Graco Ultra Max 1595 Operation manual

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

2308854
Warnings and Cautions
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.
Fluid injection is a serious injury! If high pressure fluid
pierces your skin, the injury might look like “just a cut”. But it is
a serious wound! Get immediate medical attention.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Point gun away from yourself or anyone else.
Relieve pressure before checking or repairing any leak.
Relieve pressure when you turn off the sprayer or stop
spraying
Keep drain hose outlet under fluid when opening drain valve.
Relieve pressure through the gun when you turn off the
sprayer or stop spraying.
Do not use components rated less than system Maximum
Working Pressure
Never allow children to use this unit. If you are injured using this
equipment, get immediate medical treatment.
Fire and explosion can occur when spraying or flushing
flammable fluid in an area where air circulation is poor and
flammable vapors can be ignited by an open flame or sparks.
To help prevent a fire and explosion:
Use outdoors or in an extremely well ventilated area.
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.
Remove, extinguish or unplug all ignition sources; tape wall
switches. Do not smoke in spray area.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of a grounded pail when triggering into pail.
Use a properly grounded outlet.
Use only conductive airless paint hose.
Do not modify this equipment.
WARNING

3308854
Component Identification and Function
8194A
7148B
03008
Fig. 1
N
F
H
B
A
T
C
P
R
M
D
S
G
E
U
V
LJ
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 Adjust 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 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, (3/8 in. ID, MARK V) grounded, nylon hose, spring guards both ends
PSpray 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
W10/12 Amp Switch Allows Models 232164, 232173 to operate on 10A service with reduced perfor-
mance
15/20 Amp Switch Allows Models 232160 through 232163, 232166, 232171 to operate on 15A ser-
vice with reduced performance

4308854
General Repair Information
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect a wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. adjustable wrench
Adjustable, open-end
wrench
Torque wrench
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
Tool List
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
WARNING
ELECTRIC SHOCK HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting, page
5, for other possible solutions.
WARNING
EXPLOSION HAZARD
Motor and drive housing are very hot
during operation and could burn skin if
touched. Flammable materials spilled on
hot, bare motor could cause fire or explosion. Have
motor shield in place during operation to reduce
risk of burns, fire or explosion.
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following 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.

5308854
Troubleshooting
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
Motor runs and pump strokes,
but output is low or there is no
output.
Extension cord size and length. Replace cord with a larger size, grounding
type extension cord.
Paint supply. Refill and reprime pump.
Clogged intake strainer. Remove and clean strainer and reinstall. Mark
V models 232171 and 232173 strainer is for
use in paint only.
Loose suction tube or loose fittings. Tighten; use thread sealant or sealing tape on
threads, if necessary.
Worn spray tip. Follow Pressure Relief Procedure
Warning, then replace tip. See your
separate gun or tip manual.
Motor brushes, loose leads and terminals,
minimum 13 mm brush length, broken or
misaligned springs, or brushes binding in
holders. See page 7.
Replace parts as needed. See page 7.
Motor armature for shorts. Use an armature
tester (growler).
Replace motor. See page 13.
If pump continues to stroke when gun trigger
is released. With pump on and primed, trigger
gun momentarily, then release and engage
safety latch. Relieve pressure, turn off and
unplug sprayer.
Service pump. See manual 308798.
If intake valve ball and piston ball are seating
properly.
Remove intake valve and clean. Check balls
and seats for nicks; replace if necessary.
See manual 308798. Strain paint before
using to remove particles that could clog the
pump.
Intake valve ball is packed with material. Remove and clean intake valve. Do not
leave Mark V models 232171 and 232173
sprayers under pressure for more than 5
minutes when pumping texture material and
not actively spraying.
Leaking around throat packing nut which may
indicated worn or damaged packings.
Replace packings. See manual 308798.
Also check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten the packing nut/wetcup.
Defective pressure control transducer. Replace pressure control transducer. See
page 10.
(Continued on page 6)

