Graco 232160 User manual

308802
Rev. E
First choice when
quality counts.
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
120 VAC
ULTRAMAX 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 IVDripLessTip Guard
and SwitchTip
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 IVDripLessTip Guard
and SwitchTip
U.S. PATENT NO. 4,323,741; 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
Related Manuals
Displacement Pump 308798. . . . . . . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
7952A
MODEL 232161

2308802
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 14. . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 15. . . . . . . . . . . . . . . . . . . . .
Pressure Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 18. . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Wiring 20. . . . . . . . . . . . . . . . . . . . . . . .
Motor Replacement 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod Replacement 23.
Drive Housing Replacement 24. . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 26. . . . . . . . . . . . . . . . . . . . .
Accessories 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 36. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
INSTRUCTIONS
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 35 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical 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.

3308802
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 medical attention.
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 8 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.

4308802
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 spray-
ing 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 8 to prevent the
equipment from starting unexpectedly.
Liquids can be injected into the body by high pressure airless
spray or leaks –especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable
liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground
equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic
drop cloths, open flames such as pilot lights, hot objects such as
cigarettes, arcs from connecting or disconnecting power cords
or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
NOTE: This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge. See page 35 to order.

5308802
Component Identification and Function
7148B
7952A
03008
Fig. 1
N
E
H
B
A
T
C
P
R
M
D
S
G
F
U
V
L
J
W
K
AMotor DC motor, permanent magnet, totally enclosed, fan cooled
BDrive Assembly Transfers power from DC motor to the displacement pump
CPail Hanger Container for fluid to be sprayed may be hung here
DDisplacement Pump Transfers fluid to be sprayed from source through spray gun
EPrimary Fluid Outlet Single spray gun operation is connected here
FSecondary Fluid Outlet Second spray gun operation is connected here
GPressure Drain Valve Relieves fluid outlet pressure when open
HFluid Filter Final filter of fluid between source and spray gun
JPressure Adjusting Knob Controls fluid outlet pressure
KPressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
LON/OFF Switch Power switch that controls 120 VAC main power to sprayer
M3 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
N50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
PContractor Gun High pressure spray gun with gun safety latch
RRAC IV Switch Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
SRAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
TSpray Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun
UPower Cord Rack Holds wrapped power cord for storage
VSpray Hose Rack Holds wrapped spray hose for storage
W15/20 Amp Switch Allows sprayer to operate on 15A service with reduced performance

6308802
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 Pres-
sure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over-
pressurization and rupture of the hose or gun.
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and compo-
nent 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.
Fig. 2
7677A
2. Single 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. 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 11.
6. Prepare paint according to manufacturer’s recom-
mendations. 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.

7308802
Setup
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. All models require a 120 VAC, 60 Hz, 15A circuit
with a grounding receptacle. See Fig. 3.
Fig. 3 Grounding Prong
Grounded
Outlets
9248A
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.

8308802
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 loos-
en 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 en-
sure sprayer is ready to operate safely.
Startup Procedure
NOTE: Flush sprayer if first-time startup.
See page 11.
NOTE: See Fig. 4 except where noted.
1. Close pressure drain valve (G).
2. Don’t install spray tip until pump is primed!
3. Put suction tube (M) into paint container.
4. Turn pressure adjusting knob (J) fully counter-
clockwise to zero pressure.
5. 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.
6. Prime pump.
a. Open (handle down) pressure drain valve (G).
If no secondary hose is installed, be sure sec-
ondary 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.
7. Check all fluid connections for leaks.Relieve fluid
pressure before tightening connections.
8. Fig. 5. Engage gun safety latch. Install spray tip.
Install tip guard. See manual 308644, supplied.

9308802
Startup
9. 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.
7954A
Fig. 4
J
L
M
GFE
03008
GUN SAFETY
LATCH ENGAGED
GUN SAFETY
LATCH DISENGAGED
Fig. 5
RAC IV
HANDLE
RETAINING
NUT
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 8.
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.

10 308802
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 8.
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. See Fig. 6.
If pump begins to leak, loosen packing nut and
remove throat nut spacer (B). Tighten packing nut
just snug. Over tightening causes binding and ex-
cessive packing wear. Use a round punch or brass
rod and light hammer to adjust nut. When leakage
occurs again, repack the pump.
2. Clean fluid filter often and whenever sprayer is
stored. Follow Flushing Guidelines on page 11 for
cleaning procedure.
3. Lubricate bearing housing after every 100 hours of
operation. First relieve pressure. Remove front
cover (C). Fill bearing housing cavity (D) 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 11.
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 kink-
ing, abrasion, coupling damage, etc.
A
TIGHTEN
Fig. 6 7692A
B
C
Fig. 7
D
7693A