Graco ULTRA MAX 695 232133 Operation manual

308801
Rev. E
First choice when
quality counts.
7727A7728A
Model 232133
Model 232131
Related Manuals
Displacement Pump 308815. . . . . . . . . . . . . . . . .
Fluid Filter 308249. . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun 307614. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ELECTRIC, 120 VAC
ULTRAMAX 695
Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Models 232133 and 232131, Series A
Complete sprayer with hoses, gun, RAC IVDripLess
Tip Guard and SwitchTip
Model 232132 and 232130, Series A
Basic sprayer only
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 308801
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 19. . . . . . . . . . . . . . . . . . . . .
Motor Test 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brushes 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Board 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 26. . . . . .
Pressure Transducer 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Seal 28. . . . . . . . . . . . . . . . . . . . . .
Suction Hose 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts 32. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phone Number 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 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 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.

308801 3
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.

4 308801
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 trigger-
ing 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 31 to order.

308801 5
Component Function and Identification
7727A
03008
C
Fig. 1
E
F
D
A
G
J
L
R
M
N
B
H
S
KP
AMotor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled
BPressure Adjusting Knob Controls fluid outlet pressure
CON/OFF Switch Power switch that controls 120 VAC main power to sprayer
DDrive Assembly Transfers power from DC motor to the displacement pump
EFluid Filter Filter of fluid between source and spray gun
FFluid Outlet Main hose to spray gun is connected here
GPail Hanger Container for fluid to be sprayed may be hung here
HDisplacement Pump Transfers fluid to be sprayed from source through spray gun
J50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
KRAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury
LContractor Gun High pressure spray gun with gun safety latch
MRAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip
without removing tip from spray gun
N3 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
PPressure Drain Valve Relieves fluid outlet pressure when open; diverts fluid to drain line
RPressure Control Controls motor speed to maintain fluid outlet pressure at displacement
pump outlet. Works with pressure adjusting knob.
SSpray Gun Safety Latch Inhibits accidental triggering of spray gun

6 308801
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. 2.
1. Connect hose (B) and gun (C) and screw it onto
outlet nipple (A). Don’t use thread sealant, and
don’t install spray tip yet!
2. Fill packing nut (D). Fill packing nut full with
Graco Throat Seal Liquid (TSL) (64) supplied.
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. Read FIRE OR EX-
PLOSION HAZARD on page 4 and
Grounding, page 7.
3. Plug in sprayer. Be sure ON/OFF switch (E) is
OFF. Plug cord into grounded outlet at least 20 ft
(6 m) away from spray area.
4. Flush pump to remove oil installed to protect
pump parts after factory testing. See page 12.
5. Prepare paint according to manufacturer’s recom-
mendations. Remove any paint skin. Stir paint to
mix pigments. Strain paint through a fine nylon
mesh bag (available at most paint dealers) to
remove particles that could clog gun filter or spray
tip. This is an important step toward trouble-free
paint spraying.
continued on next page
7728A
Fig. 2
A
B
C
D
E
1
3
2
Do not install any shutoff device here.
Shown in closed, or spray position.
Fill full with TSL
2
1
Model 232133 Shown
3

308801 7
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. This equipment requires a 120 Vac, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
Fig. 3
Grounding Prong
Grounded
Outlets
2. Do not alter the ground prong or use an adapter.
3. A 12 AWG, 3-wire, grounded 150 ft extension cord
may be used with this equipment.
NOTE: Long extension cords affect sprayer perfor-
mance.
How to use the gun safety latch
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 4.
WARNING
If the gun still sprays when the gun safety latch is
engaged, adjust the gun. See manual 307614,
supplied.
How to use the pressure drain valve
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over-pressure condition, it opens automati-
cally to relieve fluid pressure. If this happens, stop
spraying immediately, shut off and unplug the sprayer.
Determine the cause of the problem and correct it
before operating the sprayer again. Refer also to the
Troubleshooting Guide, page 14. See Fig. 5.
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully
counterclockwise to obtain the minimum setting. Turn
the knob clockwise to increase pressure. See Fig. 6.
03008
Engaged
Disengaged
Fig. 4
1
2
1
2
Closed, or
spray position
Open, or
drain position
Fig. 5
1
2
1
2
7731A
7732A
Fig. 6
+
–
1
1Rotate to increase (+)
or decrease (–)
pressure

