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Graco 308842H User's Manual

1. 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 Paint supply 1 Refill and reprime pump 2 For clogged intake strainer 2 Remove and clean then reinstall 3 For loose suction tube or fittings 3 Tighten use thread sealant or sealing tape on threads if necessary 4 To see if intake valve ball and piston ball are 4 Remove intake valve and clean Check seating properly See page 17 balls and seats for nicks replace if neces sary See page 17 Strain paint before us ing to remove particles that could clog pump 5 For leaking around throat packing nut which 5 Replace packings See page 17 Also may indicate worn or damaged packings See check piston valve seat for hardened paint page 17 or nicks and replace if necessary Tighten packing nut wet cup Motor runs but pump does not 1 Displacement pump connecting rod pin 66 1 Replace pin if missing Be sure retainer See page 17 spring 68 is fully in groove all around con necting rod See page 17 2 Connecting rod assembly 63 for damage 2 Replace connecting rod assembly See See page 14 page 14 3 Be sure crank in drive housing rotates plug in 3 Inspect drive housing assembly for dam sprayer and turn on briefly to check Turn off age and replace if necessary See page 15 and unplug sprayer See page 15 EXCESSIVE PRESSURE FLUCTU
2. FRAME sprayer STRAP retaining HOSE drain BALL steel 1 4 in dia HOSE grounded nylon 1 4 in ID cpld 1 4 npsm f 50 ft 15 m spring guards both ends HOSE grounded nylon 3 16 in ID cpld 1 4 npsm f 3 ft 9 m spring guards both ends SPRAY GUN see manual 307614 for parts LABEL WARNING French LABEL WARNING English Japanese QTY a aY _ N a sb mb mb son AExtra Danger and Warning tags and labels available free Motor Brush Repair Kit 220853 is available Order separately TNot part of Model 232156 308842 19 Parts Drawing Sprayer Ultra MAX 795 and 1095 Lo Boy Sprayers Model 232145 Series A Model 232157 Series A SSSR Pala N Pa Ni cz LE SSE Ee IL SEE PARTS ON PAGE 22 20 308842 Parts List Sprayer Ultra MAX 795 and 1095 Lo Boy Sprayers Model 232145 Series A Model 232157 Series A REF REF NO PARTNO DESCRIPTION QTY NO PARTNO DESCRIPTION QTY 10 110996 NUT flange head hex 1 64 239923 PUMP displacement 1 14 101242 RING retaining 2 see manual 308798 for parts 16 100644 SCREW socket head 1 4 20 x 3 4 in 4 65 206994 THROAT SEAL LIQUID 8 OZ 1 19 104811 HUBCAP 2 66 176818 PIN straight hdls 1 20 105510 LOCKWASHER spring 1 4 in 6 0 3125 in dia x 1 023 in 21 106062 WHEEL semi pneumatic 2 67 DRIVE HOUSING 1 22 240523 HOUSING bearing 1 includes replaceable items 67a and 67b 23 106115 LOCKWASHER spring 3 8 in 4
3. While supporting motor 73 to keep sprayer from tipping remove four motor mounting screws 8 Lift off motor 11 Install new motor 73 Always pull the motor leads one at a time to avoid loosening the terminals which could result in a bad connection and poor sprayer performance 12 Liberally apply approximately 4 ounces of bearing grease to gear cluster 51 Grease is supplied with drive housing replacement kit Be sure thrust balls 90 are in place 5 Fig 7 Remove strain relief 99 and pull motor wires bundle through pressure control opening 13 Place bronze colored washer 67b and then silver colored washer 67a on shaft protruding from big gear in drive housing 67 6 Remove front cover 49 14 Align gears and push drive housing 67 straight P onto front of motor 73 and locating pins 7 Remove two drive housing screws 26 15 Fig 7 Continue assembling sprayer Feed motor 8 Remove two lower screws 16 and lockwashers wires through opening in pressure control Connect 20 and then two upper screws 16 and six motor leads two yellow two violet black lockwashers 20 from front of motor 73 and red to pressure control printed circuit board Install pressure control cover A 9 Tap drive housing 67 with a plastic mallet to 16 Bundle and tie all loose wires so none lay in con loosen it from front of motor 73 and then pull tact with inductor coil on filter board drive hou
4. 239931 Ultra Max 795 Model 232145 1 24 114406 SCREW self tap filnd 1 218032 Ultra Max 1095 Model 232157 1 25 107210 CAPSCREW sch 3 8 16 x 1 1 2 in 4 67a 178967 WASHER silver colored 1 26 107218 CAPSCREW sch 1 4 20 x 2 3 4 in 4 67b 107089 WASHER bronze colored 1 30 111801 SCREW cap flange hd 7 68 176817 SPRING retaining 1 32t 222667 SPRAY GUN 70 239984 HOSE grounded nylon 1 4 in ID 1 see manual 307614 for parts 1 cpld 1 4 npsm f 29 in 715 mm 33 108691 PLUG tubing 2 spring guards both ends 34 108865 SCREW pan head no 8 x 3 8 in 6 72 170957 TUBE suction 1 35 109032 SCREW pnhd 10 32 x 1 4 in 4 73 MOTOR ELECTRIC 1 37 110243 RING retaining 2 240994 Ultra Max 795 Model 232145 1 40 162453 NIPPLE 1 4 npt m x 1 4 npsm 2 240034 Ultra Max 1095 Model 232157 1 41 LABEL WARNING 2 77 193247 HANDLE cart 1 187791 English 2 78 240512 FRAME cart 1 189702 Japanese 2 83 240513 SWIVEL inlet tube 1 421 238358 HOSE grounded nylon 3 16 in ID 85 192727 HOSE drain 1 cpld 1 4 npsm f 3 ft 9 m 90 100069 BALL 1 spring guards both ends 1 103 101818 CLAMP hose 1 43t 238361 HOSE grounded nylon 1 4 in ID 104 192691 CLIP spring 1 cpld 1 4 npsm f 50 ft 15 m 105 103473 STRAP tie 3 spring guards both ends 1 106 205473 COUPLING hose 1 45 181072 STRAINER 1 111 170706 HOSE suction 1 47 192723 NUT retaining 1 1231 192838A LABEL WARNING French 1 48 112827 BUTTON snap 2 126 LABEL WARNING 1 49 188154 COVER housing
