Graco 308842H User's Manual

Parts
INSTRUCTIONS-REPAIR
308842
Rev. H
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
First choice when
quality counts.
INSTRUCTIONS
ULTRAMAX 795 and 1095
Airless Paint Sprayers
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
230 VAC
Model
Series Description
232144
A
Ultra Max 795
Hi-boy with RAC IV tip, gun and hose
232145
A
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
110 VAC
Model 232144
Model
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
8050A
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
100 VAC
Model
Series Description
232156
A
Ultra Max 1095 Hi-boy
232157
A
Ultra Max 1095 Lo-boy
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump . . . . . . . . . . . . . . . . .
Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board . . . . . . . . . . . . . . . . . . . . . . . . . .
308840
308798
307614
308644
308816
Table of Contents
Component Function and Identification . . . . . . . . . . . . 2
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Repair Information . . . . . . . . . . . . . . . . . . . . . . 3
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . 9
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 11
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 12
Bearing Housing & Connecting Rod Replacement . 14
Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 15
GRACO INC.
P.O. BOX 1441
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . . .
Parts Drawing – Sprayer . . . . . . . . . . . . . . . . . . . . . . .
Parts List – Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MINNEAPOLIS, MN
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
16
17
18
19
23
24
24
24
24
24
Component Identification and Function
V
T
S
A
R
B
U
03008
L
P N
M
K
J
H
C
G
D
F
E
8050A
Fig. 1
2
A
Motor
DC motor, permanent magnet, totally enclosed, fan cooled
B
Drive Assembly
Transfers power from DC motor to displacement pump
C
Pail Hanger
Container for fluid to be sprayed may be hung here
D
Displacement Pump
Transfers fluid to be sprayed from source through spray gun
E
Primary Fluid Outlet
Single spray gun is connected here
F
Secondary Fluid Outlet
Second spray gun is connected here
G
Pressure Drain Valve
Relieves fluid outlet pressure when open
H
Fluid Filter
Final filter of fluid between source and spray gun
J
Pressure Adjusting Knob
Controls fluid outlet pressure
K
Pressure Control
Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
L
ON/OFF Switch
Power switch that controls VAC main power to sprayer
M
3 ft (0.9 m) Hose
3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun to
allow more flexibility when spraying
N
50 ft (15 m) Main Hose
1/4 in. ID, grounded, nylon hose with spring guards on both ends
P
Contractor Gun
High pressure spray gun with gun safety latch
R
RAC IV Switch Tip
Uses high pressure fluid to clear tip clogs without removing tip from spray gun
S
RAC IV Tip Guard
Reverse-A-Clean (RAC) tip guard reduces risk of injection injury
T
Spray Gun Safety Latch
Gun safety latch inhibits accidental triggering of spray gun
U
Power Cord Rack
Holds wrapped power cord for storage
V
Spray Hose Rack
Holds wrapped spray hose for storage
308842
General Repair Information
WARNING
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect a wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
EXPLOSION HAZARD
Motor and drive housing are very hot
during operation and could burn skin if
touched. Flammable materials spilled on
hot, bare motor could cause fire or explosion. Have
motor shield in place during operation to reduce
risk of burns, fire or explosion.
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
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.
WARNING
ELECTRIC SHOCK HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting Guide,
pages 4 – 8, for other possible solutions.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pressure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1.
2.
3.
4.
Lock gun safety latch.
Turn 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.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
308842
3
Grounding
WARNING
Grounding Plug
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. Models 232148, 158 require a 110 VAC, 50/60 Hz, 15A
circuit with a grounding receptacle. Models
232156, 157 require a 100 VAC, 50/60 Hz, 15A
circuit with a grounding receptacle. See Fig. 2.
2. Do not alter ground prong or use adapter.
Grounded
Outlets
Model 232144, 145, 154
Fig. 2
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
Troubleshooting
Relieve pressure; page 3.