8 308801
Setup
Pressure Relief Procedure
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,
install or clean the spray tip.
1. Engage gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
4. Disengage gun safety latch. Hold a metal part of
gun against a grounded metal pail and trigger gun
into pail to relieve pressure.
5. Engage gun safety latch.
6. Open any fluid drain valves in system. Leave drain
valve open until you are ready to dispense again.
How to use the RAC IV tip guard
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
preceding Pressure Relief Procedure.
The tip guard alerts you to the risk of injection and
helps prevent placing any part of the body close to the
spray tip. The tip guard also adjusts the vertical or
horizontal spray pattern. See page 10. The tip guard
holds a reversing spray tip. The tip is in the spraying
position when the tip handle points forward. See Fig. 7.
Clean front of tip frequently during day’s operation.
First, follow preceding Pressure Relief Procedure.
Fig. 7
Tip handle shown in
spraying position.
Turn handle 180,
trigger gun to clear clog
1
2
1 2
03008
How to remove a tip clog
7. Release gun trigger. Engage safety latch. Rotate
RAC IV tip handle 180. See Fig. 7.
8. Disengage safety latch. Trigger gun into a pail or
onto ground to remove clog.
9. Engage safety latch. Rotate tip handle to spraying
position.
10. If tip is still clogged, engage safety latch, shut off
and unplug sprayer, and open pressure drain valve
to relieve pressure. Clean spray tip as shown in
manual 308644, supplied.

308801 9
Startup
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely.
NOTE: If this is a first–time startup, flush the sprayer.
See page 12.
1. Open pressure drain valve (A). See Fig. 8.
2. Don’t install spray tip until pump is primed!
3. Put suction hose or tube (C) into paint. If you
are pumping from a 1 gallon (5 liter) pail, push
drain hose (D) down below top of pail to avoid
splashing paint when drain valve is opened.
4. Turn pressure knob (E) to minimum setting.
5. Disengage gun safety latch. See Fig. 4.
CAUTION
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in it
for more than 30 seconds.
6. To prime pump, turn sprayer ON/OFF switch (F)
ON. Slowly increase pressure until sprayer starts.
When fluid comes from pressure drain valve, close
valve.
7728A
Fig. 8
1Shown in closed, or spray position.
BC
D
A
F
2
2Open, or drain position
1
E
+
–
Model 232133 Shown

10 308801
Startup
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing
when priming, be sure the spray tip is
not installed on the gun, and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
7. To prime hose, lower pressure to reduce splash-
ing. Holding gun against pail, trigger gun and
slowly increase pressure until pump starts. Keep
gun triggered until all air is forced out of system
and fluid flows freely from gun. Release trigger and
engage gun safety latch.
8. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
9. Install spray tip. Engage gun safety latch first!
See manual 308644 for how to install tip.
10. Adjust spray pattern
a. Increase pressure just until spray from gun is
completely atomized. To avoid excessive
overspray and fogging, and to extend tip and
sprayer life, always use lowest pressure
needed to get desired results.
b. If more coverage is needed, use a larger tip
rather than increasing pressure.
c. Test spray pattern. To adjust direction of spray
pattern, engage gun safety latch and loosen
retaining nut (B). Position tip guard horizontally
for a horizontal pattern or vertically for a verti-
cal pattern. Hold tip guard in place while tight-
ening retaining nut. See Fig. 9.
NOTE: Spray patterns will change as tips wear.
Change spray tip if adjusting pressure will not improve
spray pattern.
For a horizontal
spray pattern
For a vertical
spray pattern
Fig. 9
1
2
2
1
B
03008

308801 11
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Check packing nut daily. Keep packing nut full of
TSL at all times to help prevent fluid buildup on
piston rod and premature wear of packings.
3. 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. 10. When leakage occurs again, repack pump.
4. Clean gun’s fluid filter often and whenever gun
is stored. Relieve pressure first. Refer to manual
307614.
5. Lubricate bearing housing after every 100 hours
of operation. Remove front cover. Apply several
drops of SAE 10 non-detergent oil in bearing
housing cavity (B). See Fig. 10.
CAUTION
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold weather,
never leave water or any type of paint in the sprayer
when it is not in use. Freezing can seriously damage
the sprayer or result in a loss of pressure or stalling.
6. Flush sprayer at end of each work day and fill it
with mineral spirits to help prevent pump corrosion
and freezing. See page 12.
7. For very short shutoff periods, leave suction
hose in paint, relieve pressure, and clean spray tip.
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
8. Coil hose when storing it, even for overnight, to
help protect hose from kinking, abrasion, coupling
damage, etc.
7734A
Fig. 10
B
Turn packing
nut clockwise to
tighten
1
1
228

