GRACO 308800F ULTRA MAX 795 Airless Paint Sprayer Instructions

Instructions for GRACO models including: ULTRA MAX 795 Airless Paint Sprayer, ULTRA MAX 795, Airless Paint Sprayer, Paint Sprayer, Sprayer

GRACO ULTRA MAX 795 232141 (01) PDF MANUAL - Manual-Hub.com

File Info : application/pdf, 36 Pages, 1.64MB

GRACO ULTRA MAX 795 232141 (01)

Instructions Parts List
120 VAC, 15A
ULTRARMAX 795 Airless Paint Sprayer
3000 psi (21 MPa, 210 bar) Maximum Working Pressure
Model 232140, Series A Basic sprayer on upright cart without hose or gun
Model 232141, 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
Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Related Manuals
Displacement Pump . . . . . . . . . . . . . . . . . 308798 Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . 307614 Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 308644

308800F
7706A

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Function and Identification . . . . . . . . . . . . 5 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 General Repair Information . . . . . . . . . . . . . . . . . . . . . 16 Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . 18 Power Supply Cord Replacement . . . . . . . . . . . . . . . 19 On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 19 Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 21

Bearing Housing & Connecting Rod Replacement . 24 Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 25 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Displacement Pump Repair . . . . . . . . . . . . . . . . . . . . . 29 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Parts Drawing Sprayer . . . . . . . . . . . . . . . . . . . . . . . 32 Parts List Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Symbols

Warning Symbol
WARNING

Caution Symbol
CAUTION

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

This symbol alerts you to the possibility of damage to 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
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D 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.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer's warnings.
D Do not use 1,1,1trichloroethane, 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.
D Do not use hoses to pull equipment.
D 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).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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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.
D 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 surgical treatment.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not "blow back" fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning, checking or servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D 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.
D 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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

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308800 3

WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present. D Do not operate a gasoline engine in the spray area.
D 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.
D Keep clear of all moving parts when starting or operating the pump.
D 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 EXPLOSION HAZARD

SKIN INJECTION HAZARD

Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop cloths, open flames such as pilot lights, hot objects such as cigarettes, arcs from connecting or disconnecting power cords or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.

Liquids can be injected into the body by high pressure airless spray or leaks especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate "Surgical Treatment".
Failure to follow this warning can result in amputation or serious injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

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Component Identification and Function
V T

S R

03008

L
K J PN M H

A B

F E

Fig. 1
A Motor B Drive Assembly C Pail Hanger D Displacement Pump E Primary Fluid Outlet F Secondary Fluid Outlet G Pressure Drain Valve H Fluid Filter J Pressure Adjusting Knob K Pressure Control
L ON/OFF Switch M 3 ft (0.9 m) Hose
N 50 ft (15 m) Main Hose P Contractor Gun R RAC IV Switch Tip S RAC IV Tip Guard T Spray Gun Safety Latch U Power Cord Rack V Spray Hose Rack

7706A
DC motor, permanent magnet, totally enclosed, fan cooled Transfers power from DC motor to the displacement pump Container for fluid to be sprayed may be hung here Transfers fluid to be sprayed from source through spray gun Single spray gun operation is connected here Second spray gun operation is connected here Relieves fluid outlet pressure when open Final filter of fluid between source and spray gun Controls fluid outlet pressure Controls motor speed to maintain fluid outlet pressure at displacement pump outlet. Works with pressure adjusting knob. Power switch that controls 120 VAC main power to sprayer 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun to allow more flexibility when spraying 1/4 in. ID, grounded, nylon hose with spring guards on both ends High pressure spray gun with gun safety latch Uses high pressure fluid to clear tip clogs without removing tip from spray gun Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury Gun safety latch inhibits accidental triggering of spray gun Holds wrapped power cord for storage Holds wrapped spray hose for storage

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308800 5

Setup

WARNING
If you supply your own hoses and spray gun, be sure the hoses are electrically conductive, that the gun has a tip guard, and that each part is rated for at least 3000 psi (210 bar, 21 MPa) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
CAUTION
To avoid damaging the pressure control, which may result in poor equipment performance and component damage, follow these precautions:
D Do not allow material to freeze in sprayer.
D Use nylon spray hose at least 50 ft (15 m) long.
D Do not use wire braid hose.
D Do not install shutoff device between sprayer and gun. See Fig. 1.

2. Single gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For more flexible gun movement, install 3/16 in. ID, 3 ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Connect gun and hose assembly to primary fluid outlet (F). Do not use thread sealant.
c. Do not install spray tip.
3. Two gun hookup.
Use 1/4 in. ID, 50 ft (minimum) main hose. For more flexible gun movement, install 3/16 in. ID, 3 ft hose between main hose and gun.
a. Connect gun, 3 ft hose and 50 ft hose.
b. Unscrew cap from 1/4 npsm(m) secondary fluid outlet (E).
c. Connect gun and hose assembly to secondary fluid outlet.