5. B from plug C 5 Disconnect four wires A from ON OFF switch 80 Fig 7 6 Press in on two retaining tabs on each side of ON OFF switch 80 and remove 7 Install new ON OFF switch 80 so tabs of switch snap into place on inside of pressure control housing 8 Connect four wires A to ON OFF switch 9 Install display connector B in plug C 10 Install pressure control cover 82 81 8052B 308842 11 Pressure Control Repair Motor Control Board Removal Installation 1 Fig 7 Install motor control board 104 with four In ms W A amp I Relieve pressure page 3 screws 102 2 Connect to motor control board 104 2 Fig 7 Remove five screws 28 and cover 82 e Lead E to transducer 3 Fig 17 Disconnect at motor control board 104 e Lead D to potentiometer Piller boards e Six motor leads two yellow two violet black e Six motor leads two yellow two violet black and red gt and red e Filter board 8 e Lead D from potentiometer 3 Bundle and tie all loose wires so none lay in con tact with inductor coil on filter board e Lead E from transducer See CAUTION Fig 17 4 Remove four screws 102 and circuit board 104 4 Install cover 82 with five screws 28 Motor Control Board Diagnostics 3 Turn ON OFF switch ON 1 Ng Ng Relieve pressure page 3 4 Observe LED operation and reference following table 2 Remove five screw
6. control board 104 4 Install cover 82 with five screws 28 3 Install cover 82 with five screws 28 308842 13 Bearing Housing and Connecting Rod Replacement 1 Read General Repair Information on page 3 AUTION 2 IA Rell Do not use bearing housing screws 25 to align or A Q Relieve pressure page 3 seat bearing housing this may cause bearing and drive housing misalignment and result in premature 3 Stop sprayer at bottom of stroke to get crank E in bearing wear lowest position To lower crank manually carefully i rotate blades of fan with a screwdriver 14 Install screws and lockwashers 25 23 Tighten screws evenly to 175 in Ib 19 N m 4 Fig 8 Remove front cover 49 Unclip drain hose 36 from pump Unscrew pump suction tube 39 15 Install pump page 17 pump intake valve 213 Disconnect pump hose Pe 70 16 Fig 8 Install remaining parts 5 Push up retaining spring 68 Push pin 66 out rear 6 Loosen locknut 47 Unscrew displacement pump 64 7 Remove four screws and lockwashers 25 23 8 Tap lower rear of bearing housing 22 with a plastic mallet to loosen from drive housing 67 Pull bearing housing and connecting rod assembly 63 straight off drive housing 9 Remove pail bracket assembly F and install it on new bearing housing 10 Inspect crank E for excessive wear and replace parts as needed Evenly lubricate inside of bronze bearing B with
7. mach panhd 5 98 BUSHING strain relief 31 240314 TRANSDUCER pressure control 1 113799 Model 232144 145 154 includes item 59 114284 Model 232148 158 156 157 46 114528 SCREW mach panhd 2 99 114689 BUSHING strain relief 50 100020 WASHER lock spring 4 100 240131 CAP for secondary outlet 55 112538 ELBOW 90 street reducing 1 101 192831 PLATE instruction 59 111457 O RING packing 1 102 114420 SCREW mach pnhd 69 240315 BOWL filter includes item 72 1 104 BOARD PC 71 187615 VALVE seat 1 240561 Model 232144 145 154 72 171941 SPRING compression 1 240168 Model 232148 158 156 157 74 235014 ASSEMBLY drain valve 1 105 236352 POTENTIOMETER pressure adjust 75 100721 PLUG pipe 1 106 112382 NUT shaft sealing 76 186075 SUPPORT filter 1 107 114391 SCREW ground 79 CORD SET power see note page 22 1 112 114393 SCREW 240539 Continental Europe CEE 7 7 1 15A LABEL warning 240540 Italy 1 193051 English 239050 United Kingdom 1 193520 Japanese 240543 None Bare End 1 116 114652 BUSHING strain relief 240721 Japan 1 127 193347 COVER display painted 241879 Australia 1 128 164736 PIN cross 80 SWITCH rocker dpst 1 129 240544 BOARD circuit display 114518 Model 232144 145 148 154 158 1 130 193348 LABEL graphic display 114277 Model 232156 157 1 131 103739 WASHER lock int 81 114273 KNOB potentiometer 1 132 114512 SCREW mach panhd 4 40 x 3 8 82 240527 COVER control box painted 1 133 192149 RETAINER cord 134 193497 GAS