12 308801
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 latex paint Warm, soapy water,
then clean water
Latex-base 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,
soapy water, and
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
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
1. Relieve pressure.
2. Remove spray tip and clean it separately. If you
are changing from water-based to oil-based paints
or solvents, be sure that tip is cleaned thoroughly.
3. Remove filter screen and then reinstall bowl, hand
tight, without screen. Clean screen separately. See
manual 308249.
4. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal flushing pail. Put suction
hose in pail.
5. Open pressure drain valve. See Fig.11.
6. To save paint still in pump and hose, follow
Step 7, except put drain hose in paint pail. When
solvent appears, close drain valve. Put drain hose
in flushing pail. Trigger gun into paint pail. When
solvent appears, release trigger. Continue with
Step 7.

308801 13
Flushing
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.
7. Lower pressure setting. Turn on sprayer. Maintain-
ing metal-to-metal contact, trigger gun into flushing
pail. Slowly increase sprayer pressure just until
pump starts. Keep gun triggered until solvent flows
freely from gun. Circulate solvent to thoroughly
clean sprayer. Release gun trigger. Engage gun
safety latch.
8. Open drain valve and circulate solvent through
drain hose to thoroughly clean it. Close drain
valve.
9. Remove suction hose from pail. Disengage gun
safety latch. Trigger gun and run pump a few
seconds to push air into hose. Do not run pump
dry for more than 30 seconds to avoid damaging
pump packings! Relieve pressure.
10. Reinstall clean filter screen.
11. Remove and clean inlet strainer. Wipe paint off
suction hose and drain hose.
12. Leave drain valve open until you use sprayer
again.
Open or
drain position
Fig. 11
1
1
7731A

14 308801
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
CAUTION
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 or damage to motor
and/or control board may occur. If paint hardened
(dried) in sprayer, the pump packings and/or pres-
sure transducer must be replaced. See page 22
(pump) or 28 (pressure transducer).
Check everything in the troubleshooting tables before disassembling the sprayer.
Basic Problem Solving
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
Fluid Pressure 1. Check pressure transducer knob setting. The
pump won’t develop much pressure if it is at mini-
mum setting (fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. Check for a clogged spray tip or fluid filter, if used.
See page 8.
2. If tip is still clogged, relieve pressure;
refer to separate gun or tip instruction
manual for tip cleaning. Clean or replace
filter element. See manual 308249.
Mechanical 1. Check for frozen or hardened paint in pump (18).
Using a screwdriver, carefully try to rotate fan at
back of motor by hand. See page 23.
1. Thaw. After thawing, plug in sprayer and
turn it on. Slowly increase pressure set-
ting to see if motor starts. If it doesn’t
start, see CAUTION above.
2. Check pump connecting rod pin (14). It must be
completely pushed into connecting rod (12), and
retaining spring (15) must be firmly in connecting
rod groove. See Fig. 18, page 22.
2. Push pin into place and secure with
spring retainer.
3. Check for motor damage. Remove drive housing
assembly (2). See page 26. Try to rotate motor
fan by hand.
3. Replace motor (85) if fan won’t turn. See
page 23.
Electrical 1. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Check extension cord for visible damage. Use a
voltmeter or test lamp at extension cord outlet to
check.
2. Replace extension cord.
3. Check sprayer power supply cord (30) for visible
damage such as broken insulation or wires.
3. Replace power supply cord. See page
25.