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. Pressure control knob setting. Motor will not run 1. Slowly increase pressure setting to see if moif 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
Problems
1. For frozen or hardened paint in pump (64). Use 1. Thaw sprayer if water or water-based paint
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).
2. Displacement pump connecting rod pin (66). 2. Push pin into place and secure with spring rePin must be completely pushed into connecting
tainer.
rod (63) and retaining spring (68) must be firmly
in groove of connecting rod. See Fig. 12.
3. 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
1. 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 8.
2. Electrical supply. Meter must read:
2. Reset building circuit breaker; replace build210–250 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
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Basic Electrical Problems
(continued)
1. That motor leads are securely fastened and 1. Replace loose terminals; crimp to leads. Be
properly mated.
sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect 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 carbon with
page 9.
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 resurgouges 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 motor 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.
tween TP1 (neutral) and TP2. Plug in sprayer.
page 23 to identify test
Meter must read:
points (TP).
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 cutoff 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. All terminals for damage or loose fit.
4. Replace damaged terminals and reconnect
securely.
308842
5
Troubleshooting
LOW 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
Low Output
1. For worn spray tip.
1. Follow Pressure Relief Procedure Warning, 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 momentarily, then release and lock safety latch. Relieve
pressure, turn off and unplug sprayer.
3. Electrical supply with volt meter.
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.
3. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or try
another outlet.
4. Extension cord size and length; must be at least 4. Replace with a correct, grounded exten12 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
board (104) for damaged or loose wires or conand 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
page 9.
with small cleaning brush. Align brush lead
with slot in brush holder to assure free vertical 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 motor armature is determined to be good. A bad
motor armature can burn out a good board.
6
308842
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. 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 necessary. See page 17. Strain paint before using 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 constroke
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 damsprayer and turn on briefly to check. Turn off
age and replace if necessary. See page 15.
and unplug sprayer. See page 15.
EXCESSIVE PRESSURE FLUCTUATIONS
TYPE OF PROBLEM
WHAT TO CHECK
If is OK, go to next check
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.
WHAT TO DO
When is not OK refer to this column
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.
4. Check LOW OUTPUT section, page 6.
308842
7
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
pressure with small tips, which causes low
size.
tently.
motor RPM and excessive heat build up.
2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible.
is located is no more than 90F and sprayer
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. All electrical wiring for damaged insulation, and 1. Repair or replace any damaged wiring or
all terminals for loose fit or damage. Also wires
terminals. Securely reconnect all wires.
as soon as sprayer switch is
between pressure control and motor. See page
turned on.
16.
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. For missing inspection plate gasket (see page 2. Correct faulty conditions.
16), bent terminal forks or other metal to metal
contact points which could cause a short.
3. Motor armature for shorts. Use an armature 3. Replace motor. See page 16.
tester (growler) or perform spin test. See page
9. Inspect windings for burns.
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 motor armature is determined to be good. A bad
motor armature can burn out a good board.
1. Basic Electrical Problems on page 4.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.
1. Perform necessary procedures.
2. ON/OFF switch (80) See page 11. Be sure 2. Replace ON/OFF switch. See page 11.
sprayer is unplugged! Disconnect wires from
switch. Check switch with ohmmeter. Reading
must be infinity with ON/OFF switch OFF, and
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.
erates for 5 to 10 minutes.
2. Electrical supply with volt meter.
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.
1. Perform necessary procedures.
2. If voltage is too high, do not operate
sprayer until corrected.
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.
To check armature, motor winding and brush electrical
continuity:
1.
Relieve pressure; page 3.
2. Remove drive housing; page 15.
1. Connect red and black motor leads together with
test lead. Turn motor fan by hand at about two
revolutions per second.
2. If uneven or no resistance, check for: broken brush
springs, brush leads, motor leads; loose brush
terminal screws, motor lead terminals; worn
brushes. Repair as needed; page 9.
3. If still uneven or no resistance, replace motor;
page 16.
3. Fig. 3. Remove pressure control cover (82). Disconnect motor leads (F) and (G).
F
4. Fig. 4. Remove motor shield (54), fan cover (A)
and inspection covers (B).