6308854
Troubleshooting
Motor runs but pump does not
stroke.
Displacement pump connecting rod pin (20).
See page 16.
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. See page 16.
Frozen or hardened paint in the pump (39). Thaw. See NOTE 1. Plug in sprayer and turn
on. Slowly increase pressure setting to see if
motor starts.
Be sure crank in drive housing rotates; plug
in sprayer and turn on briefly to check. Turn
off and unplug sprayer.
Check drive housing assembly for damage
and replace if necessary. See page 17.
Motor is hot and runs
intermittently.
Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
Decrease pressure setting or increase tip
size.
Be sure ambient temperature where sprayer
is located is no more than 90F and sprayer
is not located in direct sun.
Move sprayer to shaded, cooler area, if
possible.
Determine if sprayer was turned on,
pressurized, but not operating for long
periods of time.
Turn off sprayer whenever you stop spraying
for a while and relieve fluid pressure.
NOTE 1: Thaw sprayer in a warm area if water or water-based paint has frozen in it. Do not start sprayer until it has
thawed completely. If paint hardened (dried) in sprayer, replace pump packings. See manual 308798.

7308854
Grounding
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. Models 232160 through 233163, 232171 require a
120 Vac, 60 Hz, 10A circuit with a grounding
receptacle. Models 232164, 232173 requires a 230
Vac, 50 Hz, 10A circuit with a grounding recep-
tacle. Model 232166 requires a 100 Vac, 50 Hz,
15A circuit with a grounding receptacle. See Fig. 2.
Fig. 2
Grounded
Outlet
Model 232164 9286A
2. Do not alter ground prong or use adapter.
3. A 1.5 mm2by 90 m extension cord may be used
with this equipment.
Motor Brush Replacement
NOTE: Replace brushes worn to less than 1/2 in.
Brushes wear differently on each side of mo-
tor, check both sides. Brush Repair Kit 222157
is available for Models 232164, 232173 and
Brush Repair Kit 220853 is available for Mod-
els 232160 through 232163, 232166, 232171.
Spring clip, 110816, may be purchased sepa-
rately.
Motor Brush Removal
1. Read General Repair Information; page 4.
2. Relieve pressure;page 4.
3. Fig. 3. Remove motor shield (14). Remove in-
spection covers (B) and gaskets on each side of
motor.
(Continued on page 8)
A
B
14
Fig. 3 7703B
4. Fig. 4. Push in 110816 spring clip (A) to release
hooks (B) from brush holder (C). Pull out spring
clip.
5. Fig. 4. Loosen terminal screw (D). Pull brush lead
(E) away, leaving motor lead (F) in place. Remove
brush (G) and spring (H).
Fig. 4
H
E
D
F
G
A
01227
BC
6. 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 wear too fast.

8308854
Motor Brush Replacement
Motor Brush Installation
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
7. Fig. 5. Install new brush (G) with lead in long slot
(J) of brush holder (C).
8. Fig. 4. Slide brush lead (E) under washer of termi-
nal screw (D) and tighten screw. Be sure motor
lead (F) is connected at terminal screw.
9. Fig. 5.Place spring (H) on brush (G).
10. Fig. 5. Install spring clip (A). Push down to hook
short slots (K) in brush holder (C).
Fig. 5
G
K
J
C
NOTE SPRING COIL DIRECTION
A
01227
E
H
11. Repeat for other side.
12. 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.
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displace-
ment pump packings.
13. Install brush inspection covers and gaskets.
14. Break in brushes.
a. Operate sprayer 1 hour with no load.
b. Install connecting rod pin.

9308854
Pressure Control
CAUTION
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.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of Electric Shock: wait
5 minutes after turning sprayer off before
servicing to allow stored current to dis-
charge.
Motor Test
With motor shield off and four motor leads discon-
nected:
1. Check continuity with multimeter from each black
motor lead to ground (one at a time). Any reading
less than infinite resistance –even very high re-
sistance –means motor is shorted to ground. Re-
place motor.
CAUTION
A motor that is shorted to ground will damage the
pressure control.
2. Remove fan cover from motor.
3. Remove pump pin ( See page 16 for instructions to
remove pin).
4. With black motor leads not connected, use motor
fan to spin motor quickly. Motor should spin freely
in both directions. If not, replace motor.
5. Connect black motor leads together.
6. Use motor fan to turn motor. It should be much
harder to turn than in step 4. If there is uneven or
no resistance to turning, check brushes and re-
place if necessary.
7. If there is still uneven or no resistance to turning,
replace motor.
8. Install pump pin and fan cover.
Pressure Control Replacement
1. Relieve pressure;page 4.
2. Remove two screws (19) holding filter
assembly (A). See Fig. 7 and parts list, except as
noted.
3. Remove filter assembly by unthreading swivel
union (15) from hex nipple (102). Unthread nipple
from pressure control (5)
4. Remove 8 screws (64) and motor shield (14).
5. Remove outlet cover (221) on pressure control
wiring box. Disconnect motor leads. See Fig 6.
6. Loosen electrical tubing (22) from pressure control
fitting and pull out wires
7. Remove hose (28) from rear of pressure
control swivel union (15).
8. Support pressure control (5) and carefully remove
motor mount screws (37). Remove pressure
control.
9. Install new pressure control (5) with screws (37).
10. Continue to assemble sprayer.
7145A
Fig 6 Yellow
Red
Black/White
Black
Black

