GRACO 308800F ULTRA MAX 795 Airless Paint Sprayer Instructions

Instructions – Parts List
120 VAC, 15A
ULTRA
MAX 795
Airless Paint Sprayer
308800F

308800F ULTRA MAX 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 IV DripLess Tip Guard
and SwitchTip
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
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001

Symbols

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

Caution Symbol
CAUTION
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.

• This equipment is for professional use only.

• Read all instruction manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

• Do not alter or modify this equipment. Use only genuine Graco parts.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• 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.

• 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.

• Do not use 1,1,1–trichloroethane, 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.

• Do not use hoses to pull equipment.

• 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).

• Do not lift pressurized equipment.

• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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.

• 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.
• Do not point the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the gun when spraying.
• Check the gun diffuser operation weekly. Refer to the gun manual.
• Be sure the gun trigger safety operates before spraying.
• Lock the gun trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning, checking or servicing the equipment.
• Tighten all fluid connections before operating the equipment.
• 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.
• 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.

• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

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.

• 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.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
• Keep the spray area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the spray area.
• Extinguish all open flames or pilot lights in the spray area.
• Do not smoke in the spray area.
• Do not turn on or off any light switch in the spray area while operating or if fumes are present.
• Do not operate a gasoline engine in the spray area.
• 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.

• Keep clear of all moving parts when starting or operating the pump.
• 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.

Component Identification and Function

gun
E| Primary Fluid Outlet| Single spray gun operation is connected here
F| Secondary Fluid Outlet| Second spray gun operation 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 120 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 the 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

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:

• Do not allow material to freeze in sprayer.
• Use nylon spray hose at least 50 ft (15 m) long.
• Do not use wire braid hose.
• Do not install shutoff device between sprayer and gun. See Fig. 1.

NOTE: See Fig. 1, except where noted.

1. Fill packing nut full with Graco Throat Seal Liquid (TSL), supplied. Fig. 2.

2. Single gun hookup.
   Use 1/4 in. ID, 50 ft (minimum) main hose. For more flexible gun movement, install 3/16 in. ID, 3ft 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.
   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.

Grounding
WARNING
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.

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

2. Do not alter ground prong or use adapter.

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:

• are instructed to relieve the pressure,
• stop spraying,
• check or service any of the system equipment,
• 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.

7. Put suction tube (39) into paint container.

8. Turn pressure adjusting knob (J) fully counterclockwise to zero pressure.

9. 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.

10. 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.

11. Check all fluid connections for leaks. Relieve fluid pressure before tightening connections.

12. Fig. 5. Engage gun safety latch. Install spray tip. Install tip guard. See manual 308644, supplied.

13. 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.

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.

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.
   

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:| Flush with:| Prime with:| Clean with:| Store unit with:
---|---|---|---|---
Spray with new sprayer or sprayer that has been stored| Mineral spirits, then compatible solvent such as water or mineral spirits| Compatible paint, such as latex or oil-base| Compatible solvent such as water or mineral spirits| Mineral spirits
Spray latex paint| Warm, soapy water, then clean water| Latex paint| Warm soapy water, then clean water| Mineral spirits
Spray oil paint| Mineral spirits| Oil-base paint| Mineral spirits| Mineral spirits
Change latex to oil paint| Warm, soapy water, then clean water| Mineral spirits| Mineral spirits| Mineral spirits
Change oil to latex paint| Mineral spirits, then soapy water, and fi- nally, clean water| Latex| Warm, soapy water, then clean water| Mineral spirits
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.

6. Do not run pump dry for more than 30 seconds to avoid damaging pump packings!

7. Follow Pressure Relief Procedure on page

8. Engage gun safety latch.

9. Unscrew filter bowl and reinstall clean screen.
   Install bowl and hand tighten.

10. Remove suction tube and screen and clean them separately.
    

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.

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- for will not run if it is at the minimum setting (fully counterclockwise).| 1. Slowly increase pressure setting to see if motor starts.
2. Check for a clogged spray tip or fluid filter. Re- fer to separate gun, tip, or fluid filter instruction manual.| 2. Relieve pressure, refer to separate gun, tip,
or fluid filter instruction manual for cleaning.
Basic Mechanical Problems| 1. Check for frozen or hardened paint in pump (64). Using a screwdriver, carefully try to rotate fan at back of motor by hand. See page 17.| 1. Thaw. Plug in sprayer and turn on. Slowly increase pressure setting to see if motor starts. If it doesn’t, see NOTE 1, below.
2. Check displacement pump connecting rod pin (66). It must be completely pushed into con- necting rod (63) and retaining spring (68) must be firmly in groove of connecting rod. See Fig. 25.| 2.Push pin into place and secure with spring retainer.
3.Check for motor damage. Remove drive housing assembly (67). See page 25. Try to rotate fan by hand.| 3. Replace motor (73) if fan won’t turn. See page 27.
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 must read 105-125 VAC.| 2. Reset building circuit breaker; replace
building fuse. Try another outlet.
3.Check extension cord for damage. Check ex- tension cord continuity with a volt meter.| 3. Replace extension cord.
4. Check sprayer power supply cord (79) for damage such as broken insulation or wires.| 4. Replace power supply cord. See page 19.