Armature Short Circuit Test
82
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.
Fig. 3
G
8051A
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in.
Brushes wear differently on each side of motor,
check both sides. Brush Repair Kit 220853 is
available. Spring clip, 110816,
may be
purchased separately.
(Continued on page 10)
54
Motor Brush Removal
1. Read General Repair Information; page 3.
2.
Relieve pressure; page 3.
A
3. Fig. 4. Remove motor shield (54). Remove inspection covers (B) and gaskets on each side of
motor.
Fig. 4
B
7703B
308842
9
Motor Brush Replacement
4. Fig. 5. Push in 110816 spring clip (A) to release
hooks (B) from brush holder (C). Pull out spring
clip.
10. Fig. 6. Install spring clip (A). Push down to hook
short slots (K) in brush holder (C).
C
5. Fig. 5. Loosen terminal screw (D). Pull brush lead
(E) away, leaving motor lead (F) in place. Remove
brush (G) and spring (H).
K
J
G
H
A
A
E
C B
H
NOTE SPRING COIL DIRECTION
Fig. 6
G
E
11. Repeat for other side.
D
F
Fig. 5
01227
12. Test brushes.
01227
6. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes wear too fast.
a. 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.
Motor Brush Installation
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
7. Fig. 6. Install new brush (G) with lead in long slot
(J) of brush holder (C).
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displacement pump packings.
13. Install brush inspection covers and gaskets.
14. Break in brushes.
8. Fig. 5. Slide brush lead (E) under washer of terminal screw (D) and tighten screw. Be sure motor
lead (F) is connected at terminal screw.
9. Fig. 6.Place spring (H) on brush (G).
10
308842
a. Operate sprayer 1 hour with no load.
b. Install connecting rod pin.
On/Off Switch Replacement
1. Read General Repair Information on page 3.
6. Press in on two retaining tabs on each side of
ON/OFF switch (80) and remove.
2.
7. Install new ON/OFF switch (80) so tabs of switch
snap into place on inside of pressure control
housing.
Relieve pressure; page 3.
3. Fig. 7. Remove pressure control cover (82).
8. Connect four wires (A) to ON/OFF switch.
4. Remove display connector (B) from plug (C)
9. Install display connector (B) in plug (C)
5. Disconnect four wires (A) from ON/OFF switch
(80).
10. Install pressure control cover (82).
81
106
80
31
A
105
59
89
99
102
116
28
104
8
82
C
D
E
B
8052B
Fig. 7
308842
11
Pressure Control Repair
Motor Control Board
Removal
1.
Relieve pressure; page 3.
Installation
1. Fig. 7. Install motor control board (104) with four
screws (102).
2. Connect to motor control board (104):
2. Fig. 7. Remove five screws (28) and cover (82).
Lead (E) to transducer.
3. Fig. 17. Disconnect at motor control board (104):
Lead (D) to potentiometer.
Filter board (8).
Six motor leads: two yellow, two violet, black
(+) and red (–).
Lead (D) from potentiometer.
Lead (E) from transducer.
4. Remove four screws (102) and circuit board (104).
Six motor leads: two yellow, two violet, black
(+) and red (–).
Filter board (8).
3. Bundle and tie all loose wires so none lay in contact with inductor coil on filter board.
See CAUTION, Fig. 17.
4. Install cover (82) with five screws (28).
Motor Control Board Diagnostics
3. Turn ON/OFF switch ON.
1.
Relieve pressure; page 3.
4. Observe LED operation and reference following
table:
2. Remove five screws (28) and cover (82).
See Fig. 7.
LED
BLINKS
SPRAYER OPERATION
INDICATES
WHAT TO DO
Once
Sprayer runs
Normal operation
Do nothing
Twice
Sprayer runs
Normal operation
Do nothing
Two times
repeatedly
Sprayer shuts down and LED continues
to blink two times repeatedly
Run away pressure. Pres- Replace motor control board.
sure greater than 4500 psi See preceding Motor control
(310 bar, 31 MPa).
board removal procedure.
