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INSTRUCTIONS-PARTS LIST 309067
Rev. A
This manual contains important
warnings and information.
First choice when
READ AND KEEP FOR REFERENCE.
quality counts.
INSTRUCTIONS
ULTRA MAX 695
Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
230 VAC
232918, A
Hi-boy sprayer with hoses, gun,
RAC IV DripLessTip Guard and SwitchTip
240 VAC
232914, A
Hi-boy sprayer with hoses, gun,
RAC IV DripLessTip Guard and SwitchTip
232915, A
9659A
Lo-boy sprayer with hoses, gun,
RAC
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Component Function and Identification B S A D R E F G C M H L K N R P J 232918, 232916, 232919 and 232914 9661A Fig. 1 A Motor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled B Pressure Adjusting Knob Controls fluid outlet pressure C ON/OFF Switch Power switch that controls VAC main power to sprayer D Drive Assembly Transfers power from DC motor to the displacement pump E Fluid Filter Filter of fluid between source and spray gun F Fluid Outlet Main hose to spray gun
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General Repair Information WARNING CAUTION To reduce risk of pressure control malfunction: EXPLOSION HAZARD Motor and drive housing are very hot Use needle nose pliers to disconnect a wire. Never during operation and could burn skin if pull on wire, pull on connector. touched. Flammable materials spilled on Mate wire connectors properly. Center flat blade of hot, bare motor could cause fire or explosion. Have insulated male connector in female connector. motor shield in place during operatio
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Grounding WARNING Grounded Grounding Plug Outlets Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death. 1. The 232918, 232915, 232914 require a 230 VAC, 50 Hz, 10A circuit with a grounding receptacle. 230 VAC plug and outlet 9248A Fig. 2 The 232919 requires a 120 VAC, 50/60 Hz, 15A circuit with a grounding receptacle. The 232916, 232917 require a 100 VAC, 50 Hz, 15A circuit with a grounding receptacle.
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Basic Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK, go to next check When check is not OK, refer to this column 4. Motor brushes for the following: 4. Refer to page 10. Electrical (continued) a. Loose terminal screws. a. Tighten. b. Broken or misaligned brush springs. b. Replace broken spring and/or align spring with brush c. Brushes binding in holders. c. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to as- s
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Basic Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK, go to next check When check is not OK, refer to this column 11. Motor thermal cutout switch. Connect ohmmeter between 11. Allow motor to cool. Correct cause of motor yellow leads. Meter must read 1 ohm maximum. overheating. If switch remains open after motor cools, replace motor. 12. Pressure transducer (67) by replacing it with a new one. 12. Replace pressure transducer. See page 16. 13. Pressure adjustment potentio
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Intermediate Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK, go to next check When check is not OK, refer to this column Drain valve 1. Drain valve for correct torque and/or worn parts. Check for 1. Tighten to 185 in-lb (21 Nm). Clean leaks debris trapped on seat. valve and replace with new gasket (55) and sealant 110–110. See page 18. No output: 1. Paint supply. 1. Refill and reprime pump. motor runs and pump strokes 2. For clogged intake strainer. 2. Remove and clean
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Intermediate Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK, go to next check When check is not OK, refer to this column Spray pattern 3. Pressure adjustment potentiometer (77) by replacing 3. Replace potentiometer. See page 14.. variations with a new one. (continued) (continued) 4. Low Output section, page 6. Motor is hot and 1. Determine if sprayer was operated at high pressure with 1. Decrease pressure setting or increase tip small tips, which causes excessive heat b
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Motor Test Armature Short Circuit Test Relieve pressure; page 3. 1. Remove fan cover (B). See Fig.3. 2. Spin motor fan by hand. If there are no shorts, motor coasts two or three revolutions before coming to complete stop. If motor does not spin For checking armature, motor winding and brush freely, armature is shorted and motor must be electrical continuity. replaced. See page 12. Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) Setup 1. Fig. 4 Connect red and black motor leads
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Motor Brushes NOTE: Replace brushes worn to less than13 mm (0.5 in.). Check both brushes. Use Brush Repair Kit WARNING 236967 (243268 for sprayers 232914 and 232915) for ELECTRIC SHOCK HAZARD motor brush repair. Do not touch the brushes, leads, springs or brush holders while the sprayer is plugged in to reduce the risk of electric Relieve pressure; page 3. shock and serious bodily injury. b. With sprayer OFF, turn pressure control knob 1. Unplug sprayer. fully counterclockwise to minimum pressu
