothing
Twice Sprayer shuts down and LED continues Line voltage is too Lower line voltage to 120 VAC
repeatedly to blink twice repeatedly high
Three times Sprayer shuts down and LED continues Pressure transducer Replace pressure transducer
repeatedly to blink three times repeatedly is faulty or missing
Four times Sprayer shuts down and LED continues Run away pressure. Replace motor control board.
repeatedly to blink four times repeatedly Pressure greater than See preceding Motor control
4500 psi. board removal procedure.
Five times Sprayer shuts down and LED continues Locked rotor. Motor Clear obstruction and replace
repeatedly to blink five times repeatedly can not turn because broken parts preventing motor
of some mechanical from turning
condition.

308799 21
 Pressure Control Repair
Pressure Control Transducer Removal Pressure Adjust Potentiometer Removal
1. Relieve pressure. 1. Relieve pressure.
2. Fig. 16. Remove five screws (28) and cover (82).
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect lead (E) from motor control
board (104). 3. Disconnect lead (D) from motor control
board (104).
4. Remove strain relief bushing (116).

5. Remove pressure control transducer (31) and 4. Remove potentiometer knob (81), sealing shaft nut
packing o-ring (59) from control housing plate (89). (106) and pressure adjust potentiometer (105).

Pressure Control Transducer Installation Pressure Adjust Potentiometer Installation

1. Relieve pressure.
1. Relieve pressure.
2. Fig. 16. Install packing o-ring (59) and pressure
control transducer (31) in control housing 2. Fig. 16. Install pressure adjust potentiometer
plate (89). Torque to 30–35 ft-lb. (105), sealing shaft nut (106) and potentiometer
knob (81).
3. Install strain relief bushing (116).
3. Connect lead (D) to motor control board (104).
4. Connect lead (E) to motor control board (104).

5. Install cover (82) with five screws (28). 4. Install cover (82) with five screws (28).

22 308799
 Pressure Control Repair
59 31

97 89 99

81 116

112
98

28 91

104 86

102 120

82
87
50

107 A

111
E
D

C
7697B
Fig. 16
7697C

308799 23
 Bearing Housing and Connecting Rod
Replacement
11. Align connecting rod (63) with crank (E) and drive
WARNING housing locating pins (G) with bearing housing (22)
holes. Push bearing housing onto drive housing or
INJECTION HAZARD tap it into place with a plastic mallet.
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief CAUTION
Procedure on page 7.
DO NOT use the bearing housing screws (25) to try
to align or seat the bearing housing; the bearing and
NOTE: Read General Repair Information on page 16 drive housing will not align properly and will result in
before doing this procedure. See Fig. 17.
premature bearing wear.
NOTE: Stop sprayer at bottom of its stroke to get crank
(E) in its lowest position.T o lower crank manu- 12. Install screws and lockwashers (25,23). Tighten
ally, carefully rotate blades of fan with a screw- screws evenly to 175 in-lb (19 N.m).
driver.
13. Install pump. See page 30.
1. Relieve pressure.
14. Install remaining parts. See Fig. 17.
2. Remove front cover (49). Unclip drain hose (36)
from pump. Hold a wrench on pump intake valve 67 OIL B C PACK WITH
BEARING GREASE
(213) and unscrew pump suction tube (39). Dis-
connect pump hose (70). 63
25,23 TORQUE TO
E 175 in-lb (19 N.m)
3. Push up retaining spring (68). Push pin (66) out
rear.
49

4. Loosen locknut (47). Unscrew displacement

pump (64). G
22
5. Remove four screws and lockwashers (25,23).
68
47
6. Lightly tap lower rear of bearing housing (22) with
a plastic mallet to loosen it from drive housing (67). 66
Pull bearing housing and connecting rod assembly
70
(63) straight off drive housing. 40 F
64
7. Remove pail bracket assembly (F) and install it on
new bearing housing. 213

39
8. Inspect crank (E) for excessive wear and replace
36
parts as needed. Evenly lubricate inside of bronze
bearing (B) with high quality motor oil. Liberally 85
pack roller bearing (C) with bearing grease.

