Graco 311365J User's Manual
Contents
1. Grounding Improper installation or alteration of grounding plug results in risk of electric shock fire or explosion that could cause serious injury or death 10 Ultra Max Il 695 795 and 1095 100 200 Vac models require a 50 60 Hz 15A circuit with a grounding receptacle Ultra Max Il 1595 Mark V 120 Vac models require a 50 60 Hz 20A circuit with a grounding receptacle 220 240 Vac models require a 50 60 Hz 10A circuit with a grounding receptacle Grounding 2 Do not alter ground prong or use adapter ti2810a b ho gt A P 120 Vac A 12 AWG 3 wires with grounding prong 300 ft 90 m extension cord may be used 220 240 Vac You may use a 3 wire 1 0 mm 12 AWG minimum extension cord up to 90 m long Long lengths reduce sprayer performance A 311365J Troubleshooting Troubleshooting Mechanical Fluid Flow dO Relieve pressure page 9 WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK IENGO IS OR GOTO MextCneck to next check When check is not OK refer to this column E XX is displayed displayed 1 Fault condition exists 4 Determine fault correction from table table page 13 False tripping of WatchDog Operating conditions out of Turn pressure down Refer to operation system EMPTY is dis WatchDog parameters Pump manual for adjusting Operate without played Pump does not run output is low see below WatchDog active see operation manual Pump outpu2. TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run 1 Remove pump and try to run sprayer If motor runs Digital display shows E 05 but motor shaft does not rotate check for locked or frozen pump or drive train Possibly locked rotor condition an If sorayer does not run continue to step 2 a am open connection exists between l l motor and control there is a Set sprayer to OFF and disconnect power to l l ny problem with motor or control board sprayer e or motor amp draw is excessive Disconnect motor connector s from control board socket s Check that motor connector and control board contacts are clean and secure If contacts are clean and secure continue to step 4 Control board status light blinks 5 times repeatedly Set sprayer to OFF and spin motor fan 1 2 turn Restart sprayer If sprayer runs replace control board If sprayer does not run continue to step 5 Perform Spin Test Test at large 4 pin motor field connector Disconnect fluid pump from sprayer Test motor by placing a jumper across pins 1 amp 2 Rotate motor fan at about 2 revolutions per second A cogging resistance to motion should be felt at the fan The motor should be replaced if no resistance is felt Repeat for pin combinations 1 amp 3 and 2 amp 3 Pin 4 the green wire is not used in this test If all spin test is positive continue to step 6 Green Blue Red Black 123 4 d U
3. Remove motor shroud Disconnect and remove the provided scraper so an even layer is wiring from baffle remaining in the pocket 11 Remove nut and screw 88 and disconnect 4 5 ground wire 87 Disconnect coil connector NEU Y Remove coil 81 12 Remove top two screws 39 and control box 61 13 Remove six screws 27 two screws 102 and control board NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 26 311365J Install two screws 102 six screws 27 and control board Install and torque two screws 102 to values in illustration Install motor control board 52 with six screws 27 Torque to 9 11 in lb 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect and install wiring in baffle Install motor shroud Install control box 61 with top two screws 39 Install coil 81 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 311365J 10 11 12 13 14 15 16 Pressure Control Board Connect transducer connector E to motor control board Connect 15 20A switch 178 1595 model only Connect motor control board power lead s D to ON OFF switch 33 Connect WatchDog 49 switch connector X to motor control board Connect potentiometer connector C to motor control board Install control panel 68 wi
4. 89 and thrust washers 28 30 90a 36 see page 29 are in place Brush grease onto gear teeth 1 Push drive housing 90 onto motor 84 and install with five screws 6 Torque to 190 210 in Ib 21 23 Nem Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft Ib 34 40 Nem Install front cover 51 with four screws 31 Install shroud 72 with two screws 158 Install pump 91 see Displacement Pump Replacement page 38 695 795 page 40 1095 1595 Mark V Install pump rod cover 108 and pail hanger 55 with screw 31 and two nuts 24 311365J Drive and Bearing Housing Replacement cO LO Y LC LO ti13000a 35 311365J Motor Replacement Removal Relieve pressure page 9 1 Remove pump 91 see Displacement Pump Replacement page 38 695 795 page 40 1095 1595 Mark V NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive hous 2 Remove drive housing 90 see Drive Housing Replacement page 34 3 Remove shroud 58 4 Remove four screws 38 and control cover 96 5 Remove bottom two screws 39 and allow control panel 68 to hang down freely 6 Disconnect all three motor connectors from motor control board 52 Disconnect motor leads 8 Remove top two screws 39 and control housing 61 9 Remove strain relief 29 from
5. from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eye wear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection CALIFORNIA PROPOSITION 65 This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling Component Identification and Function Component Identification and Function ti13451a Premium Digital Display ON OFF switch Pressure control Trigger Lock Model serial tag WatchDog Switch not Mark V 8 311365J 2 3 4 5 7 10 11 12 13 14 General Repair Information Pressure Relief Procedure System pressure must be manually relieved to pre vent system from starting or spraying accidentally Fluid under high pressure can be injected through skin and cause serious injury To reduce risk of in jury from injection splashing fluid or moving parts follow Pressure Relief Procedure whenever you are instructed to relieve pressure stop spraying check or service any system equipment install or clean spray tip Turn pressure control knob to zero Turn ON OFF switch to OFF Unplug power supply cord PANS Hold metal part of gun firmly to grounded metal pail Trigger gun to relieve pressure e Lock gun safety latch 6 Open prime valve Leave prim