Three times
Sprayer shuts down and LED continues
to blink three times repeatedly
Pressure transducer is
faulty or missing
Replace pressure transducer
Four times
repeatedly
Sprayer shuts down and LED continues
to blink four times repeatedly
Line voltage is too high
Lower line voltage to 230 VAC
for models 232144, 145, 154
and to 110 VAC for models
232148, 158
Five times
repeatedly
Sprayer shuts down and LED continues
to blink five times repeatedly
Locked rotor. Motor can
not turn because of some
mechanical condition.
Clear obstruction and replace
broken parts preventing motor
from turning
repeatedly
12
308842
Pressure Control Repair
Digital Display Messages
1. Lift lid on pressure control cover and view display.
3.
2. Observe display and reference following table:
DISPLAY
No Display
SPRAYER
OPERATION
Sprayer stops. Power is not applied.
Sprayer may be pressurized.
No display does not mean
that sprayer is not pressurized. Relieve pressure before repairing;
page 3.
INDICATION
ACTION
Loss of power
Check power source
psi Sprayer is pressurized. Power is applied. Normal operation
bar (Pressure varies with tip size and presMPa sure control setting.)
Spray
Sprayer stops. Power is applied.
Pressure greater than
Replace pressure
4500 psi (310 bar, 31 MPa). control board
Sprayer stops. Power is applied.
Pressure transducer faulty
Replace
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
Sprayer stops. Power is applied.
Locked rotor. Motor can not
turn
Repair or replace
Sprayer stops. Power is applied.
Pressure less than
200 psi (14 bar, 1.4 MPa)
Increase pressure
Pressure Control Transducer
Pressure Adjust Potentiometer
Removal
Removal
1.
Relieve pressure; page 3.
1.
Relieve pressure; page 3.
2. Fig. 7. Remove five screws (28) and cover (82).
3. Disconnect lead (E) from motor control
board (104).
2. Fig. 7. Remove five screws (28) and cover (82).
4. Remove strain relief bushing (116).
3. Disconnect lead (D) from motor control
board (104).
5. Remove pressure control transducer (31) and
packing o-ring (59) from control housing plate (89).
4. Remove potentiometer knob (81), sealing shaft nut
(106) and pressure adjust potentiometer (105).
Installation
1. Fig. 7. Install packing o-ring (59) and pressure
control transducer (31) in control housing
plate (89). Torque to 30–35 ft-lb.
Installation
2. Install strain relief bushing (116).
1. Fig. 7. Install pressure adjust potentiometer (105),
sealing shaft nut (106) and potentiometer knob
(81).
3. Connect lead (E) to motor control board (104).
2. Connect lead (D) to motor 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.
2.
Relieve pressure; page 3.
3. Stop sprayer at bottom of stroke to get crank (E) in
lowest position.To lower crank manually, carefully
rotate blades of fan with a screwdriver.
4. Fig. 8. Remove front cover (49). Unclip drain hose
(36) from pump. Unscrew pump suction tube (39)
pump intake valve (213). Disconnect pump hose
(70).
5. Push up retaining spring (68). Push pin (66) out
rear.
CAUTION
Do not use bearing housing screws (25) to align or
seat bearing housing; this may cause bearing and
drive housing misalignment and result in premature
bearing wear.
14. Install screws and lockwashers (25, 23). Tighten
screws evenly to 175 in-lb (19 Nm).
15. Install pump; page 17.
16. Fig. 8. Install remaining parts.
1
67
B
6. Loosen locknut (47). Unscrew displacement
pump (64).
7. Remove four screws and lockwashers (25,23).
C
2
63
25, 23
E
3
49
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.
G
22
9. Remove pail bracket assembly (F) and install it on
new bearing housing.
68
47
66
10. Inspect crank (E) for excessive wear and replace
parts as needed. Evenly lubricate inside of bronze
bearing (B) with high quality motor oil. Pack roller
bearing (C) with bearing grease.