9. Assemble connecting rod (63) and bearing housing

(22).

10. Clean mating surfaces of bearing and drive hous- 7698A

ings (22,67). Fig. 17

24 308799
 Drive Housing Replacement
4. Lightly tap lower rear of bearing housing (22) with
WARNING a plastic mallet to loosen it from drive housing (67).
Pull assembled bearing housing and connecting
INJECTION HAZARD rod straight off drive housing.
To reduce the risk of serious injury,
whenever you are instructed to relieve 5. Remove two drive housing screws (26) and
pressure, follow the Pressure Relief lockwashers (20).
Procedure on page 7.
6. Remove two lower screws (16) and lockwashers
CAUTION (20) and then two upper screws (16) and lock-
washers (20) from front of motor (73).
DO NOT drop gear cluster (51) when removing drive
housing (67). Gear cluster may stay engaged in the 7. Tap drive housing (67) with a plastic mallet to
motor front end bell or the drive housing. loosen it from front of motor (73), and then pull
drive housing straight off.
DO NOT lose thrust balls (90) located at each end of
gear cluster (51) or drop them between gears. The
balls, which are heavily covered with grease, usually 8. Liberally apply approximately 4 ounces of bearing
stay in the shaft recesses, but could be dislodged. If grease to gear cluster (51). Grease is supplied
caught between gears and not removed, the balls will with drive housing replacement kit. Be sure thrust
seriously damage drive housing. If the balls are not balls (90) are in place.
in place, the bearings will wear prematurely.
9. Place bronze-colored washer (67b) then silver-col-
NOTE: Read General Repair Information on page 16 ored washer (67a) on shaft protruding from big
before doing this procedure. See Fig. 18. gear in drive housing (67).
1. Relieve pressure.
10. Align gears and push new drive housing straight
2. Remove front cover (49) and motor shield (54). onto front of motor and locating pins.
Unclip drain hose (85) from pump.
11. Continue reassembling sprayer.
3. Remove four bearing housing screws (25) and
lockwashers (23).

308799 25
 Drive Housing Replacement

34
2 16
20

54
90
67a
51 3
67b
67

22
25, 23 1

2 16 49
90
20

20
2 26

Torque to 175 in-lb (19 N.m) 85

2 Torque to 90–100 in-lb (10.2–11.3 N.m)
3 Liberally apply grease


Fig. 18

26 308799
 Motor Replacement
WARNING CAUTION
INJECTION HAZARD DO NOT drop gear cluster (51) when removing drive
To reduce the risk of serious injury, housing (67). The gear cluster may stay engaged in
whenever you are instructed to relieve the motor front end bell or the drive housing.
pressure, follow the Pressure Relief DO NOT lose thrust balls (90) located at each end of
Procedure on page 7. gear cluster (51) or drop them between gears. The
balls, which are heavily covered with grease, usually
NOTE: Read General Repair Information on page 16 stay in the shaft recesses, but could be dislodged. If
before doing this procedure. See Fig. 16 and 19. caught between gears and not removed, the balls will
1. Relieve pressure. seriously damage the drive housing. If the balls are
not in place, the bearings will wear prematurely.
2. Remove motor shield (54).
9. While supporting motor (73) to keep sprayer from
3. Remove pressure control cover (82). Disconnect
tipping, remove four motor mounting screws (30).
six motor leads (B). See figure 16.
Lift off motor.

CAUTION 10. Install new motor (73).

Always pull the motor leads one at a time to avoid

loosening the terminals, which could result in a bad 11. Liberally apply approximately 4 ounces of bearing
grease to gear cluster (51). Grease is supplied
connection and poor sprayer performance.
with drive housing replacement kit. Be sure thrust
balls (90) are in place.
4. Remove strain relief (99) by pushing from behind
and into the control box. Pull motor wires bundle
through pressure control opening. See figure 16. 12. Place bronze-colored washer (67b) and then
silver-colored washer (67a) on shaft protruding
5. Remove front cover (49). from big gear in drive housing (67).