NOTE: See Fig. 1, except where noted.
1. Fill packing nut full with Graco Throat Seal Liquid (TSL), supplied. Fig. 2.

Fig. 2

7677A

WARNING
FIRE AND EXPLOSION HAZARD Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious injury and property damage. Also read FIRE OR EXPLOSION HAZARD on page 4 and Grounding, page 7.
4. Turn ON/OFF (L) switch OFF. Plug sprayer power cord into grounded electrical outlet at least 20 ft (6 m) from spray area.
5. Flush pump to remove oil. See Flushing, page 10.
6. Prepare paint according to manufacturer's recommendations. Remove any paint skin. Stir paint thoroughly. Strain paint through fine nylon mesh bag (available at most paint dealers) to remove particles that could clog filter or spray tip. This is an important step for trouble-free paint spraying.

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Setup

Grounding

WARNING

Grounded Outlets

Improper installation or alteration of the grounding plug will result in a risk of electric shock, fire or explosion that could cause serious injury or death.

Grounding Prong Fig. 3 2. Do not alter ground prong or use adapter.

1. This equipment requires a 120 VAC, 60 Hz, 15A circuit with a grounding receptacle. See Fig. 3.

3. A 12 AWG, 3 wires with grounding prong, 300 ft (90 m) extension cord may be used. Long lengths reduce sprayer performance.

Startup

WARNING
INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: D are instructed to relieve the pressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tip.
Pressure Relief Procedure
1. Engage gun safety latch. 2. Turn ON/OFF switch to OFF. 3. Unplug power supply cord. 4. Disengage gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve pressure. 5. Engage gun safety latch. 6. Open pressure drain valve. Leave pressure drain valve open until ready to spray again. If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.
Use this procedure each time you start sprayer to ensure sprayer is ready to operate safely.
Startup Procedure
NOTE: Flush sprayer if first-time startup. See page 10.
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NOTE: See Fig. 4 except where noted.
4. Put suction tube (39) into paint container.
5. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
6. Plug in sprayer power cord.
CAUTION
Do not run pump without fluid in it for more than 30 seconds to avoid damaging pump packings.
WARNING
FIRE AND EXPLOSION HAZARD To reduce risk of static sparking and splashing when priming or flushing system, hold metal part of gun firmly to side of grounded metal pail before triggering gun.
7. Prime pump.
a. Open (handle down) pressure drain valve (G). If no secondary hose is installed, be sure secondary outlet cap is installed. Turn ON/OFF (L) switch ON. Slowly turn pressure adjusting knob clockwise until sprayer starts. When fluid comes from drain hose, close pressure drain valve (handle forward).
b. Fig. 5. Disengage gun safety latch. Following warning, above, trigger gun until all air is forced out of system and paint flows freely from gun.
c. Release trigger. Engage gun safety latch.
8. Check all fluid connections for leaks. Relieve fluid pressure before tightening connections.
9. Fig. 5. Engage gun safety latch. Install spray tip. Install tip guard. See manual 308644, supplied. 308800 7

Startup

10. Adjust spray pattern.
a. Increase pressure just until spray from gun is completely atomized. Use lowest pressure necessary to get desired results. This reduces overspray and fogging, decreases tip wear and extends the life of the sprayer.
b. For more coverage, use larger tip rather than increasing pressure.
c. Test spray pattern. To adjust pattern, engage gun safety latch, loosen retaining nut. Position tip guard horizontally for horizontal pattern or vertically for vertical pattern. Then tighten retaining nut. Fig. 5.

JG
F E 39

7691A

Fig. 4

RAC IV RETAINING HANDLE NUT

GUN SAFETY LATCH ENGAGED

Fig. 5

GUN SAFETY LATCH DISENGAGED

03008

Cleaning a Clogged Tip
WARNING

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

1. Relieve pressure.

2. Clean front of tip frequently during operation.

3. If spray tip clogs, release gun trigger, engage gun safety latch, and rotate RAC IV handle 180_. See Fig. 5.
4. Disengage gun safety latch and trigger gun into waste container. Engage gun safety latch again.
5. Rotate RAC IV handle 180_ to original position, disengage gun safety latch, and resume spraying.

6. If tip is still clogged, engage gun safety latch, shut off and unplug the sprayer, and open pressure drain valve to relieve pressure. Clean spray tip as shown in manual 308644.