10 308854
Pressure Control
64
14
37
5
19
A
102
221
8184A
Fig 7
15
22,85
28
1Seals (85) located inside conduit (22)
1
06964A
ULTRAMAX 1595 shown
Pressure Control Repair
General Repair and Replacement
1. Relieve pressure;page 4.
2. Remove power cord (90) and plug retainer (89) by
removing screws (230) and washers (229).
3. Remove screws (213) and lockwashers (214).
Carefully remove control housing (202) from
control motor board (201) so internal wiring is not
damaged. Lay housing on side next to control
motor board. See Fig. 8 and parts list.
4. Remove and replace only those components and
wires necessary for repair. Make a diagram show-
ing wire hook–ups for items removed to insure
correct wiring when reinstalling. See Fig 9 for
wiring information.
5. Install control housing (202) to motor control
board (201) using screws (213) and
lockwashers (214).
Pressure Control Transducer and O–Ring
Replacement
WARNING
FIRE AND EXPLOSION HAZARD
Proper o–ring replacement is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage.
NOTE: Do not replace o–ring unless damaged or if
leakage is seen around weep hole, o–ring or
transducer.
1. See Fig. 8 and pressure control part list. Disas-
semble pressure control as in steps 1 through 4 on
page 10 and remove old transducer (219) and, if
necessary, old o–ring (220).

11308854
Pressure Control Repair
8185A
Fig 8
214
202
213 201
90 REF
230
89 REF
229
214
216
217 213
215
218
219
220
1Torque to 150 in–lb (17 N.m)
C
A
B
1
2. Carefully slide new o–ring (220) down bore (A) of
motor control (201) into o–ring groove (B). Make
sure o–ring is in groove around its entire circumfer-
ence.
NOTE: PTFEo–ring (220) is stiffer than a rubber
o–ring and may be difficult to place in groove.
3. Carefully slide new transducer and plastic
spacer (217) down bore. Loosely attach
bracket (218), screws (213), and washers (214).
4. Seat transducer into o–ring by drawing down
screws and washers until bracket is flush with
motor control surface.
5. Carefully remove transducer and verify that o–ring
is seated correctly and not pushed out of groove. If
not seated correctly use new o–ring and repeat
steps 2 through 5.
6. When o–ring is correctly installed, reinstall trans-
ducer and tighten screws to 150 in-lb (17 Nm).
Install spacer (216) and C-clip (215). Connect
electrical lead and assemble sprayer.
7. Perform Flush and Prime procedures in STARTUP
of Operation Manual 308855 with compatible fluid.
8. Inspect weep hole (C) for any leakage.
9. If any leakage is present, replace o–ring repeating
steps 1 through 9.

12 308854
Pressure Control Wiring
7369C
Fig 9
Ground wire to
housing ground
From control
housing, WHITE
wire to L2
From control
housing, BLACK
wire to L1
From control housing,
one red wire to I1
From control housing,
one red wire to I2
Connector from
potentiometer to J3
Wires J4/J5 to
10/12 switch
Connector from pressure
transducer to J6
I1
I2
J3
J5 J4 J6
J7
GND
L1
L2
Twisted pair
GRN/YEL wire, E to housing ground
Housing ground
L
E
N
12
5
3
64
BLACK wire, L to on/off sw–1
WHITE wire, N to on/off sw–4
ON/OFF sw
Twisted pair
Red wires to I1
and I2 on board
To J3
Twisted pair
WHITE wire
ON/OFF
SW–5 to
L2 on board
BLACK wire
ON/OFF
SW–2 to
L1 on board
Twisted pair
7135B