308801 15
Basic Problem Solving
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
Electrical
(continued)
4. Check motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
d. Broken leads.
e. Worn brushes.
f. Brush leads snagged on spring clip.
NOTE: The brushes do not wear at same
rate on both sides of motor. Check both
brushes.
4. Refer to page 21.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
(12.5 mm) long.
f. Correctly route the wires.
See page 21.
5. Check motor armature commutator for burn spots,
gouges and extreme roughness. Remove motor
cover and brush inspection plates to check. See
page 21.
5. Remove motor and have motor shop
resurface commutator if possible.
See page 23.
6. Check motor armature for shorts using armature
tester (growler) or perform motor test.
See page 20.
6. Replace motor. See page 23.
7. Check leads from pressure transducer and motor
to motor control board (22a) to be sure they are
securely fastened and properly mated.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
8. Replace board. See page 24.
9. Check power supply cord (30). Disconnect black
and white power cord terminals; connect volt
meter to these leads. Plug in sprayer. Meter should
read 105–125 VAC. Unplug sprayer.
9. Replace power supply cord.
See page 25.
10. Check ON/OFF switch (80). Disconnect black wire
(96) between motor control board (22a) and switch
and connect volt meter between exposed terminal
switch and power cord’s white wire. Plug in
sprayer and turn ON. Meter should read 105–125
VAC. Turn off and unplug sprayer.
10. Replace ON/OFF switch. See page 25.
11. Check motor thermal cutout switch. Connect ohm-
meter between motor’s red leads. Meter should
read 1 ohm maximum.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12. Check the transducer (67) by replacing it with a
new one.
12. Replace pressure transducer.
See page 28.
13. Check pressure adjustment potentiometer (77) by
replacing it with a new one.
13. Replace potentiometer.

16 308801
Intermediate Problem Solving
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
Low Output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure
Warning on page 8, then replace tip.
See your separate gun or tip manual.
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and
turn on sprayer. Prime with paint. Trigger gun mo-
mentarily, then release and engage safety latch.
Relieve pressure, turn off and unplug sprayer.
2. Service pump. See page 22.
3. Release gun trigger. Observe resting position of
pump rod (222).
3. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 22.
4. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Check extension cord size and length. 5. Replace with a correct, grounded exten-
sion cord. Note that long lengths and/or
smaller gauges reduce performance.
6. Check motor brushes. See Electrical –What To
Check, item 4, on page 15.
6. See page 21.

308801 17
Intermediate Problem Solving
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
Low Output
(continued)
7. Check motor control board (22a) by substituting
with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
7. Replace board. See page 24.
8. Check motor armature for shorts by using an arma-
ture tester (growler) or perform motor test. See
page 20.
8. Replace motor. See page 23
.
Drain Valve Leaks 1. Check drain valve for correct torque and/or worn
parts. Check for debris trapped on seat.
1. Tighten to 185 in-lb (21 Nm). Clean
valve and replace with new gasket (55)
and sealant 110–110. See page 30.
No Output: Motor
Runs And Pump
Strokes
1. Check paint supply. 1. Refill and reprime pump.
2. Check for clogged intake strainer. 2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. See
page 29.
3. Tighten; use thread sealant on
npt threads of suction tube (43). Check
for damaged o–ring (45).
4. Check to see if intake valve ball and piston ball are
seating properly. See page 22.
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as need-
ed. See page 22. Strain paint before us-
ing to remove particles that could clog
pump.
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 22.
5. Replace packings. See page 22. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut/wet-cup.
6. Release gun trigger. Observe resting position of
pump rod (222).
6. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 22.
No Output: Motor
Runs But Pump
Does Not Stroke
1. Check displacement pump connecting rod pin (14).
See Fig. 18, page 22.
1. Replace pin if missing. Be sure retainer
spring (15) is fully in groove all around
connecting rod.
2. Check connecting rod assembly (12) for damage.
See page 26.
2. Replace connecting rod assembly. See
page 26.
3. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off and
unplug sprayer. See page 26.
3. Check drive housing assembly for dam-
age and replace if necessary. See
page 26.
Spray Pattern
Variations
1. Spray tip worn beyond sprayer pressure capability. 1. Replace spray tip.
NOTE: A smaller size tip will provide
longer life.
2. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board.
2. Replace board. See page 24.