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Shutdown and Care

WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
1. Check packing nut (A) daily. First relieve pressure. Keep packing nut full of TSL at all times to help prevent fluid buildup on piston rod and premature wear of packings.
If pump begins to leak, loosen packing nut and remove throat nut spacer (228). Tighten packing nut just snug. Over tightening causes binding and excessive packing wear. Use a round punch or brass rod and light hammer to adjust nut. Refer to Fig. 6. When leakage occurs again, repack the pump.
2. Clean fluid filter often and whenever sprayer is stored. Follow Flushing Guidelines on page 10 for cleaning procedure.
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.
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.

6. Coil hose and hang it on hose rack when storing it, even for overnight, to help protect hose from kinking, abrasion, coupling damage, etc.

Fig. 6 B

A 228
TIGHTEN
7692A
49

Fig. 7

7693A

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308800 9

Flushing

When to flush
Determine material to spray from column 1. Flush with material in column 2. Then follow recommendations in one of next three columns.

CAUTION
Do not leave water or water-based fluids in sprayer if it could freeze. Push water out with mineral spirits. Frozen fluid in sprayer prevents starting and may cause serious damage.

If you are going to: B Flush with: B

Prime with: B Clean with: B

Store unit with: B

Spray with new sprayer or sprayer that has been stored

Mineral spirits, then compatible solvent such as water or mineral spirits

Compatible paint, Compatible solvent

such as latex or such as water or

oil-base

mineral spirits

Mineral spirits

Spray latex paint

Warm, soapy water, Latex paint then clean water

Warm soapy water, Mineral spirits 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 then clean water

Mineral spirits

Change oil to latex paint

Mineral spirits, then Latex soapy water, and finally, clean water

Warm, soapy water, Mineral spirits then clean water

Change colors, same base Compatible solvent such as water or mineral spirits

How to flush
WARNING
FIRE AND EXPLOSION HAZARD To reduce static sparking and splashing, always remove the spray tip from the gun, and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing.
1. Follow Pressure Relief Procedure on page 7. Engage gun safety latch.
2. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.
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 1/2 gallon of compatible solvent. Close pressure drain valve (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 fluid compatible solvent container. Circulate flushing fluid a few minutes to thoroughly clean system.
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6. Do not run pump dry for more than 30 seconds to avoid damaging pump packings!
7. Follow Pressure Relief Procedure on page 7. Engage gun safety latch.
8. Unscrew filter bowl and reinstall clean screen. Install bowl and hand tighten.
9. Remove suction tube and screen and clean them separately.

FILTER BOWL

SCREEN

G Fig. 8
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FILTER SUPPORT
7694A

Troubleshooting

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

MOTOR WON'T OPERATE

TYPE OF PROBLEM

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO 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 of connecting 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. Try 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 105125 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).

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Troubleshooting

MOTOR WON'T OPERATE (Continued)

TYPE OF PROBLEM

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO When check is not OK refer to this column

Basic Electrical Problems (continued)
Follow Pressure Relief Procedure on page 7. Remove gun from hose. Remove pressure control cover.

1. Check leads from motor to be sure they are 1. Replace loose terminals; crimp to leads. Be

securely fastened and properly mated.

sure terminals are firmly connected.

Clean circuit board terminals. Securely reconnect leads.

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 in. 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 have motor 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. Plug in

(TP).

sprayer. Meter must read 105 to 125 VAC. 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. Meter must read 105 to 125 VAC. Turn off and unplug sprayer. Reconnect TP3.

3. Check motor thermal cutoff 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 reconnect securely.

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LOW OUTPUT
TYPE OF PROBLEM Low Output

Troubleshooting

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO When check is not OK refer to this column

1. Check for worn spray tip.

1. Follow Pressure Relief Procedure Warning, 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, turn off and unplug sprayer.

3. Check electrical supply with volt meter. Meter 3. Reset building circuit breaker; replace

must read 105125 VAC.

building fuse. Repair electrical outlet or try

another outlet.

4. Check extension cord size and length; must 4. Replace with a correct, grounded extenbe 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 loose wires 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 and termi- 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 in. 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.

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Troubleshooting

NO OUTPUT

TYPE OF PROBLEM

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO 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 sealing tape on threads if necessary.

4. Check to see if intake valve ball and piston ball 4. 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 2930. Also

which may indicate worn or damaged pack- check piston valve seat for hardened paint

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 groove all 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 Spray pattern variations.

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO When check is not OK refer to this column

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 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.
4. Check LOW OUTPUT section, page 13.

14 308800

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Troubleshooting

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF PROBLEM

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO 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 posis 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 sprayized, but not operating for long periods of time. ing for a while and relieve fluid pressure.

ELECTRICAL SHORT

TYPE OF PROBLEM

WHAT TO CHECK If check is OK, go to next check

WHAT TO DO 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
Any short in any part of the motor power circuit will cause the control circuit to inhibit sprayer operation. Correctly diagnose and repair all shorts before checking and replacing control board.