21
18
9
10
10
33
14
F
28
16
37
39
G
30
Fig. 10
79
1
2
Seals (93) located inside conduit (22)
Apply 6 ounces bearing grease
22
1
531
1
2
ULTRAMAX 1595 shown
7957A
13308854
Motor Replacement
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of Electric Shock: wait
5 minutes after turning sprayer off before
servicing to allow stored current to dis-
charge.
NOTE: Refer to Fig. 10 and parts list, except as
noted.
1. Relieve pressure;page 4.
2. Remove motor shield (14). Remove front cover
(31). Disconnect hose (28) at pump. Disconnect
drain hose (79) from pump (39).
3. Remove outlet cover on pressure control wiring
box. Disconnect four motor leads. See Fig 6.
4. Unscrew conduit connector (16) from motor and
pull motor leads from tubing (22).
5. Remove screws (33) from recess of drive housing.
6. Remove screws (21 and 30) from motor bell (F).
7. Use a plastic mallet to tap displacement pump (39)
from rear to loosen drive housing (18) from motor
bell (F). Pull off drive housing.
CAUTION
DO NOT drop gear cluster (9) when removing drive
housing (18). The gear cluster may stay engaged in
the motor front end bell or the drive housing.
DO NOT lose thrust balls (10) located at each end of
gear cluster (9) 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.
8. Lower pressure control (5) by unscrewing motor
mounting screws (37).
9. Lift off motor (1).
10. Mount and center new motor on frame and attach
pressure control (5) with motor mounting screws
(37).
11. Insert motor leads through connector (16) and
tubing (22) to pressure control. Screw connector
(125) two or three threads into motor. Tighten
locknut up to motor. Connect four motor leads.
See Fig. 6.
12. Liberally grease gear cluster (9) and pinion gear
(G) and pack all bearings in motor bell. Be sure
thrust balls (10) are in place. (One ball is included
with a replacement drive housing.)
13. Align gears and push drive housing (18) straight
onto motor bell (F) and locating pins.
14. Continue to reassemble sprayer.

14 308854
Bearing Housing and Connecting Rod
Replacement
NOTE: Read General Repair Information on page 4
before doing this procedure. See Fig. 11.
NOTE: Stop sprayer at bottom of its stroke to get crank
(E) in its lowest position.To lower crank manu-
ally, carefully rotate blades of fan with a screw-
driver.
1. Relieve pressure;page 4.
2. Remove front cover (31). Unclip drain hose (79)
from pump. Hold a wrench on pump intake valve
(H) and unscrew pump suction tube (42). Discon-
nect pump hose (28).
3. Push up retaining spring (35). Push pin (20) out
rear.
4. Loosen locknut (38). Unscrew displacement
pump (39).
5. Remove four screws (33) and lockwashers (49).
6. Lightly tap lower rear of bearing housing (27) with
a plastic mallet to loosen it from drive housing (18).
Pull bearing housing and connecting rod assembly
(29) straight off drive housing.
7. Remove pail bracket assembly (F) and install with
locknuts (13) 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 (29) and bearing
housing (27).
10. Clean mating surfaces of bearing (27) and
drive (18) housings.
11. Align connecting rod (29) with crank (E) and drive
housing locating pins (G) with bearing housing (27)
holes. Push bearing housing onto drive housing or
tap it into place with a plastic mallet.
CAUTION
DO NOT use the bearing housing screws (33) 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 (33) and lockwashers (49). Tighten
screws evenly to 300 in-lb (34 N.m).
13. Install pump. See page 17.
14. Install remaining parts. See Fig. 11.
F
7955A
Fig. 11
27
18
49
31
35
20
39
E
TORQUE TO
300 in-lb (34 N.m)
28
38
29
BC
101
PACK WITH
BEARING GREASE
OIL
79
H
G
42
86
33
25
13
ULTRAMAX 1595 shown