18 308801
Intermediate Problem Solving
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
Spray Pattern
Variations
(continued)
3. Check pressure adjustment potentiometer (77) by
replacing it with a new one.
(continued) 4. Check Low Output section, page 16.
Motor Is Hot and
Runs Intermittently
1. Determine if sprayer was operated at high pressure
with small tips, which causes excessive heat build
up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer is lo-
cated is no more than 90F (32C) and sprayer is
not located in direct sun.
2. Move sprayer to shaded, cooler area if
possible.
3. Check motor. 3. Replace motor. See page 23.
Building Circuit
Breaker Opens As
Soon As Sprayer
Switch Is Turned
1. Check all electrical wiring for damaged insulation,
and all terminals for loose fit or damage.
Also check wires between pressure transducer
and motor. See page 23.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
On. 2. Check for missing motor brush inspection plate
gasket (see page 21), bent terminal forks or other
metal to metal contact points which could cause a
short.
2. Correct faulty conditions.
3. Check motor armature for shorts. Use an
armature tester (growler) or perform motor test.
See page 18. Inspect windings for burns.
3. Replace motor. See page 23.
4. Check motor control board (22a) by performing
motor control board diagnostics on page 24. If
diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor
armature is determined to be good. A bad motor
armature can burn out a good board
4. Replace board. See page 24.
Circuit breaker
opens after sprayer
operates for 5 to 10
minutes.
1. Check ‘Basic Problems –Electrical’on page 14.
Building circuit
breaker opens as
soon as sprayer is
plugged into outlet
and sprayer is NOT
turned on.
1. Check ON/OFF switch (80). Be sure sprayer is
unplugged! Disconnect wires from switch. Check
switch with ohmmeter. The reading should be
infinity with ON/OFF switch OFF, and zero with
switch ON.
CAUTION: A short in motor circuit can damage
switch and or motor control board (22a).
1. Replace ON/OFF switch. See page 25.
2. Check for damaged or pinched wires in junction
box (20).
2. Replace damaged parts.
Unit will not run on
generator but does
run on AC power
1. Check the generator’s “peak”voltage. This sprayer
will not run if the peak voltage is above 190V or
below 100V.
1. Use AC power or a different generator.

308801 19
General Repair Information
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
Tool List
These service tools are required.
12”adjustable wrench: pump
1/4”Allen wrench: filter plug
3/8”Allen wrench: pump manifold
3/16”Allen wrench: gear housing, legs, handle
5/64”Allen wrench: pressure adjustment knob
Phillipsscrewdriver: junction box, front cover, motor
shield
3/8”socket wrench: motor mount
5/8”socket wrench: drain valve, on/off switch boot,
piston
5/8”open end wrench: outlet fittings
13/16”socket wrench: drain valve
1-1/4”socket wrench: pump inlet valve
1/2”open end wrench: pump rod
11/16”open end wrench: piston jam nut
15/16”open end wrench: flats of inlet tube
1-3/4”open end wrench: pump jam nut
5/64”drive pin: drain valve pin
3”needle nose pliers: wiring, on/off switch
Hammer & punch: packing nut
Torque wrenches: various fasteners
Pipe wrench: suction tube
CAUTION
To reduce the risk of a pressure transducer malfunc-
tion, properly mate connectors and never pull on a
wire to disconnect it.
1. When disconnecting wires, use needle nose
pliers to separate mating connectors.
2. When reconnecting wires, center flat blade of
male connector in blade of female connector.
3. Route wires carefully and avoid pinching any
wires between covers.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure transducer.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures.
5. Test your repair before regular operation to be
sure problem is corrected.
6. If sprayer does not operate properly, verify that
everything was done correctly. Also refer to Trou-
bleshooting Guide, page 14, to help identify other
possible problems and solutions.
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury, in-
cluding electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the sprayer.
Shut off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
WARNING
FIRE HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materi-
als spilled on the hot, bare motor could cause a fire
or explosion.

20 308801
Motor Test
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
For checking armature, motor winding and brush
electrical continuity.
Setup
1. Unplug sprayer.
2. Remove drive housing. See page 26. This is to
ensure that any resistance you notice in armature
test is due to motor and not to worn gears in drive
housing.
3. Remove motor brush inspection covers (A). See
Fig. 12.
4. Remove screws (25, 26). Lower control board
(22a). Disconnect two leads (C) from motor to
board. See Fig.13.
A
B
Fig. 12
02991
Armature Short Circuit Test
1. Remove fan cover (B). See Fig.12.
2. Spin 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 23.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Connect red and black motor leads (C) together
with a test lead. Turn motor fan by hand at about
two revolutions per second. See Fig. 13.
7869B
Fig. 13
77
67
30
80
78
C
22a
96 D
E
black
green
white
black red
yellow
107
108
2. When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is
irregular turning resistance, or no turning resis-
tance, check and repair the following as needed:
broken brush springs, brush leads, motor leads;
loose brush terminal screws or motor lead termi-
nals; worn brushes. See page 21.
3. If there is still uneven or no turning resistance,
replace motor. See page 23.