6. Remove two drive housing screws (26).

13. Align gears and push drive housing (67) straight
onto front of motor (73) and locating pins.
7. Remove two lower screws (16) and lockwashers
(20) and then two upper screws (16) and lo-
ckwashers (20) from front of motor (73). 14. Continue reassembling sprayer. Feed motor wires
through opening in pressure control. Connect six
8. Tap drive housing (67) with a plastic mallet to motor leads to pressure control printed circuit
loosen it from front of motor (73), and then pull board. Install pressure control cover (A).
drive housing straight off. See Fig. 16.

308799 27
 Motor Replacement

34
54
16 1
20
73
90
67a
51 2
67b
67

22
30
20

26 49

90

79 98
10

70
A
40

1 16 20 85
1 Torque to 90–100 in-lb (10.2–11.3 N.m)
2 Liberally apply grease


Fig. 19

28 308799
 Displacement Pump Repair
Removing pump
1. Flush pump. Relieve pressure. Fig. 20. Cycle 4. Fig. 22. Push out pin.
pump with piston rod (222) in its lowest position.

2. Fig. 20. Unscrew suction tube and hose from

pump.

222

7675A
Fig. 22

5. Fig. 23. Loosen locknut by hitting firmly with a

20 oz (maximum) hammer. Unscrew pump.

7672A
Fig. 20

3. Fig. 21. Use screwdriver to push retaining spring

up.

7673A
Fig. 23

Repairing Pump
7674A
Fig. 21 See manual 308798 for pump repair instructions.

308799 29
 Displacement Pump Repair
Installing pump
3. Fig. 26. Push retaining spring into groove all the
WARNING way around connecting rod.

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, includ-
ing 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.

7674A
1. Fig. 24. Pull piston rod out 1.5 in. Screw in pump Fig. 26
until holes in bearing cross link and piston rod
align. Fig. 27. 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 approxi-
mately 75" 5 ft–lb (102 N
m).

7676A

Fig. 24
7673A
Fig. 27
2. Fig. 25. Push pin (21) into holes.
Fig. 28. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.

21

7675A
Fig. 25 Fig. 28 7677A


 Accessories Technical Data
Power Requirements . . . . . . . . . . . . . . . . . . .120 . VAC, 60 Hz,
DANGER LABELS 1 phase, 15A minimum or 4000W generator
Motor 1.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP
The English language DANGER label shown on (with latex at 2000 psi (138 bar, 13.8 MPa)
page 4 is also on your sprayer. If you have paint- Working Pressure Range 0–3000 psi (0–210 bar, 0–21 MPa)
ers who do not read English, order one of the fol- Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . 193 . . (51)
lowing labels to apply to your sprayer. The draw- Maximum Delivery Rating . . . . . . . . . . . . . . 1.1 . gpm (4.1 lpm)
ing shows the best placement of these labels for Tip Size . . . . . . . . . . . . . . one. gun – 0.032; two guns – 0.021
good visibility. (with latex at 2000 psi (138 bar, 13.8 MPa)
Order the labels directly from Graco, free of Power Cord . . . . . . . . . . . . . . . . 14 . AWG, 3 wire, 15 ft (4.5 m)
charge. Toll Free: 1–800–328–0211 Inlet Paint Strainer . . . . . . . . . . . . . . . . 16 . mesh (975 micron)
stainless steel screen, reusable
Apply other
language here Outlet Paint Filter . . . . . . . . . . . . . . . . . 60 . mesh (238 micron)
stainless steel screen, reusable
Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/4 . npt(m)
French 185955 Fluid Outlet Size
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/8
. . npt(f)
Spanish 185962 Filter with standard 3/8 npt(f) to 1/4 npsm adapter 1/4 npsm
German 186042 Basic Sprayer Wetted Parts: . . . . . . zinc-plated carbon steel,
Greek 186046 polyurethane, polyethylene, stainless steel,
Korean 186050 Delrin , chrome plating, leather,
V-Max UHMWPE, aluminum,
stainless steel, tungsten carbide
NOTE: Delrin is a registered trademark of the DuPont Co.

