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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
120 VAC
ULTRArMAX 1595
AIRLESS PAINT SPRAYER
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
Model 232160, Series A
Basic sprayer on Upright cart without
hose or gun
Model 232161 Series A
Complete sprayer on Upright cart with hose,
gun, RAC IVt DripLesst Tip Guard
and SwitchTipt
Model 232162, Series A
Basic CSA/UL sprayer on Upright cart without
hose or gun
Model 232163 Series A
Complete CSA/UL 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
Related Manuals
Displacement Pump
. . . . . . . . . . . . . . . . . . . . . .
Spray Gun
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
308798
307614
308644
ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308802
First choice when
quality counts.t
MODEL 232161
Rev. E
7952A
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Table of Contents
Related Manuals for Graco 232160
Summary of Contents for Graco 232160
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Page 1: Related Manuals
....... . 308644 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 1998, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001... -
Page 2: Table Of Contents
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. -
Page 3: Warnings
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. -
Page 4: Fire And Explosion Hazard
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 spray- ing immediately. -
Page 5: Component Identification And Function
Component Identification and Function 03008 7148B 7952A Fig. 1 Motor DC motor, permanent magnet, totally enclosed, fan cooled Drive Assembly Transfers power from DC motor to the displacement pump Pail Hanger Container for fluid to be sprayed may be hung here Displacement Pump Transfers fluid to be sprayed from source through spray gun Primary Fluid Outlet... -
Page 6: Setup
See Fig. 1. fluid outlet. NOTE: See Fig. 1, except where noted. WARNING 1. Fill packing nut full with Graco Throat Seal Liquid FIRE AND EXPLOSION HAZARD (TSL), supplied. Fig. 2. Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious injury and property damage. - Page 7 Setup Grounding Grounded Outlets WARNING Improper installation or alteration of the grounding Grounding Prong 9248A plug will result in a risk of electric shock, fire or Fig. 3 explosion that could cause serious injury or death. 2. Do not alter ground prong or use adapter. 3.
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Page 8: Startup
Startup Startup Procedure WARNING NOTE: Flush sprayer if first-time startup. See page 11. INJECTION HAZARD NOTE: See Fig. 4 except where noted. The system pressure must be manually relieved to prevent the system from 1. Close pressure drain valve (G). starting or spraying accidentally. - Page 9 Startup 9. Adjust spray pattern. RAC IV RETAINING HANDLE GUN SAFETY LATCH ENGAGED a. Increase pressure just until spray from gun is completely atomized. Use lowest pressure necessary to get desired results. This reduces overspray and fogging, decreases tip wear and extends the life of the sprayer.
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Page 10: Shutdown And Care
Shutdown and Care 6. Coil hose and hang it on hose rack when storing it, WARNING even for overnight, to help protect hose from kink- ing, abrasion, coupling damage, etc. INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. -
Page 11: Flushing
Flushing When to flush CAUTION Determine material to spray from column 1. Flush with material in column 2. Then follow recommendations in Do not leave water or water-based fluids in sprayer if one of next three columns. it could freeze. Push water out with mineral spirits. Frozen fluid in sprayer prevents starting and may cause serious damage. -
Page 12: Troubleshooting
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 8. Check everything in the guide before disassembling the sprayer. TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column... - Page 13 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Motor runs and pump strokes, Check extension cord size and length. Replace cord with a larger size, grounding type extension cord.
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Page 14: General Repair Information
General Repair Information 2. Test repair after problem is corrected. CAUTION 3. If sprayer does not operate properly, review To reduce the risk of a pressure control malfunction: repair procedure again to verify that everything was done correctly. If necessary, see Trouble- Always use needle nose pliers to disconnect a shooting on page 12, to help identify other possible wire. -
Page 15: Motor Brush Replacement
Motor Brush Replacement NOTE: Replace brushes worn to less than 1/2 in. Note 5. Inspect commutator for excessive pitting, burning that brushes wear differently on each side of mo- or gouging. A black color on commutator is normal. tor, so check both. Brush Repair Kit 220853 is Have commutator resurfaced by a qualified motor available. - Page 16 Motor Brush Replacement 11. Test brushes. CAUTION a. Remove pump connecting rod pin. Do not run the sprayer dry for more than 30 seconds b. With sprayer OFF, turn pressure control knob while checking the brushes to avoid damaging the fully counterclockwise to minimum pressure.