2. Check for missing inspection plate gasket 2. Correct faulty conditions. (see page 27), bent terminal forks or other metal to metal contact points which could cause a short.
3. Check motor armature for shorts. Use an ar- 3. Replace motor. See page 27. mature tester (growler) or perform spin test. See page 17. Inspect windings for burns.

4. Check motor control board (104) by perform- 4. Replace with a 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.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

1. Check Basic Electrical Problems on page 11. 1. Perform necessary procedures.
2. Check ON/OFF switch (80) See page 19. Be 2. Replace ON/OFF switch. See page 19. sure sprayer is unplugged! Disconnect wires from switch. Check switch with ohmmeter. The reading must be infinity with 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.

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308800 15

General Repair Information

CAUTION
To reduce the risk of a pressure control malfunction:
D Always use needle nose pliers to disconnect a wire. Never pull on the wire, pull on the connector.
D Mate wire connectors properly. Be sure flat blade of insulated male connector is centered in wraparound blade of female connector.
D Route wires carefully to avoid interference with other connections of pressure control. Be sure wires are not pinched between cover and control box.

Tool List
Phillips screwdriver Small flat blade
screwdriver Needle nose pliers Plastic mallet or 20 oz
(max) hammer 12 in. adjustable wrench Adjustable, open-end
wrench Torque wrench

1/4 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 procedures. These parts are not normally provided with replacement assemblies.
2. Test repair before regular operation of sprayer to be sure problem is corrected.

WARNING
ELECTRIC SHOCK HAZARD To reduce the risk of serious injury, including electric shock, DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair. Shut off the sprayer and unplug it as soon as you complete the inspection. Reinstall all covers, gaskets, screws and washers before operating the sprayer.
3. If sprayer does not operate properly, review repair procedure again to verify that everything was done correctly. If necessary, see Troubleshooting Guide, pages 11 15, to help identify other possible problems and solutions.
WARNING
EXPLOSION HAZARD During operation, the motor and drive housing become very hot and could burn your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire or explosion. Always have the motor shield in place during regular operation to reduce the risk of burns, fire or explosion.
CAUTION
Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings.
4. Reinstall motor shield before regular operation of sprayer and replace if damaged. The cover directs cooling air around the motor to help prevent overheating. It can also help reduce the risk of burns, fire or explosion; see preceding WARNING.

16 308800

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Spin Test

WARNING
ELECTRIC SHOCK HAZARD Do not touch brushes, leads, springs or brush holders while the sprayer is plugged in to reduce risk of electric shock and serious bodily injury.
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.
For checking armature, motor winding and brush electrical 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 there are no shorts, the motor will coast two or three revolutions before coming to a complete stop. If the motor does not spin freely, the armature is shorted and the motor must be replaced. See page 27.

Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity)
1. Relieve pressure. Connect red and black motor leads together with a test lead. Turn motor fan by hand at about two revolutions per second.
2. If there is uneven or no turning resistance, check following: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair parts as needed. See page 18.
3. If there is still uneven or no turning resistance, replace motor. See page 27.
F

82 Fig. 10

G
7695A

Fig. 9

A B

7703B

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308800 17

Motor Brush Replacement

NOTE: Replace brushes worn to less than 1/2 in. Note that brushes wear differently on each side of motor, so check both. Brush Repair Kit 220853 is available. A new spring clip, 110816, may be purchased separately.
WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
NOTE: Read General Repair Information on page 16 before doing this procedure.
1. Relieve pressure.
2. Remove motor shield (54). Remove inspection covers (B) and gaskets on each side of motor. See Fig. 11.

5. Inspect commutator for excessive pitting, burning or gouging. A black color on commutator is normal. Have commutator resurfaced by a qualified motor repair shop if brushes seem to wear too fast.
CAUTION
When installing the brushes, follow all steps carefully to avoid damaging the parts.
6. Install new brush so lead is in long slot of holder. See Fig. 13.
BRUSH HOLDER SHORT SLOT LONG SLOT
BRUSH SPRING CLIP

Fig. 13

NOTE: SPRING MUST COIL IN THIS DIRECTION

01227

7. Slide terminal under terminal screw washer and tighten screw. Be sure motor lead is still connected at screw. See Fig. 14.

Fig. 11

7703B

3. Push in spring clip to release hooks from brush holder. Pull out spring clip. See Fig. 12.

SPRING

HOOK

BRUSH

Fig. 12

SPRING CLIP 110816
01227

4. Loosen brush lead terminal screw. Pull brush lead away, leaving motor lead terminal in place. Remove brush and spring. See Fig. 14.

SPRING

SPRING CLIP

BRUSH
Fig. 14

BRUSH LEAD

TERMINAL SCREW

MOTOR LEAD TERMINAL

01227

8. Place spring on brush as shown in Fig. 13.
9. Install spring clip and push it down to hook short slots in housing. See Fig. 13.
10. Repeat for other side.