8. motor lead F in place Remove brush G and spring H Fig 6 NOTE SPRING COIL DIRECTION Paroa 11 Repeat for other side 12 Test brushes Fig 5 pa a Remove pump connecting rod pin b With sprayer OFF turn pressure control knob 6 Inspect commutator for excessive pitting burning fully counterclockwise to minimum pressure or gouging A black color on commutator is normal Plug in sprayer Have commutator resurfaced by a qualified motor repair shop if brushes wear too fast c Turn sprayer ON Slowly increase pressure until motor is at full speed A CAUTION Motor Brush Installation A CAUTION When installing brushes follow all steps carefully to avoid damaging parts Do not run sprayer dry for more than 30 seconds while checking brushes to avoid damaging displace ment pump packings 7 Fig 6 Install new brush G with lead in long slot a4 ot brush Haider 4C 13 Install brush inspection covers and gaskets 14 Break in brushes 8 Fig 5 Slide brush lead E under washer of termi a Operate sprayer 1 hour with no load nal screw D and tighten screw Be sure motor b Install connecting rod pin lead F is connected at terminal screw 9 Fig 6 Place spring H on brush G 10 308842 On Off Switch Replacement 1 Read General Repair Information on page 3 2 Ins P W Wk Relieve pressure page 3 3 Fig 7 Remove pressure control cover 82 4 Remove display connector
9. motor leads loose brush terminal screws motor lead terminals worn ln brushes Repair as needed page 9 1 Ba Relieve pressure page 3 p pag 3 If still uneven or no resistance replace motor page 16 N Remove drive housing page 15 3 Fig 3 Remove pressure control cover 82 Dis connect motor leads F and G 4 Fig 4 Remove motor shield 54 fan cover A and inspection covers B Armature Short Circuit Test Quickly turn motor fan by hand If no electrical shorts motor coasts two or three revolutions before complete stop If motor does not spin freely armature is shorted Replace motor page 16 Motor Brush Replacement NOTE Replace brushes worn to less than 1 2 in Continued on page 10 Brushes wear differently on each side of motor check both sides Brush Repair Kit 220853 is available Spring clip 110816 may be purchased separately 8051A Motor Brush Removal 54 1 Read General Repair Information page 3 2 Ins W Wk Relieve pressure page 3 3 Fig 4 Remove motor shield 54 Remove in spection covers B and gaskets on each side of motor 7703B Fig 4 308842 9 Motor Brush Replacement 4 Fig 5 Push in 110816 spring clip A to release 10 Fig 6 Install spring clip A Push down to hook hooks B from brush holder C Pull out spring short slots K in brush holder C clip 5 Fig 5 Loosen terminal screw D Pull brush lead E away leaving
10. 1 187975 A English 1 50 193347 COVER display painted 1 189699A Japanese 1 51 179961 REDUCER gear 1 52 183350 WASHER 1 AExtra Danger and Warning tags and labels available free 59 SHIELD motor 1 240317 Ultra MAX 795 1 Motor Brush Repair Kit 220853 is available 240313 Ultra MAX 1095 1 Order separately 62 192027 SLEEVE cart 2 TNot part of Model 232157 63 218034 KIT rod connecting 1 308842 21 Parts Drawing Sprayer Ultra MAX 795 and 1095 Sprayers C Model 232144 Series A Model 232145 Series A Model 232148 Series A 69 i Model 232154 Series A Model 232156 Series A Model 232157 Series A Model 232158 Series A A i 46 A NE Ca z aaa 5 87 55 85 AG 8056C pai Model 232 148 and 232 158 NG 22 308842 REF REF NO PART NO DESCRIPTION QTY NO PART NO DESCRIPTION 4 224807 ASSEMBLY cam drain valve 1 85 240144 HOSE drain 5 111600 PIN grooved 1 86 240316 HOUSING filter includes item 9 6 187625 HANDLE valve drain 1 87 107183 CAPSCREW 7 111699 GASKET seat valve 1 89 192726 PLATE housing control 8 BOARD filter 1 91 107505 PACKING o ring 240557 Models 232144 145 154 1 92 164672 ADAPTER 240723 Models 232148 158 1 97 HOUSING control box 9 104361 O RING packing 1 193239 Model 232144 145 154 12 167025 STRAINER mesh 60 1 192694 Model 232148 158 156 157 28 114392 SCREW
11. 444 inaia EE veges a 9 Parts List Sprayer 00 neern nnn 19 General Repair Information 45 3 Wiring Diagram 0 kiani ink EERE e 23 Motor Brush Replacement a 9 Accessories 600s 24 On Off Switch Replacement 11 Technical Data 0 c eee eee 24 Pressure Control Repair 2000000 12 DIMENSIONS eesse ceed DNA DAA eae ee 24 Bearing Housing amp Connecting Rod Replacement 14 Graco Phone Number 00000 eee eees 24 Drive Housing Replacement 15 Graco Warranty cece eee eee eee 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 Component Identification and Function 8050A Container for fluid to be sprayed may be hung here F Fluid Filter Final filter of fluid between source and spray gun Pressure Adjusting Knob Controls fluid outlet pressure Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet Works with pressure adjusting knob ON OFF Switch Power switch that controls VAC main power to sprayer 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 High pressure spray gun with gun safety latch RAC IV Switch Tip Uses high pressure fluid to clear tip clogs without removing