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).

General Repair Information

CAUTION
To reduce the risk of a pressure control malfunction:

• Always use needle nose pliers to disconnect a wire. Never pull on the wire, pull on the connector.
• Mate wire connectors properly. Be sure flat blade of insulated male connector is centered in wraparound blade of female connector.
• 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

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.

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.
   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 ofburns, fire or explosion; see preceding WARNING.

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.

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.

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

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

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.

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

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.

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 orbrush holders when sprayer is plugged in to reduce risk of electric shock and serious bodily injury.

Power Supply Cord and On/Off Switch Replacement

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 Removal

1. Relieve pressure.

2. Fig. 16. Remove five screws (28) and cover (82).

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

4.  Remove four screws (102), washers (103) and circuit board (104).

Motor Control Board Installation

1. Relieve pressure.

2. Fig. 16. Install motor control board (104) with four screws (102) and washers (103).

3. Connect to motor control board:
   Lead (E) to transducer.
   Lead (D) to potentiometer.
   Lead (111) to ON/OFF switch.
   Lead (C) to power cord.
   Six motor leads (B).

4. Install cover (82) with five screws (28).

Motor control board diagnostics

1. Relieve pressure.
2. Remove five screws (28) and cover (82). See Fig. 16.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following table:

transducer
Four times
repeatedly| Sprayer shuts down and LED continues to blink four times repeatedly| Run away pressure. Pressure greater than 4500 psi.| Replace motor control board. See preceding Motor control board removal procedure.
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

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 30–35 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).

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.

9. Assemble connecting rod (63) and bearing housing (22).

10. Clean mating surfaces of bearing and drive housings (22,67).

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.
    

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.

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.

Displacement Pump Repair

Removing pump

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

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

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

4. Fig. 22. Push out pin.

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

Repairing Pump
See manual 308798 for pump repair instructions.

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.
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.

2. Fig. 25. Push pin (21) into holes.

3. Fig. 26. Push retaining spring into groove all the way around connecting rod.
   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 ft–lb (102 N m).
   Fig. 28. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal.

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.

Technical Data

Power Requirements. . . . . . . . . . . . . . . . . . . .120 VAC, 60 Hz,
1 phase, 15A minimum or 4000W generator. . . . . . . . . . . . . . . . . . . . . . . . .(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) Motor 1.0 HP. . . . . . . . . . . . . . . . . . . . . . . . . .244 (64.6)
Maximum Delivery Rating. . . . . . . . . . . . . . . .0.8 gpm (3 lpm)
Tip Size. . . . . . . . . . . . . . .(with latex at 2000 psi (138 bar, 13.8 MPa)
Power Cordone gun – 0.028; two guns – 0.019. . . . . . . . . . . . . . . . .14 AWG, 3 wire, 15 ft (4.5 m)
Inlet Paint Strainer. . . . . . . . . . . . . . . . .stainless steel screen, reusable
Outlet Paint Filter 16 mesh (975 micron). . . . . . . . . . . . . . . . . .stainless steel screen, reusable
Pump Inlet Size 60 mesh (238 micron). . . . . . . . . . . . . . . . . . . . . . . . . . . . .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, Delrin, chrome plating, leather,
V-Max UHMWPE, aluminum,
stainless steel, tungsten carbide
NOTE: Delrin 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). . . . . . . . . . .  . . . .20.5 in. (521 mm)

Parts Drawing – Sprayer

Parts Drawing – Sprayer

Ultra MAX 795 Sprayers
Model 232–140, Series A
Includes items 1 – 112, 123, 126
Basic Sprayer

REF
NO.| PART NO.| DESCRIPTION
---|---|---
4| 224807| ASSEMBLY, cam, drain valve
5| 111600| PIN, grooved
6| 187625| HANDLE, valve, drain
7| 111699| GASKET, seat, valve
9| 104361| O-RING, packing
12| 167025| STRAINER, mesh, 60
28| 114392| SCREW, mach, panhd
31| 240314| TRANSDUCER, pressure control includes item 59
50| 100020| WASHER, lock spring
55| 112538| ELBOW, 90, street, reducing
59| 111457| O-RING, packing
69| 240315| BOWL, filter

Wiring Diagram

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 non–Graco 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 1–800–690–2894 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
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
PRINTED IN USA 308800F
01/1997 Rev. 06/2005

References

• Graco Inc.
• Manual-Hub.com – Free PDF manuals!

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