70
40
64
F
213
11. Assemble connecting rod (63) and bearing housing
(22).
39
12. Clean mating surfaces of bearing and drive housings (22, 67).
13. 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 into place with plastic mallet.
14
308842
85
1
Oil
2
Pack with bearing grease
3
Torque to 175 in-lb (19 Nm)
Fig. 8
36
7698B
Drive Housing Replacement
6. Remove two drive housing screws (26) and
lockwashers (20).
CAUTION
Do not drop gear cluster (51) when removing drive
housing (67). Gear cluster may stay engaged in
motor front end bell or drive housing.
7. Remove two lower screws (16) and lockwashers
(20) and then two upper screws (16) and lockwashers (20) from front of motor (73).
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.
8. Tap drive housing (67) with plastic mallet to loosen
from front of motor (73); pull drive housing straight
off.
1. Read General Repair Information on page 3.
2.
9. 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.
Relieve pressure; page 3.
3. Fig. 9. Remove front cover (49) and motor shield
(54). Unclip drain hose (85) from pump.
10. Place bronze-colored washer (67b) then silver-colored washer (67a) on shaft protruding from big
gear in drive housing (67).
4. Remove four bearing housing screws (25) and
lockwashers (23).
11. Align gears and push new drive housing straight
onto front of motor and locating pins.
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.
34
16
12. Continue reassembling sprayer.
2
20
54
90
67a
51
3
67b
67
22
25, 23
2
16
20
49
90
2
1
Torque to 175 in-lb (19 Nm)
2
Torque to 90–100 in-lb (10.2–11.3 Nm)
3
Liberally apply grease
Fig. 9
1
20
26
85
36
7699B
308842
15
Motor Replacement
1. Read General Repair Information on page 3.
2.
CAUTION
Do not drop gear cluster (51) when removing drive
housing (67). Gear cluster may stay engaged in
motor front end bell or drive housing.
Relieve pressure; page 3.
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.
3. Fig. 10. Remove motor shield (54).
4. Fig. 7. Remove pressure control cover (82). Disconnect six motor leads: two yellow, two violet,
black (+) and red (–).
10. While supporting motor (73) to keep sprayer from
tipping, remove four motor mounting screws (8).
Lift off motor.
CAUTION
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
onto front of motor (73) and locating pins.
7. Remove two drive housing screws (26).
8. Remove two lower screws (16) and lockwashers
(20) and then two upper screws (16) and
lockwashers (20) from front of motor (73).
15. Fig. 7. Continue assembling sprayer. Feed motor
wires through opening in pressure control. Connect
six motor leads: two yellow, two violet, black (+)
and red (–), to pressure control printed circuit
board. Install pressure control cover (A).
9. Tap drive housing (67) with a plastic mallet to
loosen it from front of motor (73), and then pull
drive housing straight off.
16. Bundle and tie all loose wires so none lay in contact with inductor coil on filter board.
See CAUTION, Fig. 17.
34 54
16
1
20
73
90
67a
51
2
67b
67
22
30
20
26
49
90
79
98
10
1
A
Torque to 90–100 in-lb (10.2–11.3 Nm)
70
2
Liberally apply grease
40
85
1
Fig. 10
16
308842
16 20
36
8054A
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.
3. Fig. 12. Use screwdriver: push retaining spring up
and push out pin.
21
2. Fig. 11. Remove suction tube and hose.
222
7675B
Fig. 12
7672B
Fig. 11
4. Fig. 13. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
7673B
Fig. 13
Installing pump
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 property damage.
CAUTION
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 approximately 75" 5 ft–lb (102 Nm).
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.
Fig. 15
7673B
Fig. 16. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.
1.5 in.
