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Graco ULTRA MAX 795, Instructions-Parts List Manual

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Graco ULTRA MAX 795 Instructions-Parts List Manual Download Page 24

24

308800

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 manu-
ally, carefully rotate blades of fan with a screw-
driver.

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). Dis-
connect 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 hous-

ings (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

.

Fig. 17

22

67

25,23

49

68

66

64

E

TORQUE TO
175 in-lb (19 N.m)

70

47

63

B

C

F

40

PACK WITH 
BEARING GREASE

OIL

85

213

G

39

36

7698A

Summary of Contents for ULTRA MAX 795

Page 1: ... 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 308800F Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Related Manuals Displacement Pump 3087...

Page 2: ...al 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 compo...

Page 3: ...afety 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 ...

Page 4: ...ocedure on page 7 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 ...

Page 5: ...luid 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 ...

Page 6: ...nd 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 Connec...

Page 7: ...etely 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 p...

Page 8: ...ED 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 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 hand...

Page 9: ...id 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 ...

Page 10: ...ts 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 ...

Page 11: ...nt 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 pressu...

Page 12: ...ure commutator for burn spots gouges and extreme roughness See page 18 6 Remove motor and have motor shop resur face commutator if possible See page 27 7 Check motor armature for shorts using arma ture tester growler or perform spin test See page 17 7 Replace motor See page 27 8 Check motor control board 104 by perform ing motor control board diagnostics on page 21 If diagnostics indicate substitu...

Page 13: ...rmly connected to female terminals Replace any loose terminal or damaged wiring Securely reconnect terminals 6 Check for loose motor brush leads and termi nals See page 18 6 Tighten terminal screws Replace brushes if leads are damaged See page 18 7 Check for worn motor brushes which must be 1 2 in minimum See page 18 7 Replace brushes See page 18 8 Check for broken and misaligned motor brush sprin...

Page 14: ...n if missing Be sure retainer spring 68 is fully in groove all around con necting rod See page 30 2 Check connecting rod assembly 63 for dam age See page 24 2 Replace connecting rod assembly See page 24 3 Be sure crank in drive housing rotates plug in sprayer and turn on briefly to check Turn off and unplug sprayer See page 25 3 Check drive housing assembly for damage and replace if necessary See ...

Page 15: ...n test See page 17 Inspect windings for burns 3 Replace motor See page 27 4 Check motor control board 104 by perform ing motor control board diagnostics on page 21 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 with a new pressure control board 104 See page...

Page 16: ...yer to be sure problem is corrected WARNING ELECTRIC SHOCK HAZARD To reduce the risk of serious injury including electric shock DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair 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 3 If sprayer do...

Page 17: ...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 Fig 9 B A 54 7703B Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Relieve pressure Connect...

Page 18: ... BRUSH 4 Loosen brush lead terminal screw Pull brush lead away leaving motor lead terminal in place Re move 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...

Page 19: ...Read General Repair Information on page 16 before doing this procedure See Fig 15 1 Relieve pressure 2 Remove pressure control cover 82 3 Disconnect power supply cord black J lead from ON OFF switch 80 the white wire D going to circuit board and green wire E to grounding screw 107 4 Loosen strain relief bushing G and remove power supply cord 79 5 Install power supply cord 79 and tighten strain rel...

Page 20: ...20 308800 Power Supply Cord and On Off Switch Replacement 7696B Fig 15 D 107 E B 82 80 79 G J ...

Page 21: ...ics 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 LED BLINKS SPRAYER OPERATION INDICATES WHAT TO DO Once Sprayer runs Normal operation Do nothing Twice Sprayer runs Normal operation Do nothing Twice repeatedly Sprayer shuts down and LED continues to blink twice repeatedly Line voltage is too high Low...

Page 22: ...trol 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 ...

Page 23: ...23 308800 Pressure Control Repair Fig 16 D B 102 C 82 28 107 A 98 104 120 86 87 89 E 111 112 97 91 7697C 50 116 99 59 31 81 ...

Page 24: ...ousing 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 surface...