12. APSCREW sch 1 4 20 x 2 75 in SCREW serrated flange hex hd 5 16 18 x 1 2 NUT hex PLUG tubing SCREW pan head no 8 x 3 8 in SCREW pnhd 10 32 x 1 4 in RING retaining CLIP spring TUBE intake NIPPLE 1 4 npt m x 1 4 npsm LABEL DANGER English Japanese NUT hex BUTTON snap COVER housing Ultra Max 795 Ultra Max 1095 GEAR REDUCER WASHER STRAINER SHIELD motor includes 41 Ultra Max 795 Ultra Max 1095 HANGER pail SLEEVE CONNECTING ROD DISPLACEMENT PUMP see manual 308798 for parts THROAT SEAL LIQUID 8 OZ QTY sAaNSSASsSNAsNNNN NRBANN NNBBRBRAHNONBNSB aah mk NJ i mh mk i REF NO PART NO 66 176818 67 239931 239929 218032 67a 178967 67b 107089 68 176817 70 239984 73 240994 240566 240015 240034 77 239998 78 239980 84 114271 85 240144 90 100069 120T 238361 121T 238358 1221 222667 1231 1928384 126 187975 A 189699 A DESCRIPTION PIN straight hdls 0 3125 in dia x 1 023 in DRIVE HOUSING includes 67a and 67b Ultra Max 795 Model 232144 148 Ultra Max 1095 Model 232154 158 Ultra Max 1095 Model 232156 WASHER silver colored WASHER bronze colored SPRING retaining HOSE grounded nylon 1 4 in ID cpld 1 4 npsm f 25 in 635 mm spring guards both ends MOTOR ELECTRIC includes 41 Ultra Max 795 Model 232144 Ultra Max 1095 Model 232154 Ultra Max 795 Model 232148 Ultra Max 1095 Model 232158 156 HANDLE cart
13. ATIONS TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If is OK go to next check When 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 17 connected Be sure all male terminal blades are centered and firmly connected to female terminals See Fig 17 2 Maximum working pressure 2 Replace pressure control board 104 See page 12 3 Motor control board 104 by performing motor 3 Replace with a new pressure control board control board diagnostics on page 12 If diag 104 See page 12 nostics 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 308842 7 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 is not located in direct sun 3 Determine if sprayer was turned on pressur 3 Tum off sprayer whenever you stop spray ized but not operati
14. INSTRUCTIONS REPAIR N KEEP FOR REFERENCE Read this and all related manuals for important warnings and instructions 308842 Rev H GRACO First choice when quality counts RA INSTRUCTIONS ULTRA MAX 795 and 1095 Airless Paint Sprayers 3000 psi 210 bar 21 MPa Maximum Working Pressure 230 vac CE model Series Description 232144 A Ultra Max 795 Hi boy with RAC IV tip gun and hose 232145 JA Ultra Max 795 Lo boy with RAC IV tip gun and hose 232154 A Ultra Max 1095 Hi boy with RAC IV tip gun and hose novac CE Model 232144 i a Modei Series Description 232148 A Ultra Max 795 Hi boy with RAC IV tip gun and hose 232158 A Ultra Max 1095 Hi boy with RAC IV tip gun and hose 100 VAC All models are not available in all countries U S PATENT NO 4 323 741 4 397 610 PATENTED 1983 CANADA AND OTHER PATENTS PENDING Related Manuals Operator 0 ccc 308840 Model Series Description Displacement Pump 00e 0 308798 232156 Ultra Max 1095 Hi boy Spray Gun 0 00 0 eee 307614 7 Spray Tip 0 eee eee 308644 ah Binaril Poe PC Board La 308816 Table of Contents Component Function and Identification 2 Motor Replacement aa 16 Grounding 0 cece eee eee ee 4 Displacement Pump Repair 0 17 Troubleshooting 0 cece eee ees 4 Parts Drawing Sprayer aa 18 Spin TeSt 24
15. KET Brown JE Blue A Extra Danger and Warning tags and labels available free Motor Brush Repair Kit 220853 Order separately a a a SS Wiring Diagram TP3 a P2 Heat from inductor coil of filter board may destroy wire insulation that comes in contact ON OFF View C C with it Exposed wires could cause shorts and Switch Gr component damage Bundle and tie all loose a 2 wires so none lay in contact with inductor coil KN Che ANG Blue of filter board 104 m o o TP5 fa 3 Brown O jo Digital Display Blue ae ae ee J Lf Power Pressure Transducer Plug LJ j Potentiometer Black Red l ee Inductor Coil Filter Board 8100B ig Parts List Sprayer Ultra MAX 795 and 1095 Sprayers Models 232144 Series A 232145 Series A 232148 Series A Models 232154 Series A 232158 Series A 232157 Series A 232156 Series A 308842 QTY N e e d a o COR M UO M M M Md Md Md A A A L l d d d d d Oe ee M ee 23 Accessories Technical Data Power Requirements DANGER LABELS Model 232144 145 154 230 VAC 50 Hz An English language DANGER label is on your
16. Model 232148 iss ee pees ma ne AG core sprayer If you have painters who do not read En 1 phase 15A minimum or 4000W generator glish order one of the following labels to apply to Model 232156 157 100 VAC 50 60 Hz your sprayer The drawing shows the best place 1 phase 15A minimum or 4000W generator ment of these labels for good visibility Motor Order the labels from your Graco distributor Ultra Max 795 pe eee anaes mang ei ern eee 1 0 HP with latex at 2000 psi 138 bar 13 8 MPa Apply other Ultra Max 1095 cece eee eee eee 1 2 HP language here with latex at 2000 psi 138 bar 13 8 MPa Working Pressure Range 0 3000 psi 0 210 bar 0 21 MPa Cycles Gallon liter French 185955 Ultra Max 795 ooo 244 64 6 Spanish 8185962 Ultra Max 1095 2 a 200 53 German 186042 Maximum Delivery Rating Greek 186046 Ultra Max 795 aaa 0 8 gpm 3 Ipm Korean 186050 Ultra Max 1095 aan 1 1 gpm 4 1 Ipm Tip Size Ultra Max 795 one gun 0 028 two guns 0 019 with latex at 2000 psi 138 bar 13 8 MPa Ultra Max 1095 one gun 0 032 two guns 0 021 with latex at 2000 psi 138 bar 13 8 MPa Power Cord 14 AWG 1 5 mm2 3 wire 15 ft 4 5 m Inlet Paint Strainer 16 mesh 975 micron stainless steel screen reusable Outlet Paint Filter 60 mesh 238 micron stainless steel screen reusable Pump Inlet Size eee eee eee 3 4 npt m Flui