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Motor Brush Replacement

11. Test brushes.
a. Remove pump connecting rod pin.
b. With sprayer OFF, turn pressure control knob fully counterclockwise to minimum pressure. Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure until motor is at full speed.
d. Inspect brush and commutator contact area for excessive arcing. Arcs must not trail or circle around commutator surface.
WARNING
ELECTRIC SHOCK HAZARD Do not touch brushes, leads, springs or brush holders when sprayer is plugged in to reduce risk of electric shock and serious bodily injury.

CAUTION
Do not run the sprayer dry for more than 30 seconds while checking the brushes to avoid damaging the displacement pump packings.
12. Install brush inspection covers and gaskets.
13. Break in brushes.
a. Operate sprayer for one hour with no load.
b. Install connecting rod pin.

Power Supply Cord Replacement

On/Off Switch Replacement

WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
NOTE: Read General Repair Information on page 16 before doing this procedure. See Fig. 15.
1. Relieve pressure.
2. Remove pressure control cover (82).
3. Disconnect two wires (B) and (J) from ON/OFF switch (80).
4. Press in on two retaining tabs on each side of ON/OFF switch (80) and remove.
5. Install new ON/OFF switch (80) so tabs of switch snap into place on inside of pressure control housing.
6. Connect two wires (B) and (J) to ON/OFF switch.
7. Install pressure control cover (82). 308800 19

Power Supply Cord and On/Off Switch Replacement
80 B J
79 G 107 E

D 82 Fig. 15

7696B

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Pressure Control Repair

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.

Motor Control Board Installation
1. Relieve pressure.
2. Fig. 16. Install motor control board (104) with four screws (102) and washers (103).

Motor Control Board Removal
1. Relieve pressure. 2. Fig. 16. Remove five screws (28) and cover (82).

3. Connect to motor control board: D Lead (E) to transducer.

3. Disconnect from motor control board: D Six motor leads (B). D Lead (C) from power cord. D Lead (111) from ON/OFF switch. D Lead (D) from potentiometer.

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

D Lead (E) from transducer.

D 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). See Fig. 16.

4. Observe LED operation and reference following table:

LED BLINKS Once
Twice
Twice repeatedly
Three times repeatedly
Four times repeatedly
Five times repeatedly

SPRAYER OPERATION

INDICATES

WHAT TO DO

Sprayer runs Sprayer runs Sprayer shuts down and LED continues to blink twice repeatedly Sprayer shuts down and LED continues to blink three times repeatedly Sprayer shuts down and LED continues to blink four times repeatedly
Sprayer shuts down and LED continues to blink five times repeatedly

Normal operation

Do nothing

Normal operation

Do nothing

Line voltage is too high

Lower line voltage to 120 VAC

Pressure transducer Replace pressure transducer is faulty or missing

Run away pressure. Replace motor control board.

Pressure greater than See preceding Motor control

4500 psi.

board removal procedure.

Locked rotor. Motor can not turn because of some mechanical condition.

Clear obstruction and replace broken parts preventing motor from turning

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308800 21

Pressure Control Repair

Pressure Control Transducer Removal
1. Relieve pressure.
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect lead (E) from motor control board (104).
4. Remove strain relief bushing (116).
5. Remove pressure control transducer (31) and packing o-ring (59) from control housing plate (89).
Pressure Control Transducer Installation
1. Relieve pressure.
2. Fig. 16. Install packing o-ring (59) and pressure control transducer (31) in control housing plate (89). Torque to 3035 ft-lb.
3. Install strain relief bushing (116).
4. Connect lead (E) to motor control board (104).
5. Install cover (82) with five screws (28).

Pressure Adjust Potentiometer Removal
1. Relieve pressure.
2. Fig. 16. Remove five screws (28) and cover (82).
3. Disconnect lead (D) from motor control board (104).
4. Remove potentiometer knob (81), sealing shaft nut (106) and pressure adjust potentiometer (105).
Pressure Adjust Potentiometer Installation
1. Relieve pressure.
2. Fig. 16. Install pressure adjust potentiometer (105), sealing shaft nut (106) and potentiometer knob (81).
3. Connect lead (D) to motor control board (104).
4. Install cover (82) with five screws (28).