7956A
Fig. 12
21 63
31
18
9
10
10
64
51
63
14
27
63
30
49
79
Torque to 300 in-lb (34 N.m)
3
2Torque to 90–100 in-lb (10.2–11.3 N.m)
Liberally apply grease
1
2
2
2
3
1
33 1
ULTRAMAX 1595 shown
15308854
Drive Housing Replacement
CAUTION
DO NOT drop gear cluster (9) when removing drive
housing (18). Gear cluster may stay engaged in the
motor front end bell or the drive housing.
DO NOT lose thrust balls (10) located at each end of
gear cluster (9) 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 4
before doing this procedure. See Fig. 12.
1. Relieve pressure;page 4.
2. Remove front cover (31) and motor shield (14).
Unclip drain hose (79) from pump.
3. Remove four bearing housing screws (33) and
lockwashers (49).
4. Lightly tap lower rear of bearing housing (27) with
a plastic mallet to loosen it from drive housing (18).
Pull assembled bearing housing and connecting
rod straight off drive housing.
5. Remove two drive housing screws (51) and
lockwashers (63).
6. Remove two lower screws (30) and lockwashers
(63) and then two upper screws (21) and lock-
washers (63) from front of motor (1).
7. Tap drive housing (18) with a plastic mallet to
loosen it from front of motor (1), and then pull drive
housing straight off.
8. Liberally apply approximately 4 ounces of bearing
grease to gear cluster (9). Grease is supplied with
drive housing replacement kit. Be sure thrust balls
(10) are in place.
9. Align gears and push new drive housing straight
onto front of motor and locating pins.
10. Continue reassembling sprayer.

16 308854
Displacement Pump Repair
Removing pump
1. Flush pump. Relieve pressure. Fig. 13. Cycle
pump with piston rod (A) in its lowest position.
2. Fig. 13. Unscrew suction tube and hose from
pump.
Fig. 13 7672A
A
3. Fig. 14. Use screwdriver to push retaining spring
(35) up and pin (20) out.
Fig. 14 7674A
35
20
4. Fig. 15. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 15
7673A
Repairing Pump
See manual 308798 for pump repair instructions.

17308854
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, includ-
ing 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. 16. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
Fig. 16
7676A
2. Fig. 17. Push pin (20) into holes.
Fig. 17
20
7675A
3. Fig. 18. Push retaining spring (35) into groove all
the way around connecting rod.
Fig. 18 7674A
35
Fig. 19. 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 approxi-
mately 75"5 ft–lb (102 Nm).
Fig. 19 7673A
Fig. 20. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.
Fig. 20 7677A

18 308854
Parts Drawing –Sprayer
A
Detail B
A
Detail A–A
7951A
REF
61
53
34
79
35
18
101
27
90
60
50
6
19
63
30
61
14
64 21
1
32
31
13
949
86
29
20
5
19
58
11
62
17
80
52
REF
6
79 REF
43
47
15
36
10
10
64
82 81
74
44
63
51
33
73
38
39
42
25
28
69
83
89
26
72
59
56
48
71
94
75
92
93
95
41
102
57
24
8
15
16
22
54
,
28
Detail B
37
Models 232160 through 232164, 232166, Series A
55
77
104
99
98 97
96
103
105
106
107
57
237 REF
88
110