17. ard 104 for damaged or loose wires or con and firmly connected to female terminals nectors Inspect wiring insulation and terminals Replace any loose terminal or damaged for signs of overheating wiring Securely reconnect terminals 6 For loose motor brush leads and terminals See 6 Tighten terminal screws Replace brushes page 9 if leads are damaged See page 9 7 For worn motor brushes which must be 1 2 in 7 Replace brushes See page 9 minimum See page 9 8 For broken and misaligned motor brush 8 Replace spring if broken Realign spring springs Rolled portion of spring must rest with brush See page 9 squarely on top of brush 9 Motor brushes for binding in brush holders See 9 Clean brush holders remove carbon dust with small cleaning brush Align brush lead with slot in brush holder to assure free verti cal brush movement 10 Stall pressure 10 Replace with new pressure control board 104 See page 12 11 Motor armature for shorts by using an armature 12 Replace motor See page 16 tester growler or perform spin test See page 9 12 Motor control board 104 by performing motor 11 Replace with new pressure control board control board diagnostics on page 12 If diag 104 See page 12 nostics indicate substitute with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 6 308842 Troubleshooting
18. cedures 2 ON OFF switch 80 See page 11 Be sure 2 Replace ON OFF switch See page 11 Building circuit breaker opens sprayer is unplugged Disconnect wires from as soon as sprayer is plugged switch Check switch with ohmmeter Reading into outlet and sprayer is NOT must be infinity with ON OFF switch OFF and turned on zero with switch ON 3 For damaged or pinched wires in pressure con 3 Replace damaged parts See page 12 trol See page 12 Sprayer quits after sprayer op 1 Basic Electrical Problems on page 4 1 Perform necessary procedures erates for 5 to 10 minutes 2 Electrical supply with volt meter 2 If voltage is too high do not operate Meter must read sprayer until corrected 210 250 VAC for models 232144 145 154 100 120 VAC for models 232148 158 90 110 VAC for models 232156 157 3 Tightness of pump packing nut Over tightening 3 Loosen packing nut Check for leaking tightens packings on rod restricts pump action around throat Replace pump packings if and damages packings necessary See page 17 8 308842 Spin Test Setup Armature Brushes and Motor Wiring Open Circuit Test Continuity Electric Shock Hazard page 3 1 Connect red and black motor leads together with 4 test lead Turn motor fan by hand at about two revolutions per second To check armature motor winding and brush electrical f continuity 2 If uneven or no resistance check for broken brush springs brush leads
19. d 2 Reset building circuit breaker replace build 210 250 VAC for models 232144 145 154 ing fuse Try another outlet 100 120 VAC for models 232148 158 90 110 VAC for models 232156 157 3 Extension cord for damage Check extension 3 Replace extension cord cord continuity with volt meter 4 Sprayer power supply cord 79 for damage 4 Replace power supply cord such as broken insulation or wires 4 308842 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 That motor leads are securely fastened and 1 Replace loose terminals crimp to leads Be continued properly mated sure terminals are firmly connected Clean circuit board terminals Securely re connect leads 2 For loose motor brush lead connections and ter 2 Tighten terminal screws Replace brushes if minals See page 9 leads are damaged See page 9 3 Brush length which must be 1 2 in minimum 3 Replace brushes See page 9 See page 9 NOTE Brushes do not wear at the same rate on both sides of motor Check both brushes 4 For broken or misaligned motor brush springs 4 Replace spring if broken Realign spring with Rolled portion of spring must rest squarely on brush See page 9 top of brush See page 9 5 Motor brushes for binding in brush holders See 5 Clean brush holders Remove carb
20. d Outlet Size AA asa a hehe 3 8 npt f Filter with standard 3 8 npt f to 1 4 npsm adapter 1 4 npsm Sound Data Sound Power Level a 100 dB A Sound Pressure Level aa 90 dB A Measured while spraying waterbase paint specific gravity 1 36 through a 0 019 tip at 3000 psi 207 bar Per ISO 3744 Basic Sprayer Wetted Parts zinc plated carbon steel polyurethane polyethylene stainless steel Delrin chrome plating leather V Max UHMWPE aluminum stainless steel tungsten carbide NOTE Delrin is a registered trademark of the DuPont Co Dimensions Weight Ultra Max 795 a ala oe eo aoe eee 101 Ib 46 kg Ultra Max 1095 aa 107 Ib 49 kg Height aang cap eae Denno BUNAK eke 28 5 in 724 mm kla LA 25 5 in 648 mm Width ceitein a ala LEAH teas 20 5 in 521 mm Graco Phone Number TO PLACE AN ORDER contact your Graco distributor All written and visual data contained in this document reflect 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 International Offices Belgium Korea Hong Kong Japan www graco com PRINTED IN USA 308842 May 1998 Revised 2 2003 24 308842