Page 25: ...t 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 lockwashe...

Page 26: ...08800 Drive Housing Replacement Fig 18 16 20 49 67 67b 51 67a 90 90 34 26 20 54 22 20 16 25 23 85 7699A Torque to 175 in lb 19 N m 3 2 Torque to 90 100 in lb 10 2 11 3 N m Liberally apply grease 1 1 2 2 2 3 ...

Page 27: ...er 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 driv...

Page 28: ...28 308800 Motor Replacement 7700B 16 20 49 67 67b 51 67a 90 90 34 26 20 54 22 73 20 16 70 40 A 30 10 85 Fig 19 98 79 1 2 Torque to 90 100 in lb 10 2 11 3 N m Liberally apply grease 2 1 1 ...

Page 29: ...position 2 Fig 20 Unscrew suction tube and hose from pump Fig 20 7672A 222 3 Fig 21 Use screwdriver to push retaining spring up Fig 21 7674A 4 Fig 22 Push out pin Fig 22 7675A 5 Fig 23 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump Fig 23 7673A Repairing Pump See manual 308798 for pump repair instructions ...

Page 30: ... rod out 1 5 in Screw in pump until holes in bearing cross link and piston rod align Fig 24 7676A 2 Fig 25 Push pin 21 into holes Fig 25 21 7675A 3 Fig 26 Push retaining spring into groove all the way around connecting rod Fig 26 7674A 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 ...

Page 31: ...ge 0 3000 psi 0 210 bar 0 21 MPa Cycles Gallon liter 244 64 6 Maximum Delivery Rating 0 8 gpm 3 lpm Tip Size one gun 0 028 two guns 0 019 with latex at 2000 psi 138 bar 13 8 MPa Power Cord 14 AWG 3 wire 15 ft 4 5 m Inlet Paint Strainer 16 mesh 975 micron stainless steel screen reusable Outlet Paint Filter 60 mesh 238 micron stainless steel screen reusable Pump Inlet Size 3 4 npt m Fluid Outlet Siz...

Page 32: ...20 16 30 77 54 34 16 20 73 90 67a 51 67b 90 67 63 22 23 25 49 26 20 30 10 73a 38 41 21 14 19 122 121 120 64 Ultra MAX 795 Sprayers Model 232 140 Series A Includes items 1 112 123 126 Basic Sprayer Model 232 141 Series A Includes items 1 126 Complete Sprayer 62 48 52 37 35 REF 78 Ref 85 Ref 120 41 84 7705B 65 126 123 ...

Page 33: ...using 1 51 179961 GEAR REDUCER 1 52 183350 WASHER 2 53 181072 STRAINER 1 54 240317 SHIELD motor 1 includes labels 41 and 73a 61 192719 HANGER pail 1 62 192027 SLEEVE 2 63 218034 CONNECTING ROD 1 64 239923 DISPLACEMENT PUMP 1 see manual 308 798 for parts 65 206994 THROAT SEAL LIQUID 8 OZ 1 66 176818 PIN straight hdls 1 0 3125 in dia x 1 023 in 67 239931 DRIVE HOUSING 1 includes 67a and 67b 67a 1789...

Page 34: ...34 308800 Parts Drawing Sprayer 40 70 79 80 81 106 101 28 82 89 97 31 112 92 100 87 50 55 5 6 69 72 12 76 9 7 71 74 4 86 75 91 59 98 7701B 102 107 104 105 85 99 116 115 ...

Page 35: ...ter 1 79 239995 CORD SET power 1 80 114277 SWITCH rocker spst 1 81 114273 KNOB potentiometer 1 82 193012 COVER painted 1 85 240144 HOSE drain 1 86 240316 HOUSING filter 1 includes item 9 87 107183 CAPSCREW 4 89 192726 PLATE housing control 1 91 107505 PACKING o ring 1 92 164672 ADAPTER 2 98 114284 BUSHING strain relief 1 99 114285 BUSHING strain relief 1 100 240131 CAP for secondary outlet 1 101 1...

Page 36: ...r 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 FO...

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