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Displacement Pump NOTE: Packing Repair Kit 239939 is available. Refer- 7. Loosen screws (17). Remove pump (18). ence numbers of parts included in the kit are marked with an asterisk, i.e., (223*). Repairing pump See manual 308815 for displacement pump repair Removing pump (See Fig.8) instructions and parts. Torque to 232912, 50 ft-lb (68 Nm) Installing pump (See Fig. 8 and 9) 232913, Apply pipe 232915, sealant (110110) 232917 12 11 15 14 215 201 15 *214 222 18 14 *227 48 202 213 36 17
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Motor NOTE: See Fig. 12 except where noted. 10. Align new motor with cart and reinstall screws (75). 1. Try to stop pump with piston rod (222) in lowest 11. Assemble drive housing to motor. Follow steps 9 position. To lower piston rod manually, remove to 15 on page 15. Install junction box. shroud (32) and rotate motor fan blades. Use a 12. Connect wires to motor control board (22a). Refer screwdriver to push retaining spring (15) up and to Fig. 4. Install motor control board. push out pin (14
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Pressure Control Repair Motor control board removal 6. Install new motor control board (22a) with four 1. screws. Reconnect all wires and secure heat sink Relieve pressure; page 3. (22) to junction box (20). 2. Remove screws (25, 26) and lower heat sink (22) CAUTION and motor control board (22a). See Fig. 12. To reduce the risk of a malfunction: 3. Disconnect wires (C), (D), (96), (E) and 108 from motor control board (22a). See Fig. 4. Be sure the flat blade of the insulated male connector is
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Power Cord 232916, 232917, 232910–232913 6. Install heat sink (22). Be sure no leads are pinched between heat sink and junction box (20). 1. Relieve pressure; page 3. 232915, 232918, 232919 and 232914 2. Remove screws (25, 26) and lower heat sink (22). 1. See Fig. 12. Relieve pressure; page 3. 3. Disconnect power cord leads (30), including green wire to grounding screw (78). See Fig. 4. 2. Loosen screw on power cord retainer (120) and 4. Loosen strain relief bushing (29). Remove power remove pow
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Drive Housing, Connecting Rod, Crankshaft NOTE: Inspect parts as they are removed. Replace 7. Tap lower rear of drive housing (2) with a plastic parts that are worn or damaged. mallet to loosen motor. Pull drive housing straight off motor. 1. 8. Remove and inspect crankshaft (5) and connecting Relieve pressure; page 3. rod (12). Replace all damaged or worn parts. 2. Remove displacement pump. See page 11. 9. Install connecting rod. 3. Remove shroud (32). 10. Lubricate inside of connecting rod be
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Pressure Transducer NOTE: See Fig. 14 and 15 for this procedure. 3. Guide harness up through leg and notch of drive housing (2). Secure guide wire over connector. NOTE: The pressure transducer (67) cannot be re- 4. While pulling guide wire out through bottom of paired or adjusted. If it malfunctions, replace it. motor, guide harness through drive housing and Removal motor castings. 5. Place grommet (65) over harness and push into 1. position in drive housing hole. Relieve pressure; page 3. 6. F
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Pressure Transducer Seal Installation 4. Lightly grease or oil transducer (67) and install pump (18). See page 11. 1. Lightly coat cleaned packing recess in manifold with a light grease or oil. 69 2. Heat seal (69) in hot water for several minutes. 229 CAUTION Excess pressure from the probes or fingernails will damage the packing and cause subsequent leakage. 3. Use a blunt wooden or plastic probe and install seal (69) into recess in manifold (229). Be careful not to cause kinks or bends in pa
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Drain Valve Repair 1. Relieve pressure; page 3. 1. Unscrew spring retainer from valve body. Remove spring, washers and stem/ball. Clean any debris from ball or seat area. 2. Turn handle (54) to closed position. Drive out pin (53). Remove handle. 2. If replacing gasket (55) or seat (56), pry out gas- ket. 3. Remove base (52). NOTE: Whenever gasket (55) is removed, replace it 4. Unscrew drain valve assembly (51). gasket (55) with a new one. and seat (56) will stay in valve. 3. Place seat (56) in d
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Technical Data Power Requirements Inlet Paint Strainer . . . . . . . . . . . . 16 mesh (975 micron) 232914, 232915 . . . . . . . . . . . . . . . . 240 VAC, 50 Hz, Stainless Steel Screen, reusable 1 phase, 10A minimum Outlet Filter . . . . . . . . . . . . . . . . . . 60 mesh (238 micron) 232918 . . . . . . . . . . . . . . . . . . . . . . . . 230 VAC, 50 Hz, Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f) 1 phase, 10A minimum Fluid Outlet Size . . . . . . . . . . . . .
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Complete Sprayer Parts 232915, A 44 232917, A 101 49 100 126 50 Ref 47 Ref 197 60 105 71 9 57 126 30 102 32 3 4 19 85 7 31 74 13 72 9 2 37 70 73 39 16 65 41 12 2a 15 40 5 75 21 6 11 8 99 24 34 38 14 23 95 68 30 35 20 120 18 67 22a 69 112 26 55 66 22 56 17 51 116 121 25 52 48 54 42 20 Ref 114 36 64 43 125 53 111 118 117 50 46 108 80 119 107 22a 96 47 103 67 Ref 27 28 76 78 77 116 Ref 20 Ref 78 Ref 77 Ref 80 232914, 232915, 232918, 232919 1 81 Pressure Control Box 1 232917; page 22 82 9668A (Botto