21. f switch Turn sprayer OFF 3 If thermal switch is open no continuity allow Check for continuity between TP4 and TP5 with motor to cool If switch remains open after ohmmeter motor cools replace motor If thermal switch closes after motor cools correct cause of overheating 4 Allterminals for damage or loose fit 4 Replace damaged terminals and reconnect securely 308842 5 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 For worn spray tip 1 Follow Pressure Relief Procedure Warn ing then replace tip See your separate gun or tip manual 2 Verify pump does not continue to stroke when 2 Service pump See page 17 gun trigger is released Plug in and turn on sprayer Prime with paint Trigger gun momen tarily then release and lock safety latch Relieve pressure turn off and unplug sprayer 3 Electrical supply with volt meter 3 Reset building circuit breaker replace Meter must read building fuse Repair electrical outlet or try 210 250 VAC for models 232144 145 154 another outlet 100 120 VAC for models 232148 158 90 110 VAC for models 232156 157 4 Extension cord size and length must be at least 4 Replace with a correct grounded exten 12 gauge wire and no longer than 300 ft sion cord 5 Leads from motor to pressure control circuit 5 Be sure male terminal blades are centered bo
22. high quality motor oil Pack roller bearing C with bearing grease 11 Assemble connecting rod 63 and bearing housing 22 12 Clean mating surfaces of bearing and drive hous ings 22 67 13 Align connecting rod 63 with crank E and drive AN Pack with bearing grease housing locating pins G with bearing housing 22 AN Torque to 175 in Ib 19 N m holes Push bearing housing onto drive housing or Fia 8 cond tap into place with plastic mallet 9 oS 14 308842 A CAUTION 1 Drive Housing Replacement Do not drop gear cluster 51 when removing drive housing 67 Gear cluster may stay engaged in motor front end bell or drive housing Do not lose thrust balls 90 or drop thrust balls between gears If thrust balls are caught between gears and not removed serious damage will occur to drive housing If thrust balls are not in place at each end of gear cluster bearings will wear prematurely Read General Repair Information on page 3 2 Ins z w XA Relieve pressure page 3 3 Fig 9 Remove front cover 49 and motor shield 54 Unclip drain hose 85 from pump 4 Remove four bearing housing screws 25 and lockwashers 23 5 Tap lower rear of bearing housing 22 with plastic mallet to loosen from drive housing 67 Pull bearing housing and connecting rod straight off drive housing 54 A Torque to 175 in Ib 19 N m AN Torque to 90 100 in Ib 10 2 11 3 N m AN Liberal
23. i 310 bar 31 MPa control board Sprayer stops Power is applied Pressure transducer faulty Sprayer stops Power is applied Line voltage too high Set voltage to 230 VAC for models 232144 145 154 110 VAC for models 232148 158 100 VAC for models 232156 157 Ec 06 Sprayer stops Power is applied Locked rotor Motor can not Repair or replace abi turn Sprayer stops Power is applied Pressure less than Increase pressure 200 psi 14 bar 1 4 MPa Pressure Control Transducer Pressure Adjust Potentiometer Removal Removal N Ng Ka wai Relieve pressure page 3 1 IN i w Wk Relieve pressure page 3 2 Fig 7 Remove five screws 28 and cover 82 Disconnect lead E from motor control 2 Fig 7 Remove five screws 28 and cover 82 board 104 3 Disconnect lead D from motor control Remove strain relief bushing 116 board 104 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 Installation Installation 1 Fig 7 Install packing o ring 59 and pressure control transducer 31 in control housing 1 Fig 7 Install pressure adjust potentiometer 105 plate 89 Torque to 30 35 ft lb sealing shaft nut 106 and potentiometer knob 2 Install strain relief bushing 116 81 Connect lead E to motor control board 104 2 Connect lead D to motor
24. l 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 Guide pages 4 8 for other possible solutions A WARNING EXPLOSION HAZARD Motor and drive housing are very hot during operation and could burn skin if touched Flammable materials spilled on W hot bare motor could cause fire or explosion Have motor shield in place during operation to reduce risk of burns fire or explosion A 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 A 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 injec tion splashing fluid or moving parts follow Pres sure Relief Procedure whenever you e are instructed to relieve pressure e stop spraying e check or service any system equipment e or install or clean spray tip Lock gun safety latch Tur