22 308800

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Pressure Control Repair

81 116

112 98
28
104 102

82 87
107 A

50 B

89 99
91 86 120

Fig. 16

111 C

E D
7697C

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308800 23

Bearing Housing and Connecting Rod Replacement

WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
NOTE: Read General Repair Information on page 16 before doing this procedure. See Fig. 17.
NOTE: Stop sprayer at bottom of its stroke to get crank (E) in its lowest position.To lower crank manually, carefully rotate blades of fan with a screwdriver.
1. Relieve pressure.
2. Remove front cover (49). Unclip drain hose (36) from pump. Hold a wrench on pump intake valve (213) and unscrew pump suction tube (39). Disconnect pump hose (70).
3. Push up retaining spring (68). Push pin (66) out rear.
4. Loosen locknut (47). Unscrew displacement pump (64).
5. Remove four screws and lockwashers (25,23).
6. Lightly tap lower rear of bearing housing (22) with a plastic mallet to loosen it from drive housing (67). Pull bearing housing and connecting rod assembly (63) straight off drive housing.
7. Remove pail bracket assembly (F) and install it on new bearing housing.
8. Inspect crank (E) for excessive wear and replace parts as needed. Evenly lubricate inside of bronze bearing (B) with high quality motor oil. Liberally pack roller bearing (C) with bearing grease.

11. Align connecting rod (63) with crank (E) and drive housing locating pins (G) with bearing housing (22) holes. Push bearing housing onto drive housing or tap it into place with a plastic mallet.

CAUTION
DO NOT use the bearing housing screws (25) to try to align or seat the bearing housing; the bearing and drive housing will not align properly and will result in premature bearing wear.

12. Install screws and lockwashers (25,23). Tighten screws evenly to 175 in-lb (19 N.m).

13. Install pump. See page 30.

14. Install remaining parts. See Fig. 17.

OIL B

C PACK WITH
BEARING GREASE
63

25,23 TORQUE TO

175 in-lb (19 N.m)

G 22
68 47
70 40 64 213
39
85

66 F
36

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 308800

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Drive Housing Replacement

WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
CAUTION
DO NOT drop gear cluster (51) when removing drive housing (67). Gear cluster may stay engaged in the motor front end bell or the drive housing. 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 stay in the shaft recesses, but could be dislodged. If caught between gears and not removed, the balls will seriously damage drive housing. If the balls are not in place, the bearings will wear prematurely.
NOTE: Read General Repair Information on page 16 before doing this procedure. See Fig. 18.
1. Relieve pressure.
2. Remove front cover (49) and motor shield (54). Unclip drain hose (85) from pump.
3. Remove four bearing housing screws (25) and lockwashers (23).

4. Lightly tap lower rear of bearing housing (22) with a plastic mallet to loosen it from drive housing (67). Pull assembled bearing housing and connecting rod straight off drive housing.
5. Remove two drive housing screws (26) and lockwashers (20).
6. Remove two lower screws (16) and lockwashers (20) and then two upper screws (16) and lockwashers (20) from front of motor (73).
7. Tap drive housing (67) with a plastic mallet to loosen it from front of motor (73), and then pull drive housing straight off.
8. 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.
9. Place bronze-colored washer (67b) then silver-colored washer (67a) on shaft protruding from big gear in drive housing (67).
10. Align gears and push new drive housing straight onto front of motor and locating pins.
11. Continue reassembling sprayer.

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308800 25

Drive Housing Replacement

16 20

54 90 67a 51 3 67b 67

22 25,23 1

2 16

20 2 26

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

2 Torque to 90100 in-lb (10.211.3 N.m)

3 Liberally apply grease

Fig. 18

7699A

26 308800

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Motor Replacement

WARNING
INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 7.
NOTE: Read General Repair Information on page 16 before doing this procedure. See Fig. 16 and 19.
1. Relieve pressure.
2. Remove motor shield (54).
3. Remove pressure control cover (82). Disconnect six motor leads (B). See figure 16.
CAUTION
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.
4. Remove strain relief (99) and pull motor wires bundle through pressure control opening. See figure 16.
5. Remove front cover (49).
6. Remove two drive housing screws (26).
7. Remove two lower screws (16) and lockwashers (20) and then two upper screws (16) and lockwashers (20) from front of motor (73).
8. Tap drive housing (67) with a plastic mallet to loosen it from front of motor (73), and then pull drive housing straight off.

CAUTION
DO NOT drop gear cluster (51) when removing drive housing (67). The gear cluster may stay engaged in the motor front end bell or the drive housing. 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 stay in the shaft recesses, but could be dislodged. If caught between gears and not removed, the balls will seriously damage the drive housing. If the balls are not in place, the bearings will wear prematurely.
9. While supporting motor (73) to keep sprayer from tipping, remove four motor mounting screws (8). Lift off motor.
10. Install new motor (73).
11. 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.
12. Place bronze-colored washer (67b) and then silver-colored washer (67a) on shaft protruding from big gear in drive housing (67).
13. Align gears and push drive housing (67) straight onto front of motor (73) and locating pins.
14. Continue reassembling sprayer. Feed motor wires through opening in pressure control. Connect six motor leads to pressure control printed circuit board. Install pressure control cover (A). See Fig. 16.