Dimensions
Weight (dry w/o packaging) . . . . . . . . . . . . . . . .107 lb (49 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28.5
. . in. (724 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.5
. . in. (648 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.5
. . in. (521 mm)

308799 31
 Parts Drawing – Sprayer

Ultra MAX 1095 Sprayers

41* Model 232150, Series A
Includes items 1 – 112, 123, 126
77 Basic Sprayer
84
Model 232151, Series A
54 Includes items 1 – 126
34 73a* Complete Sprayer
41*
16
20
73
90
67a
51
67b
90 67 63

REF
77
22
62 23
25 49
48
52
37 30 30
35 16 20
10 26 61
REF 20 32
78
68
47

66
24
70
64
78 40

14 38
19 21 33
126
123
Ref 85
39
Ref 70

53
65
Ref 120
122

SEE PARTS ON PAGE 34

Ref 85

120 121 7689B

32 308799
 Parts List – Sprayer
Ultra MAX 1095 Sprayers
Model 232150 Series A Model 232151, Series A
Includes items 1 – 112, 123, 126 Includes items 1 – 126
Basic Sprayer Complete Sprayer

REF REF
NO. PART NO. DESCRIPTION QTY NO. PART NO. DESCRIPTION QTY

10 110996 NUT, 5/16–18 unc–2a 4 65 206994 THROAT SEAL LIQUID, 8 OZ 1

14 101242 RING, retaining 2 66 176818 PIN, straight, hdls, 1
16 100644 SCREW, socket head, 1/4–20 x 0.75” 4 0.3125” dia x 1.023”
19 104811 HUBCAP 2 67 239929 DRIVE HOUSING 1
20 105510 LOCKWASHER, spring, 1/4” 6 includes 67a and 67b
21 106062 WHEEL, semi–pneumatic 2 67a 178967 .WASHER, silver–colored 1
22 240523 BEARING HOUSING 1 67b 107089 .WASHER, bronze–colored 1
includes 32 and 61 68 176817 SPRING, retaining 1
23 106115 LOCKWASHER, spring, 3/8” 4 70 239984 HOSE, grounded, nylon,1/4” ID 1
24 114406 SCREW, filh, no. 8–32 x1” 4 cpld 1/4 npsm (f), 25” (635 mm),
25 107210 CAPSCREW, sch, 3/8–16 x 1–1/2” 4 spring guards both ends
26 107218 CAPSCREW, sch, 1/4–20 x 2.75” 2 73 240034* MOT OR, ELECTRIC 1
30 111801 SCREW, serrated flange, hex hd, 7 includes 41 & 73a
5/16–18 x 1/2” 73a 187784 .LABEL, DANGER, French 2
32 112746 NUT, hex 2 77 239998 HANDLE, cart 1
33 108691 PLUG, tubing 2 78 239980 FRAME, sprayer 1
34 108865 SCREW, pan head, no. 8 x 3/8” 6 84 114271 STRAP, velcro 1
35 109032 SCREW, pnhd, 10–32 x 1/4” 4 90 100069 BALL, steel, 1/4” dia. 2
37 110243 RING, retaining 2 97 192694 HOUSING, control, box 1
38 192691 CLIP, spring 1 120 238361 HOSE, grounded, nylon, 1/4” ID,
39 192641 TUBE, intake 1 cpld 1/4 npsm(f), 50 ft (15 m)
40 162453 NIPPLE, 1/4 npt(m) x 1/4 npsm 2 spring guards both ends 1
41 187791 LABEL, DANGER, English 2 121 238358 HOSE, grounded, nylon, 3/16” ID,
47 192723 NUT, hex 1 cpld 1/4 npsm(f), 3 ft (.9 m),
48 112827 BUTTON, snap 2 spring guards both ends 1
49 179899 COVER, housing 1 122 220955 SPRAY GUN
51 179961 GEAR REDUCER 1 see manual 307614 for parts 1
52 183350 WASHER 2 123 192838 LABEL, WARNING, French 1
53 181072 STRAINER 1 126 187975 LABEL, WARNING, English 1
54 240313 SHIELD, motor 1
includes labels 41 & 73a Extra Danger and Warning tags and labels available free.
61 192719 HANGER, pail 1 *Motor Brush Repair Kit 220853 is available.
62 192027 SLEEVE 2 Order separately.
63 218034 CONNECTING ROD 1
64 239923 DISPLACEMENT PUMP 1
see manual 308798 for parts