25. ly apply grease Fig 9 10 11 12 Remove two drive housing screws 26 and lockwashers 20 Remove two lower screws 16 and lockwashers 20 and then two upper screws 16 and lock washers 20 from front of motor 73 Tap drive housing 67 with plastic mallet to loosen from front of motor 73 pull drive housing straight off Apply approximately 4 oz of bearing grease to gear cluster 51 Grease is supplied with drive housing replacement kit Be sure thrust balls 90 are in place Place bronze colored washer 67b then silver col ored washer 67a on shaft protruding from big gear in drive housing 67 Align gears and push new drive housing straight onto front of motor and locating pins Continue reassembling sprayer 7699B 308842 15 Motor Replacement 1 Read General Repair Information on page 3 A CAUTION Do not drop gear cluster 51 when removing drive 2 Ba Relieve pressure page 3 housing 67 Gear cluster may stay engaged in motor front end bell or drive housing Do not lose thrust balls 90 or drop thrust balls 3 Fig 10 Remove motor shield 54 between gears If thrust balls are caught between gears and not removed serious damage will occur to drive housing If thrust balls are not in place at each 4 Fig 7 Remove pressure control cover 82 Dis end of gear cluster bearings will wear prematurely connect six motor leads two yellow two violet black and red 10
26. n ON OFF switch to OFF Unplug power supply cord Unlock gun safety latch Hold metal part of gun firmly to grounded metal pail Trigger gun to relieve pressure 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 INS 308842 3 Grounding A WARNING Grounded Grounding Plug Outlets Improper installation or alteration of grounding plug results in risk of electric shock fire or explosion that could cause serious injury or death 1 Models 232144 145 154 require a 230 VAC 50 Hz 10A circuit with a grounding receptacle Mod els 232148 158 require a 110 VAC 50 60 Hz 15A Fig 2 circuit with a grounding receptacle Models 232156 157 require a 100 VAC 50 60 Hz 15A circuit with a grounding receptacle See Fig 2 Model 232144 145 154 3 A 12 AWG 3 wires with grounding prong 300 ft 90 m extension cord may be used Long lengths 2 Do not alter ground prong or use adapter reduce sprayer performance Troubleshooting Relieve pressure page 3 MOTOR WON T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is
27. ng 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 All electrical wiring for damaged insulation and 1 Repair or replace any damaged wiring or as soon as sprayer switch is all terminals for loose fit or damage Also wires terminals Securely reconnect all wires turned on between pressure control and motor See page 16 CAUTION 2 For missing inspection plate gasket see page 2 Correct faulty conditions Any short in any part of the 16 bent terminal forks or other metal to metal motor power circuit will cause contact points which could cause a short the control circuit to inhibit sprayer operation Correctly 3 Motor armature for shorts Use an armature 3 Replace motor See page 16 diagnose and repair all shorts tester growler or perform spin test See page before checking and replac 9 Inspect windings for burns ing control board 4 Motor control board 104 by performing motor 4 Replace with a new pressure control board control board diagnostics on page 12 If diag 104 See page 12 nostics indicate substitute with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 1 Basic Electrical Problems on page 4 1 Perform necessary pro
28. not OK refer to this column Basic Fluid Pressure 1 Pressure control knob setting Motor will not run 1 Slowly increase pressure setting to see if mo Problems if at minimum setting fully counterclockwise tor starts 2 For clogged spray tip or fluid filter Refer to sepa 2 Relieve pressure refer to separate gun tip rate gun tip or fluid filter instruction manual or fluid filter instruction manual for cleaning Basic Mechanical 1 For frozen or hardened paint in pump 64 Use 1 Thaw sprayer if water or water based paint Problems a screwdriver and carefully rotate fan at back of has frozen in sprayer Place sprayer in warm motor by hand See page 9 area to thaw Do not start sprayer until thawed completely If paint hardened dried in sprayer replace pump packings See page 17 Displacement Pump Repair Displacement pump connecting rod pin 66 2 Push pin into place and secure with spring re Pin must be completely pushed into connecting tainer rod 63 and retaining spring 68 must be firmly in groove of connecting rod See Fig 12 For motor damage Remove drive housing as 3 Replace motor 73 if fan won t turn See sembly 67 See page 15 Try to rotate fan by page 16 hand Basic Electrical Problems Pressure control safety circuit 2 Turn pressure control ON OFF switch to OFF to RESET If pressure control safety contin ues to trip see ELECTRICAL SHORT on page 8 Electrical supply Meter must rea
29. on with small cleaning brush Align brush leads with slot in brush holder to assure free vertical brush movement 6 Motor armature commutator for burn spots 6 Remove motor and have motor shop resur gouges and extreme roughness face commutator if possible See page 16 See page 9 7 Motor armature for shorts using armature tester 7 Replace motor See page 16 growler or perform spin test See page 9 8 Motor control board 104 by performing motor 8 Replace with new pressure control board control board diagnostics on page 12 If diag 104 See page 12 nostics indicate substitute with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board Refer to wiring diagram on 1 Power supply cord 79 Connect volt meter be 1 Replace power supply cord page 23 to identify test tween TP1 neutral and TP2 Plug in sprayer points TP Meter must read 210 250 VAC for models 232144 145 154 100 120 VAC for models 232148 158 90 110 VAC for models 232156 157 Unplug sprayer 2 ON OFF switch 80 Connect volt meter be 2 Replace ON OFF switch See page 11 tween TP1 and TP3 terminal on ON OFF switch Plug in sprayer and turn ON Meter must read 210 250 VAC for models 232144 145 154 100 120 VAC for models 232148 158 90 110 VAC for models 232156 157 Turn off and unplug sprayer Reconnect TP3 3 Motor thermal cutof