Fig. 14
7676B
7677B
Fig. 16
308842
17
Parts Drawing – Sprayer
Ultra MAX 795 and 1095 Hi-boy Sprayers
Model 232144, Series A
Model 232154, Series A
Model 232148, Series A
Model 232158, Series A
Model 232156, Series A
41*
77
84
54
34 73a*
41*
16
20
73
90
67a
51
67b
90
67
63
REF
77
22
62
23
25
48
52
37
35
30
30
10
16
REF
20
26
20
78
49
61
32
68
47
66
70
40
78
14
19
21
24
64
38
33
126
123
85
39
Ref 70
65
53
Ref 120
122
SEE PARTS ON PAGE 22
Ref 85
120
18
308842
121
8055A
Parts List – Sprayer
Ultra MAX 795 and 1095 Hi-boy Sprayers
Model 232144, Series A; Model 232154, Series A
Model 232148, Series A; Model 232156, Series A; Model 232158, Series A
REF
REF
NO.
PART NO.
DESCRIPTION
10
14
16
19
20
21
22
23
24
25
26
30
110996
101242
100644
104811
105510
106062
240523
106115
114406
107210
107218
111801
32
33
34
35
37
38
39
40
41
112746
108691
108865
109032
110243
192691
192641
162453
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.
CAPSCREW, 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
47
48
49
51
52
53
54
187791
189702
192723
112827
188154
179899
179961
183350
181072
61
62
63
64
240317
240313
192719
192027
218034
239923
65
206994
QTY
4
2
4
2
6
2
1
4
4
4
2
7
2
2
6
4
2
1
1
2
2
2
2
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
NO.
PART NO.
DESCRIPTION
66
176818
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
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
67
239931
239929
67a
67b
68
70
218032
178967
107089
176817
239984
73
240994*
240566*
240015*
240034*
77
239998
78
239980
84
114271
85
240144
90
100069
120 238361
121 238358
122 222667
123 192838
126
187975
189699
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available.
Order separately.
Not 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
59
35
37
34
16
20
78
52
48
62
73
67b
77
67
63
22
23
25
49
90
10
67a
51
30
20
16
20
26
24
68
47
66
126
123
70
19 14 21
33
72
85 40
105
64
45
Ref 70
103
Ref 43
106
SEE PARTS ON PAGE 22
104
65
83
111
Ref 85
32
8126A
43
20
308842
42
Parts List – Sprayer
Ultra MAX 795 and 1095 Lo-Boy Sprayers
Model 232145, Series A; Model 232157, Series A
REF
REF
NO.
PART NO.
DESCRIPTION
10
14
16
19
20
21
22
23
24
25
26
30
32
110996
101242
100644
104811
105510
106062
240523
106115
114406
107210
107218
111801
222667
33
34
35
37
40
41
108691
108865
109032
110243
162453
NUT, flange head, hex
RING, retaining
SCREW, socket head, 1/4–20 x 3/4 in.
HUBCAP
LOCKWASHER, spring, 1/4 in.
WHEEL, semi–pneumatic
HOUSING, bearing
LOCKWASHER, spring, 3/8 in.
SCREW, self tap, filnd
CAPSCREW, sch, 3/8–16 x 1–1/2 in.
CAPSCREW, sch, 1/4–20 x 2–3/4 in.
SCREW, cap, flange hd
SPRAY GUN
see manual 307614 for parts
PLUG, tubing
SCREW, pan head, no. 8 x 3/8 in.
SCREW, pnhd, 10–32 x 1/4 in.
RING, retaining
NIPPLE, 1/4 npt(m) x 1/4 npsm
LABEL, WARNING
English
Japanese
HOSE, grounded, nylon, 3/16 in. ID,
cpld 1/4 npsm(f), 3 ft (.9 m),
spring guards both ends
HOSE, grounded, nylon, 1/4 in. ID,
cpld 1/4 npsm(f), 50 ft (15 m)
spring guards both ends
STRAINER
NUT, retaining
BUTTON, snap
COVER, housing
COVER, display, painted
REDUCER, gear
WASHER
SHIELD, motor
Ultra MAX 795
Ultra MAX 1095
SLEEVE, cart
KIT, rod, connecting
42
187791
189702
238358
43
238361
45
47
48
49
50
51
52
59
181072
192723
112827
188154
193347
179961
183350
62
63
240317
240313
192027
218034
QTY
1
2
4
2
6
2
1
4
1
4
4
7
1
2
6
4
2
2
2
2
2
1
1
1
1
2
1
1
1
1
1
1
1
2
1
NO.
