Motor Replacement - Graco ULTRA MAX 1095 Instructions-Parts List Manual

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 (13) and lockwashers
(20) and then two upper screws (16) and lo-
ckwashers (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.

Motor Replacement

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.