19308854
Parts List –Sprayer
Models 232160 through 232164, 232166, Series A
REF
NO. PART NO. DESCRIPTION QTY
REF
NO. PART NO. DESCRIPTION QTY
1 MOTOR, ELECTRIC 1
includes 41 and 73a
235726*Model 232164 1
220854*Models 232160 thru 232163 1
5 PRESSURE CONTROL 1
see parts list on page 23
239429 Model 232164 1
239750 Models 232160 thru 232163 1
6 240143 FRAME, cart 1
8 107266 TERMINAL 2
9 220637 GEAR REDUCER 1
10 100069 BALL 2
11 104811 CAP, hub 2
13 112746 LOCKNUT, 5/16 –18 2
14 240483 SHIELD, motor (includes label 77) 1
15 155494 UNION, swivel, 902
16 110138 CONNECTOR, conduct 1
17 112827 BUTTON, snap 2
18 220879 DRIVE HOUSING 1
19 114402 SCREW, hex hd, flanged 4
20 183210 PIN, straight, hdls 1
21 100644 SCREW, cap 2
22 065312 TUBING, electrical, flexible, 5.5 in. 1
24 107264 TERMINAL 2
25 161889 UNION, swivel 1
26 154636 WASHER 2
27 240701 BEARING HOUSING 1
28 240246 HOSE, coupled, 1/4in. by 20 in. 1
29 220640 ROD CONNECTING KIT 1
30 100643 SCREW, cap 2
31 188423 COVER, housing 1
32 108850 SCREW, mach, filh 4
33 110141 SCREW, cap, sch 4
34 193081 BRACKET, manifold, filter 1
35 183169 SPRING, retaining 1
36 111699 GASKET, seat, valve 1
37 110963 SCREW, flange, hex hd 4
38 193031 NUT, retaining 1
39 240291 KIT, pump, displacement 1
manual 308798
41 112538 ELBOW, 90, street, reducing 1
42 193097 TUBE, suction 1
43 PLUG, packless
240131 Models 232160 thru 232164, 1/4 in. 1
240987 Model 232166, 3/8 in. 1
44 114271 STRAP, retaining 1
47 206994 THROAT SEAL LIQUID, 8 OZ 1
48 240315 BOWL, filter 1
49 106115 WASHER, lock, spring 4
50 181072 STRAINER, inlet 1
51 108849 SCREW, cap, sch 2
52 110243 RING, retaining 2
53 108691 PLUG, tubing 2
54 108460 CONNECTOR, conduit, 451
55LABEL, caution 1
192839 English 1
193521 Japanese 1
56 104361 PACKING, o–ring 1
57 ADAPTER
164672 Models 232160 thru 232164, 2
3/8 npt x 1/4 npsm
162485 Model 232166, 3/8 npt x 3/8 npsm 2
58 101242 RING, retaining, ext. 2
59 167025 STRAINER, 60 mesh 1
60 179811 WHEEL, semi–pneumatic 2
61 240136 HANDLE, cart 1
62 192027 SLEEVE, cart 2
63 105510 WASHER, lock, spring 6
64 108865 SCREW, machine, pan hd 10
69 111482 RIVET, snap 1
71 171941 SPRING, compression 1
72 186075 SUPPORT, filter 1
73 192719 HANGER, pail 1
74 100020 CONNECTOR, tube, female 2
75 187615 VALVE, seat 1
77LABEL, DANGER 1
187791 English 1
189702 Japanese 1
79 240144 HOSE, drain 1
80 109032 SCREW, machine, pan hd 4
81 185384 BRACKET 2
82 110240 NUT, self–retaining 2
83 183350 WASHER 2
85 107447 SEAL, conduit 2
86 192691 CLIP, spring 1
87290447 LABEL, warning 3
(on brush covers–not shown)
88 187784 LABEL, danger, French 1
89 192149 RETAINER, plug 1
90 CORD SET 1
240539 European 1
240540 Italy 1
240541 Denmark 1
240542 Switzerland 1
240543 Bare end, European 1
240247 Japan 1
92 235014 DRAIN VALVE ASSEMBLY 1
93 224807 CAM, drain valve 1
94 111600 PIN, grooved 1
95 187625 HANDLE, valve, drain 1
96 102814 GAUGE, pressure, fluid 1
97 100176 BUSHING, hex 1
98 156849 NIPPLE, pipe 1
99 100483 TEE, pipe 1
101 162485 NIPPLE, adapter 1
102 193024 NIPPLE, hex 1
103 240700 HOUSING KIT, filter (includes item 56) 1
104192839 LABEL, warning, French 1
105238361 HOSE, grounded, nylon, 1/4”ID, 1
cpld 1/4 npsm(f), 50 ft (15m)
spring guards both ends
106238358 HOSE, grounded, nylon, 3/16”ID, 1
cpld 1/4 npsm(f), 3 ft (.9 m)
spring guards both ends
107222667 GUN, contractor, basic 1
manual 307614
108 221621 TIP, spray, cylinder (not shown) 1
manual 308644
109 237859 GUARD, rac (not shown) 1
110 LABEL, WARNING 1
187975 English 1
193520 Japanese 1
Extra Danger and Warning tags and labels available free.
*Motor Brush Repair Kit is available:
Model 232164; order 222157
Models 232160 thru 232163, 232166; order 220853
Models 232160 and 232162 have items 88 & 104, but not 105
thru 107. Model 232166 does not nave any of these items.

20 308854
Parts Drawing –Sprayer
Models 232171, 232173; Series A
A
Detail B
A
Detail A–A
A
Detail B
A
Detail A–A
REF 61
53
34
79
35
18
27
90
60
6
19
63
30
61
14
64 21
1
32
31
13
949
29
5
19
62
17
80
52
REF 6
47
15
10
64
82 81
74
44
63
51
33
73
38
25
69
83
89
72
59
56
48
71
94
95
41
57
24
8
16
22
54,85
28 REF
Detail B
37
55
77
104
103
105
106
107
88
110
79 REF
86
42
10128
50
26
11 58
93
92
36
75
97
63
237 REF
39
15
20
119
115
9001C
102
96
99
43
120
101 121