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Page 17: Pressure Control
Pressure Control Pressure Control Replacement CAUTION Do not install the pressure control until motor is WARNING checked. A defective motor may damage the pres- sure control. Make sure to test the motor prior to INJECTION HAZARD pressure control installation. To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief WARNING... -
Page 18: Pressure Control Repair
Pressure Control 22,85 06964A Seals (85) located inside conduit (22) 7957A Fig 14 Pressure Control Repair General Repair and Replacement 5. Install control housing (202) to motor control board (201) using screws (213) and lockwashers (214). WARNING Pressure Control Transducer and O-Ring INJECTION HAZARD Replacement To reduce the risk of serious injury,... - Page 19 Pressure Control Repair 90 REF 89 REF Torque to 150 in–lb (17 N.m) 7202D Fig 15 2. Carefully slide new o-ring (220) down bore (A) of 5. Carefully remove transducer and verify that o-ring motor control (201) into o-ring groove (B). Make is seated correctly and not pushed out of groove.
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Page 20: Pressure Control Wiring
Pressure Control Wiring GRN/YEL wire, E to housing ground BLACK wire, L to on/off sw–1 WHITE wire, N to on/off sw–4 Twisted pair Housing ground ON/Off sw Red wires to I1 and I2 on board WHITE wire ON/ OFF SW–5 to to L2 on Twisted pair board... -
Page 21: Motor Replacement
Motor Replacement WARNING CAUTION INJECTION HAZARD DO NOT drop gear cluster (9) when removing drive To reduce the risk of serious injury, housing (18). The gear cluster may stay engaged in whenever you are instructed to relieve the motor front end bell or the drive housing. pressure, follow the Pressure Relief DO NOT lose thrust balls (10) located at each end of Procedure on page 8. - Page 22 Motor Replacement Seals (93) located inside conduit (22) Apply 6 ounces bearing grease 7957A Fig. 17 308802...
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Page 23: Bearing Housing & Connecting Rod Replacement
Bearing Housing and Connecting Rod Replacement 11. Align connecting rod (29) with crank (E) and drive WARNING housing locating pins (G) with bearing housing (27) holes. Push bearing housing onto drive housing or INJECTION HAZARD tap it into place with a plastic mallet. To reduce the risk of serious injury, whenever you are instructed to relieve CAUTION... -
Page 24: Drive Housing Replacement
Drive Housing Replacement 3. Remove four bearing housing screws (33) and WARNING lockwashers (49). INJECTION HAZARD 4. Lightly tap lower rear of bearing housing (27) with To reduce the risk of serious injury, a plastic mallet to loosen it from drive housing (18). whenever you are instructed to relieve Pull assembled bearing housing and connecting pressure, follow the Pressure Relief... - Page 25 Drive Housing Replacement Torque to 300 in-lb (34 N.m) Torque to 90–100 in-lb (10.2–11.3 N.m) Liberally apply grease 7956A Fig. 19 308802...
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Page 26: Displacement Pump Repair
Displacement Pump Repair Removing pump 1. Flush pump. Relieve pressure. Fig. 20. Cycle 4. Fig. 21. Push out pin. pump with piston rod (222) in its lowest position. 5. Fig. 22. Loosen locknut by hitting firmly with a 2. Fig. 20. Unscrew suction tube and hose from 20 oz (maximum) hammer. - Page 27 7676A Fig. 23 2. Fig. 24. Push pin (21) into holes. 7673A Fig. 26 Fig. 27. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal. 7675A Fig. 24 7677A Fig. 27...
- Page 28 Notes 308802...
- Page 29 Notes 308802...
- Page 30 Parts Drawing - Sprayer Ultra MAX 1595 Sprayers Ultra MAX 1595 Sprayers Model 232161, Series A Model 232160, Series A Model 232163, Series A Model 232162, Series A Includes items 1 –107 Includes items 1 – 104 Complete Sprayer Basic Sprayer...
- Page 31 13 and 73) 240246 HOSE, coupled, 3/8 in. by 20 in. 114426 RETAINER, plug 220640 ROD CONNECTING KIT 114514 CORD SET (used on 232160, 232161) 1 100643 SCREW, cap 114515 CORD SET, CSA 188423 COVER, housing (used on 232162, 232163)
- Page 32 Notes 308802...
- Page 33 Pressure Control Drawing 90 REF 90a REF 54 REF Torque to 150 in–lb (17 N.m) To housing ground, Fig. 16. Located this point, inside housing WARNING! See Pressure Control Transducer and O-Ring Replacement on page 18 for correct replacement procedure. 7202D Fig 28 308802...
- Page 34 Pressure Control Parts List Part Number 239750 Pressure Control Includes items 201 – 327 Part No. Description Part No. Description 239750 PRESSURE CONTROL 192050 ELECTRICAL ENCLOSURE KIT M71503 SCREW See Ref. No. 5 on page 31 for 224[ 192142 PLUG location on Sprayer 239751 MOTOR CONTROL BOARD...
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Page 35: Accessories
....12 AWG, 3 wire, 15 ft (4.5 m) Order the labels from your Graco distributor. Inlet Paint Strainer .... -
Page 36: Graco Standard Warranty
Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub- stitution of non-Graco component parts.