30. roxi mately 75 5 ft lb 102 N m 7673B Fig 15 Fig 16 Fill packing nut with Graco TSL through one of the slits until fluid flows onto the top of seal 7677B Fig 16 308842 17 Parts Drawing Sprayer es A es A esA esA es A Ser Ser Ser Ser Ser 232144 232154 232148 232158 232156 Ultra MAX795 and 1095 Hi boy Sprayers Mode Mode Mode Mode Mode LEE PA LE LLLP RN LILL S ALK 7 re Lily by Ref 70 SEE PARTS ON PAGE 22 308842 18 Ultra MAX 795 and 1095 Hi boy Sprayers Model 232144 Series A Model 232154 Series A Parts List Sprayer Model 232148 Series A Model 232156 Series A Model 232158 Series A REF NO PART NO 10 110996 14 101242 16 100644 19 104811 20 105510 21 106062 22 240523 23 106115 24 114406 25 107210 26 107218 30 111801 32 112746 33 108691 34 108865 35 109032 37 110243 38 192691 39 192641 40 162453 41 1877914 1897024 47 192723 48 112827 49 188154 179899 51 179961 52 183350 53 181072 54 240317 240313 61 192719 62 192027 63 218034 64 239923 65 206994 DESCRIPTION NUT heavy hex 5 16 18 unc 2a RING retaining SCREW socket hd 1 4 20 x 0 75 in HUBCAP LOCKWASHER spring 1 4 in WHEEL semi pneumatic BEARING HOUSING LOCKWASHER spring 3 8 in SCREW filh no 8 32 X1 in CAPSCREW sch 3 8 16 x 1 1 2 in C
31. s 28 and cover 82 See Fig 7 LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Two times Sprayer shuts down and LED continues Run away pressure Pres Replace motor control board repeatedly to blink two times repeatedly sure greater than 4500 psi See preceding Motor control 310 bar 31 MPa board removal procedure Three times Sprayer shuts down and LED continues Pressure transducer is Replace pressure transducer to blink three times repeatedly faulty or missing repeatedly Four times Sprayer shuts down and LED continues Line voltage is too high Lower line voltage to 230 VAC repeatedly to blink four times repeatedly for models 232144 145 154 and to 110 VAC for models 232148 158 Five times Sprayer shuts down and LED continues Locked rotor Motor can Clear obstruction and replace repeatedly to blink five times repeatedly not turn because of some broken parts preventing motor mechanical condition from turning 12 308842 Pressure Control Repair Digital Display Messages x 1 Lift lid on pressure control cover and view display 3 Ba No display does not mean f l that sprayer is not pressur 2 Observe display and reference following table ized Relieve pressure before repairing page 3 DISPLAY SPRAYER INDICATION ACTION OPERATION iad Spray Pressure varies with tip size and pres sure control setting Do Sprayer stops Power is applied Pressure greater than Replace pressure ab 4500 ps
32. sing straight off See CAUTION Fig 17 49 79 98 A AN Torque to 90 100 in Ib 10 2 11 3 N m Liberally apply grease 8054A Fig 10 16 308842 Displacement Pump Repair See manual 308798 for pump repair instructions Removing pump 1 Flush pump Relieve pressure Fig 11 Cycle pump with piston rod 222 in its lowest position 2 Fig 11 Remove suction tube and hose 222 7672B Fig 11 3 Fig 12 Use screwdriver push retaining spring up and push out pin 21 agi Bo TA sata 4 Fig 13 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump Fig 12 Fig 13 ka Installing pump A WARNING If pin works loose parts could break off due to force of pumping action Parts could project through the air and result in serious injury or prop erty damage If the pump locknut loosens during operation the threads of the bearing housing will be damaged 1 Fig 14 Pull piston rod out 1 5 in Screw in pump until holes in bearing cross link and piston rod align 7676B Fig 14 2 Fig 12 Push pin 21 into hole And push retaining spring into groove all the way around connecting rod Fig 15 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 app
33. tip from spray gun Reverse A Clean RAC tip guard reduces risk of injection injury U Power Cord Rack Holds wrapped power cord for storage Spray Hose Rack Holds wrapped spray hose for storage 2 308842 General Repair Information A CAUTION To reduce risk of pressure control malfunction e 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 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 1 Keep all screws nuts washers gaskets and electrical fittings removed during repair proce dures These parts are not normally provided with replacement assemblies A 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 Instal

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