PART NO.
DESCRIPTION
64
239923
65
66
206994
176818
PUMP, displacement
1
see manual 308798 for parts
THROAT SEAL LIQUID, 8 OZ
1
PIN, straight, hdls,
1
0.3125 in. dia x 1.023 in.
DRIVE HOUSING
1
includes replaceable items 67a and 67b
Ultra Max 795, Model 232145
1
Ultra Max 1095, Model 232157
1
.WASHER, silver–colored
1
.WASHER, bronze–colored
1
SPRING, retaining
1
HOSE, grounded, nylon,1/4 in. ID
1
cpld 1/4 npsm (f), 29 in. (715 mm),
spring guards both ends
TUBE, suction
1
MOTOR, ELECTRIC
1
Ultra Max 795, Model 232145
1
Ultra Max 1095, Model 232157
1
HANDLE, cart
1
FRAME, cart
1
SWIVEL, inlet tube
1
HOSE, drain
1
BALL
1
CLAMP, hose
1
CLIP, spring
1
STRAP, tie
3
COUPLING, hose
1
HOSE, suction
1
LABEL, WARNING, French
1
LABEL, WARNING
1
English
1
Japanese
1
67
67a
67b
68
70
72
73
239931
218032
178967
107089
176817
239984
170957
240994*
240034*
77
193247
78
240512
83
240513
85
192727
90
100069
103 101818
104 192691
105 103473
106 205473
111 170706
123 192838
126
187975
189699
QTY
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853 is available.
Order separately.
Not part of Model 232157
308842
21
Parts Drawing – Sprayer
Ultra MAX 795 and 1095 Sprayers
Model 232144, Series A
Model 232145, Series A
Model 232148, Series A
Model 232154, Series A
Model 232156, Series A
Model 232157, Series A
Model 232158, Series A
69
72
70
12
76
40
9
102
89
31
81
80
79
106
1
46
59
101
134
99
107
133
75
116
1
129
98
112 2
97
130
104
105
91
92
86
128
115
131 132
127
82
7
100
74
8
28
71
4
6
50
5
79
22
308842
55
85
8056C
98
1
87
Model 232–148
and 232–158 only
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
REF
REF
NO.
PART NO.
DESCRIPTION
4
5
6
7
8
224807
111600
187625
111699
240539
240540
ASSEMBLY, cam, drain valve
PIN, grooved
HANDLE, valve, drain
GASKET, seat, valve
BOARD, filter
Models 232144, 145, 154
Models 232148, 158
O-RING, packing
STRAINER, mesh, 60
SCREW, mach, panhd
TRANSDUCER, pressure control
includes item 59
SCREW, mach, panhd
WASHER, lock spring
ELBOW, 90, street, reducing
O-RING, packing
BOWL, filter; includes item 72
VALVE, seat
SPRING, compression
ASSEMBLY, drain valve
PLUG, pipe
SUPPORT, filter
CORD SET, power (see note, page 22)
Continental Europe (CEE 7/7)
Italy
239050
United Kingdom
1
240543
240721
241879
None (Bare End)
Japan
Australia
SWITCH, rocker, (dpst)
Model 232144, 145, 148, 154, 158
Model 232156, 157
KNOB, potentiometer
COVER, control box, painted
1
1
1
1
1
1
1
1
240557
240723
104361
167025
114392
240314
9
12
28
31
46
50
55
59
69
71
72
74
75
76
79
114528
100020
112538
111457
240315
187615
171941
235014
100721
186075
80
114518
114277
114273
240527
81
82
Brown
NO.
PART NO.