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308800 27

Motor Replacement

30 79 98
A

34 54 16 1
20 73 90

67a 51 2
67b

22 20 26

10 70
40

1 16 20

1 Torque to 90100 in-lb (10.211.3 N.m)

2 Liberally apply grease

Fig. 19

49
7700B

28 308800

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Displacement Pump Repair

Removing pump
1. Flush pump. Relieve pressure. Fig. 20. Cycle pump with piston rod (222) in its lowest position.

4. Fig. 22. Push out pin.

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

222

Fig. 20

7672A

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

Fig. 22

7675A

5. Fig. 23. Loosen locknut by hitting firmly with a 20 oz (maximum) hammer. Unscrew pump.

Fig. 21

Fig. 23

7673A

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

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308800 29

Displacement Pump Repair

Installing pump
WARNING
If the pin works loose, it or other parts could break off due to the force of the pumping action. These parts could be projected through the air and result in serious bodily injury or property damage, including damage to the pump, connecting rod or bearing housing.

3. Fig. 26. Push retaining spring into groove all the way around connecting rod.

CAUTION
If the pump locknut loosens during operation, the threads of the bearing housing will be damaged.
1. Fig. 24. Pull piston rod out 1.5 in. Screw in pump until holes in bearing cross link and piston rod align.

Fig. 26

7674A

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 approximately 75" 5 ftlb (102 Nm).

7676A
Fig. 24 2. Fig. 25. Push pin (21) into holes.
21

Fig. 27

7673A

Fig. 28. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal.

Fig. 25

7675A

30 308800

Fig. 28
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7677A

Accessories

DANGER LABELS

The English language DANGER label shown on page 4 is also on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing shows the best placement of these labels for good visibility.

Order the labels directly from Graco, free of

charge. Toll Free:

18003280211

Apply other language here

French Spanish German Greek Korean

185955 185962 186042 186046 186050

7691A

Technical Data
Power Requirements . . . . . . . . . . . . . . . . . . . . 120 VAC, 60 Hz, 1 phase, 15A minimum or 4000W generator
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 HP (with latex at 2000 psi (138 bar, 13.8 MPa)
Working Pressure Range 03000 psi (0210 bar, 021 MPa) Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . 244 (64.6) Maximum Delivery Rating . . . . . . . . . . . . . . . . 0.8 gpm (3 lpm) Tip Size . . . . . . . . . . . . . . . one gun 0.028; two guns 0.019
(with latex at 2000 psi (138 bar, 13.8 MPa) Power Cord . . . . . . . . . . . . . . . . . 14 AWG, 3 wire, 15 ft (4.5 m) Inlet Paint Strainer . . . . . . . . . . . . . . . . . 16 mesh (975 micron)
stainless steel screen, reusable Outlet Paint Filter . . . . . . . . . . . . . . . . . . 60 mesh (238 micron)
stainless steel screen, reusable Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(m) Fluid Outlet Size
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f) Filter with standard 3/8 npt(f) to 1/4 npsm adapter 1/4 npsm Basic Sprayer Wetted Parts: . . . . . . zinc-plated carbon steel,
polyurethane, polyethylene, stainless steel, PTFE, DelrinR, chrome plating, leather, V-Maxt UHMWPE, aluminum, stainless steel, tungsten carbide
NOTE: DelrinR is a registered trademark of the DuPont Co.
Dimensions
Weight (dry w/o packaging) . . . . . . . . . . . . . . . . 101 lb (46 kg) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 in. (724 mm) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 in. (648 mm) Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 in. (521 mm)

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308800 31

Parts Drawing Sprayer

77 54

REF
77
62

REF
78

126 123

Ref 70

41*
84
34 73a* 41* 16 20 73 90 67a 51 67b 90

Ultra MAX 795 Sprayers Model 232140, Series A
Includes items 1 112, 123, 126 Basic Sprayer Model 232141, Series A Includes items 1 126 Complete Sprayer
67 63

26 32

70 40
33 Ref 85
53

22 23 25 49

68 47

38 39
65

SEE PARTS ON PAGE 34

Ref 120 Ref 85

122
7705B

32 308800

120

121

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7705B

Parts List Sprayer

Ultra MAX 795 Sprayers
Model 232140 Series A Includes items 1 112, 123, 126 Basic Sprayer

REF NO. PART NO. DESCRIPTION

QTY

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 187791Y 47 192723 48 112827 49 179899 51 179961 52 183350 53 181072 54 240317
61 192719 62 192027 63 218034

NUT, 5/1618 unc2a

RING, retaining

SCREW, socket head, 1/420 x 0.75

in.

HUBCAP

LOCKWASHER, spring, 1/4 in.

WHEEL, semipneumatic

BEARING HOUSING

includes 32 and 61

LOCKWASHER, spring, 3/8 in.