 Parts Drawing – Sprayer
69

70

72
40
76 12

79 89
9 31
81
59

80 106
101
127

99

98
116 75
112
28 97
107
82 91
105
104 86 92
102
115 7
71 100
74
4
6
50

5 87 55
85



34 308799
 Parts List – Sprayer
Ultra MAX 1095 Sprayers
Model 232150, Series A Model 232151, Series A
Includes items 1 – 112, 123, 127 Includes items 1 – 127
Basic Sprayer Complete Sprayer

REF REF
NO. PART NO. DESCRIPTION QTY NO. PART NO. DESCRIPTION QTY

4 224807 ASSEMBLY, cam, drain valve 1 86 240316 HOUSING, filter 1

5 111600 PIN, grooved 1 includes item 9
6 187625 HANDLE, valve, drain 1 87 111832 CAPSCREW 4
7 111699 GASKET, seat, valve 1 89 192726 PLATE, housing, control 1
9 104361 O-RING, packing 1 91 107505 PACKING, o-ring 1
12 167025 STRAINER, mesh, 60 1 92 164672 ADAPTER 2
28 114392 SCREW, mach, panhd 5 98 114284 BUSHING, strain relief 1
31 240314 TRANSDUCER, pressure control 1 99 114285 BUSHING, strain relief 1
includes item 59 100 240131 CAP, for secondary outlet 1
50 100020 WASHER, lock spring 4 101 192831 PLATE, instruction 1
55 112538 ELBOW, 90
, street, reducing 1 102 114420 SCREW, mach, pnhd 4
59 111457 O-RING, packing 1 104 240168 BOARD, PC 1
69 240315 BOWL, filter 1 105 236352 POTENTIOMETER, pressure adjust 1
includes item 72 106 112382 NUT, shaft, sealing 1
71 187615 VALVE, seat 1 107 114391 SCREW, ground 1
72 171941 SPRING, compression 1 111 240495 WIRE, jumper 1
74 235014 ASSEMBLY, drain valve 1 112 114393 SCREW 3
includes items 7 and 71 115 193051 LABEL, warning 1
75 100721 PLUG, pipe 1 116 114409 BUSHING, strain relief 1
76 186075 SUPPOR T, filter 1 127 193497 GASKET 2
79 239995 CORD SET, power 1
80 114277 SWITCH, rocker, (spst) 1 Extra Danger and Warning tags and labels available free.
81 114273 KNOB, potentiometer 1
82 193012 COVER, painted 1 *Motor Brush Repair Kit 220853 is available.
85 240144 HOSE, drain 1 Order separately.

Wiring Diagram
PRESSURE CONTROL BOARD 240168

TP3 111
BLACK

Pressure
Transducer YELLOW
104
ON/OFF TP4
Switch TP2 VIOLET
Ground
TP5

BLACK
107
Potentiometer

Power Supply
Cord
TP1

GREEN
from Motor
WHITE RED (+)
BLACK(–)


Fig. 29
308799 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 theipment
equ
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 sub-
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibilit y 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 distributo r for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defecti
ve 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 ANYOTHER 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 no thatother
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person operty,
or pr or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two ears (2) yof the
date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED W ARRANTIES 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 assistan
ce in mak-
ing 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 abreach 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 proceedi ngs
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parti
es reconnais-
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciai res
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 W arranty
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.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

www.graco.com
PRINTED IN USA 308799 November 1997, Revised May 1999
36 308799