DESCRIPTION
1
1
1
1
1
1
1
1
1
5
1
85
86
87
89
91
92
97
240144
240316
107183
192726
107505
164672
2
4
1
1
1
1
1
1
1
1
1
1
1
99
100
101
102
104
HOSE, drain
HOUSING, filter; includes item 9
CAPSCREW
PLATE, housing, control
PACKING, o-ring
ADAPTER
HOUSING, control box
Model 232144, 145, 154
Model 232148, 158, 156, 157
BUSHING, strain relief
Model 232144, 145, 154
Model 232148, 158, 156, 157
BUSHING, strain relief
CAP, for secondary outlet
PLATE, instruction
SCREW, mach, pnhd
BOARD, PC
Model 232144, 145, 154
Model 232148, 158, 156, 157
POTENTIOMETER, pressure adjust
NUT, shaft, sealing
SCREW, ground
SCREW
LABEL, warning
English
Japanese
BUSHING, strain relief
COVER, display, painted
193239
192694
98
105
106
107
112
115
116
127
113799
114284
114689
240131
192831
114420
240561
240168
236352
112382
114391
114393
193051
193520
114652
193347
164736
PIN, cross
1
129
130
131
132
133
134
240544
193348
103739
114512
192149
193497
BOARD, circuit, display
LABEL, graphic, display
WASHER, lock, int
SCREW, mach, panhd, 4–40 x 3/8
RETAINER, cord
GASKET
1
1
1
1
1
2
View C–C
C
Yellow
Brown
TP4
TP5
1
1
4
1
1
2
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
3
1
1
1
1
1
128
Wiring Diagram
TP2
C
QTY
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit 220853. Order separately.
Blue
TP3
ON/OFF
Switch
QTY
Blue
Caution
Heat from inductor coil of filter board may
destroy wire insulation that comes in contact
with it. Exposed wires could cause shorts and
component damage. Bundle and tie all loose
wires so none lay in contact with inductor coil
of filter board.
104
Violet
Digital Display
Brown
Blue
Power
Plug
107
Pressure Transducer
TP1
Green
Fig. 17
from Motor
Black (–)
Red (+)
Inductor Coil
Potentiometer
Filter Board
8100B
308842
23
Technical Data
Accessories
DANGER LABELS
An English language DANGER label is on your
sprayer. If you have painters who do not read English, order one of the following labels to apply to
your sprayer. The drawing shows the best placement of these labels for good visibility.
Order the labels from your Graco distributor.
Apply other
language here
French
Spanish
German
Greek
Korean
185955
185962
186042
186046
186050
Power Requirements
Model 232144, 145, 154 . . . . . . . . . . . . . . . . . 230 VAC, 50 Hz,
1 phase, 10A minimum or 4000W generator
Model 232148, 158 . . . . . . . . . . . . . . . . . . . . . 110 VAC, 50 Hz,
1 phase, 15A minimum or 4000W generator
Model 232156, 157 . . . . . . . . . . . . . . . . . . 100 VAC, 50/60 Hz,
1 phase, 15A minimum or 4000W generator
Motor
Ultra Max 795 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 HP
with latex at 2000 psi (138 bar, 13.8 MPa)
Ultra Max 1095 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 HP
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)
Ultra Max 795 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 (64.6)
Ultra Max 1095 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 (53)
Maximum Delivery Rating
Ultra Max 795 . . . . . . . . . . . . . . . . . . . . . . . . 0.8 gpm (3 lpm)
Ultra Max 1095 . . . . . . . . . . . . . . . . . . . . . . 1.1 gpm (4.1 lpm)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(m)
Fluid Outlet Size
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Filter with standard 3/8 npt(f) to 1/4 npsm adapter 1/4 npsm
Sound Data
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . . 100 dB(A)*
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 101 lb (46 kg)
Ultra Max 1095 . . . . . . . . . . . . . . . . . . . . . . . . . 107 lb (49 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 in. (724 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 in. (648 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
24
308842
PRINTED IN USA 308842 May 1998, Revised 2/2003