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Graco ULTRA MAX 1595 Instructions-Parts List Manual
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Graco ULTRA MAX 1595 Instructions-Parts List Manual

Graco ULTRA MAX 1595 Instructions-Parts List Manual

Airless paint sprayers
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INSTRUCTIONS-PARTS LIST
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
Airless Paint Sprayers
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
ULTRArMAX 1595
230 VAC
Model
Series
232164
A
Hi-boy with RAC IVt tip, gun and hose
120 VAC
Model
Series
232160
A
232161
A
Hi-Boy with RAC IV tip, gun and hose
232162
A
232163
A
CSA/UL Hi-Boy with RAC IV tip, gun
MARK Vt
100 VAC
Model
Series
232166
A
230 VAC
Model
Series
232173
A
Hi-boy with RAC IVt tip, gun and hose
120 VAC
Model
Series
232171
A
Hi-Boy with RAC IV tip, gun and hose
All models are not available in all countries
Component Function and Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Wiring
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Description
Description
Hi-Boy
CSA/UL Hi-Boy
and hose
Description
Hi-Boy
Description
Description
Table of Contents
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ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
First choice when
quality counts.t
Related Manuals
Operator
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump
Spray Gun
. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip
. . . . . . . . . . . . . . . . . . . . . . . . . . .
3
5
4
Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Technical Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
Graco Warranty
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
308854
Rev. F
8194A
Model 232164
308855
. . . . . . . . . . . . . . . . .
308798
308491
308644
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
18
23
23
23
24
24

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Summary of Contents for Graco ULTRA MAX 1595

  • Page 1 ....... Bearing Housing & Connecting Rod Replacement 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: Warning Symbol

    Warnings and Cautions Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the instructions.

  • Page 3: Component Identification And Function

    Component Identification and Function 03008 7148B 8194A 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 4: General Repair Information

    General Repair Information WARNING CAUTION To reduce risk of pressure control malfunction: EXPLOSION HAZARD Motor and drive housing are very hot Use needle nose pliers to disconnect a wire. Never during operation and could burn skin if pull on wire, pull on connector. touched.

  • Page 5: Troubleshooting

    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, Extension cord size and length. Replace cord with a larger size, grounding type extension cord.
  • Page 6 Troubleshooting Motor runs but pump does not Displacement pump connecting rod pin (20). Replace pin, if missing. Be sure retainer stroke. See page 16. spring (35) is fully in groove all around connecting rod. See page 16. Frozen or hardened paint in the pump (39). Thaw.

  • Page 7: Motor Brush Replacement

    Grounding Grounding Grounded Outlet WARNING Improper installation or alteration of the grounding Model 232164 9286A plug will result in a risk of electric shock, fire or Fig. 2 explosion that could cause serious injury or death. 1. Models 232160 through 233163, 232171 require a 120 Vac, 60 Hz, 10A circuit with a grounding 2.
  • Page 8 Motor Brush Replacement Motor Brush Installation 11. Repeat for other side. CAUTION 12. Test brushes. When installing brushes, follow all steps carefully to a. Remove pump connecting rod pin. avoid damaging parts. b. With sprayer OFF, turn pressure control knob 7.

  • Page 9: Pressure Control

    Pressure Control 8. Install pump pin and fan cover. CAUTION Pressure Control Replacement Do not install the pressure control until motor is checked. A defective motor may damage the pres- sure control. Make sure to test the motor prior to pressure control installation.

  • Page 10: Pressure Control Repair

    Pressure Control 22,85 06964A Seals (85) located inside conduit (22) ULTRArMAX 1595 shown Fig 7 8184A Pressure Control Repair General Repair and Replacement Pressure Control Transducer and O–Ring Replacement Relieve pressure; page 4. WARNING 2. Remove power cord (90) and plug retainer (89) by FIRE AND EXPLOSION HAZARD removing screws (230) and washers (229).
  • Page 11 Pressure Control Repair 90 REF 89 REF Torque to 150 in–lb (17 N.m) 8185A Fig 8 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.
  • Page 12 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 WHITE wire and I2 on board ON/OFF SW–5 to L2 on board Twisted pair 7369C...

  • Page 13: Motor Replacement

    Motor Replacement WARNING CAUTION ELECTRIC SHOCK HAZARD DO NOT drop gear cluster (9) when removing drive To reduce the risk of Electric Shock: wait housing (18). The gear cluster may stay engaged in 5 minutes after turning sprayer off before the motor front end bell or the drive housing.

  • Page 14: Bearing Housing And Connecting Rod

    Bearing Housing and Connecting Rod Replacement NOTE: Read General Repair Information on page 4 CAUTION before doing this procedure. See Fig. 11. NOTE: Stop sprayer at bottom of its stroke to get crank DO NOT use the bearing housing screws (33) to try (E) in its lowest position.To lower crank manu- to align or seat the bearing housing;...

  • Page 15: Drive Housing Replacement

    Drive Housing Replacement 4. Lightly tap lower rear of bearing housing (27) with CAUTION a plastic mallet to loosen it from drive housing (18). Pull assembled bearing housing and connecting DO NOT drop gear cluster (9) when removing drive rod straight off drive housing. housing (18).

  • Page 16: Displacement Pump Repair

    Displacement Pump Repair Removing pump 1. Flush pump. Relieve pressure. Fig. 13. Cycle 4. Fig. 15. Loosen locknut by hitting firmly with a pump with piston rod (A) in its lowest position. 20 oz (maximum) hammer. Unscrew pump. 2. Fig. 13. Unscrew suction tube and hose from pump.
  • Page 17 7676A Fig. 16 2. Fig. 17. Push pin (20) into holes. 7673A Fig. 19 Fig. 20. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal. 7675A Fig. 17 7677A Fig. 20...
  • Page 18 Parts Drawing – Sprayer Models 232160 through 232164, 232166, Series A 79 REF 237 REF Detail B Detail A–A Detail B 7951A 308854...
  • Page 19 Parts List – Sprayer Models 232160 through 232164, 232166, Series A NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION MOTOR, ELECTRIC 240136 HANDLE, cart includes 41 and 73a 192027 SLEEVE, cart 235726* Model 232164 105510 WASHER, lock, spring 220854* Models 232160 thru 232163 108865 SCREW, machine, pan hd PRESSURE CONTROL...
  • Page 20 Parts Drawing – Sprayer Models 232171, 232173; Series A Detail B 54,85 Detail A–A Detail A–A Detail B Detail B 9001C 308854...
  • Page 21 Parts List – Sprayer Models 232171, 232173; Series A NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION MOTOR, ELECTRIC 108865 SCREW, machine, pan hd includes 41 and 73a 111482 RIVET, snap 235726* Model 232173 171941 SPRING, compression 220854* Model 232171 186075 SUPPORT, filter PRESSURE CONTROL...
  • Page 22 Pressure Control Drawing 90 REF 89 REF 54 REF Torque to 150 in–lb (17 N·m) To housing ground, Fig. 9. Located this point, inside housing WARNING! See Pressure Control Transducer and O–Ring Replacement on page 10 for correct replacement procedure. 7202D Fig 21 308854...
  • Page 23 Outlet Paint Filter ....60 mesh (238 micron) sprayer. Order labels from your Graco distributor. stainless steel screen, reusable Apply other Pump Inlet Size .

  • Page 24: 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.