SCREW, filh, no. 832 x1 in.

CAPSCREW, sch, 3/816 x 11/2 in. 4

CAPSCREW, sch, 1/420 x 2.75 in. 2

SCREW, serrated flange, hex hd,

5/1618 x 1/2 in.

NUT, hex

PLUG, tubing

SCREW, pan head, no. 8 x 3/8 in.

SCREW, pnhd, 1032 x 1/4 in.

RING, retaining

CLIP, spring

TUBE, intake

NIPPLE, 1/4 npt(m) x 1/4 npsm

LABEL, DANGER, English

NUT, hex

BUTTON, snap

COVER, housing

GEAR REDUCER

WASHER

STRAINER

SHIELD, motor

includes labels 41 and 73a

HANGER, pail

SLEEVE

CONNECTING ROD

Model 232141, Series A Includes items 1 126 Complete Sprayer

REF NO. PART NO. DESCRIPTION

QTY

64 239923
65 206994 66 176818
67 239931
67a 178967 67b 107089 68 176817 70 239984
73 240015*
73a 187784Y 77 239998 78 239980 84 114271 90 100069 97 192694 120 238361
121 238358
122 220955
123 192838Y 126 187975Y

DISPLACEMENT PUMP

see manual 308798 for parts

THROAT SEAL LIQUID, 8 OZ

PIN, straight, hdls,

0.3125 in. dia x 1.023 in.

DRIVE HOUSING

includes 67a and 67b

.WASHER, silvercolored

.WASHER, bronzecolored

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 and 73a

.LABEL, DANGER, French

HANDLE, cart

FRAME, sprayer

STRAP, retaining

BALL, steel, 1/4 in. dia.

HOUSING, control, box

HOSE, grounded, nylon, 1/4 in. ID, 1

cpld 1/4 npsm(f), 50 ft (15 m)

spring guards both ends

HOSE, grounded, nylon, 3/16 in. ID, 1

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

YExtra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available. Order separately.

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308800 33

Parts Drawing Sprayer
69

79 81
80 106 101

89 9

116

112

107

105

104

102 115

100

5 87

7701B

34 308800

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Parts List Sprayer

Ultra MAX 795 Sprayers
Model 232140, Series A Includes items 1 112, 123, 126 Basic Sprayer

Model 232141, Series A Includes items 1 126 Complete Sprayer

REF NO. PART NO. DESCRIPTION

QTY

REF NO. PART NO. DESCRIPTION

QTY

4 224807 5 111600 6 187625 7 111699 9 104361 12 167025 28 114392 31 240314
50 100020 55 112538 59 111457 69 240315
71 187615 72 171941 74 235014
75 100721 76 186075 79 239995 80 114277 81 114273 82 193012 85 240144

ASSEMBLY, cam, drain valve

PIN, grooved

HANDLE, valve, drain

GASKET, seat, valve

O-RING, packing

STRAINER, mesh, 60

SCREW, mach, panhd

TRANSDUCER, pressure control 1

includes item 59

WASHER, lock spring

ELBOW, 90_, street, reducing

O-RING, packing

BOWL, filter

includes item 72

VALVE, seat

SPRING, compression

ASSEMBLY, drain valve

includes items 7 and 71

PLUG, pipe

SUPPORT, filter

CORD SET, power

SWITCH, rocker, (spst)

KNOB, potentiometer

COVER, painted

HOSE, drain

86 240316
87 107183 89 192726 91 107505 92 164672 98 114284 99 114285 100 240131 101 192831 102 114420 104 240168 105 236352 106 112382 107 114391 111 240495 112 114393 115Y 193051 116 114409

HOUSING, filter

includes item 9

CAPSCREW

PLATE, housing, control

PACKING, o-ring

ADAPTER

BUSHING, strain relief

CAP, for secondary outlet

PLATE, instruction

SCREW, mach, pnhd

BOARD, PC

POTENTIOMETER, pressure adjust 1

NUT, shaft, sealing

SCREW, ground

WIRE, jumper

SCREW

LABEL, warning

BUSHING, strain relief

YExtra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available. Order separately.

Wiring Diagram

TP3

111

ON/OFF Switch TP2
BLACK 107

Pressure Transducer
TP4
Ground TP5

BLACK YELLOW

Power Supply Cord GREEN
Fig. 29

TP1 WHITE

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104 VIOLET

Potentiometer

RED (+) BLACK()

from Motor
7702A
308800 35

Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of nonGraco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the "Graco Contractor Equipment Warranty Program".
Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call 18006902894 to identify the nearest distributor.

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. MM 308800

Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea

36 308800

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN
http://www.graco.com
PRINTED IN USA 308800F 01/1997 Rev. 06/2005

554401441

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References