6. motor control board Install control panel 68 with two screws 39 15 Connect display connector A to motor control board Install cover 96 with four screws 38 21 100 120 Vac North American and Japan Taiwan 22 Tighten 2 screws to 14 17 in lb 102 Pressure Control Board Ey M ti12994b 311365J Pressure Control Board 240 Vac Motor Control Board Removal Installation N 1 Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar Relieve pressure page 9 Wait 5 minutes before servicing 2 Apply thermal compound a For 2 capacitor boards and 6 capacitor Remove all four screws 38 and cover 96 boards with the Powerbar shown in Figure 2 Disconnect display connector A from motor 1 below apply a small amount of thermal control board 52 compound 15U114 or 110009 5 to shaded 3 Remove bottom two screws 39 disconnect component areas on rear of motor control board 52 potentiometer connector C from motor control board 52 Disconnect power cord connectors gt D and filter board connectors J from 52 lt 2 ON OFF switch 33 and remove control panel NI 68 4 Disconnect WatchDog switch connector X from motor control board 5 Disconnect motor control board power connectors K from filter board 146 ti17334a 6 Remove top two screws 39 and control box Figure 1 61 b For 6 capacitor boards w
7. motor wires and power bar plate 69 36 10 Motor Replacement Remove motor wires from baffle 278075 and remove baffle 11 Remove two screws 23 and nuts 19 on side opposite control 12 Loosen two nuts 19 on side near control and remove motor 84 from cart frame 62 Installation 1 Slide new motor 84 under two screws 23 in cart frame 62 near control 2 Install two screws 23 and nuts 19 on motor side opposite control 3 Install baffle and connect motor wires 4 Tighten all four screws 23 and nuts 19 torque nuts to 115 135 in lb 13 15 Nem 5 Install strain relief 29 onto motor wires and into power bar plate 69 6 Install control housing 61 with top two screws 39 Connect motor leads 8 Connect all three motor connectors to motor control board 52 9 Install control panel 68 with two screws 39 10 Install control cover 96 with four screws 38 11 Install drive housing 90 see Drive Housing Replacement page 34 12 Install pump 91 see Displacement Pump Replacement page 38 695 795 page 40 1095 1595 Mark V 311365J Motor Replacement 37 311365J Displacement Pump Replacement for 695 795 Displacement Pump Replacement for 695 795 See pump manual 310643 or 310894 for pump OFF and unplug power cord Push up retaining repair instructions ring 43 and push pump pin out See manual 311362 311363 or 311364 for 44 applicable sprayer part
8. number references ti7168a Removal Relieve pressure page 9 Wait 5 minutes before servicing 4 Remove suction tube 76 hose 94 and any 1 Flush pump washers and o rings 2 Remove screw 31 and slide pump rod shield 5 Loosen pump jam nut 56 Unscrew pump 108 forward 31 ti7170a LI 3 Cycle pump in JOG mode until pump pin 44 is in position to be removed Turn power switch 38 311365J Installation If pump pin works loose parts could break off due to force of pumping action Parts could project through the air and result in serious injury or property damage NOTICE If the pump jam nut loosens during operation the threads of the drive housing will be damaged 1 Extend pump piston rod 1 5 in Apply grease to top of pump rod at A or inside connecting rod ti7171a 311365J Displacement Pump Replacement for 695 795 Install pump pin 44 Verify retaining spring 43 is in groove of connecting rod 85 Push pump up until pump threads engage Screw in pump until threads are flush with drive housing opening Align pump outlet to back Install washers o rings and suction tube 76 and hose 94 Screw jam nut 56 up onto pump until nut stops Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately 75 5 ft lb 102 Nem Install pump rod shield 108 with screw 31 Fill packing nut with Graco TSL until fluid flows
9. potentiometer connector C from save for reuse motor control board N 2 e ti13495a 311365J 31 Pressure Control Board Installation 3 Install control box 61 and control panel 68 with four screws 39 1 Install o ring 20 and transducer 86 in filter base 67 Torque to 35 45 ft lb 47 61 Nem Install grommet onto transducer 86 and transducer into control box 40 67 4 Connect potentiometer connector C to motor control board ti13496a 2 Connect transducer connector E to motor control board 95 EN C ES P i Z EC ti12997a o ti12999a ti13493a 32 311365J Notes 311365J Notes 33 Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing Disassembly Relieve pressure page 9 34 Remove screw 31 two nuts 24 pail hanger 55 and pump rod cover 108 Remove pump 91 see Displacement Pump Replacement page 38 695 795 page 40 1095 1595 Mark V Remove two screws 158 and shroud 72 Remove four screws 31 and front cover 51 Remove four screws 14 and washers 12 to remove bearing housing 83 and connecting rod 85 Remove five screws 6 and pull drive housing 90 off motor 84 Assembly Make sure gear
10. set sprayer ON and control knob 1 2 turn clockwise If sprayer does not run properly set sprayer to OFF and go to next step Install new transducer Connect power set sprayer ON and control knob 1 2 turn clockwise Replace control board if sprayer does not run properly 311365J 13 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run atall does not run at all Digital display shows E 03 Control board status light blinks 3 times repeatedly 14 Check transducer or transducer transducer or transducer connections control board is not detecting a pressure signal 11 Set sprayer to OFF and disconnect power to sprayer to OFF and disconnect power to sprayer Check transducer and connections to control board Disconnect transducer from control board socket Check to see if transducer and control board contacts are clean and secure Reconnect transducer to control board socket Connect power set sprayer ON and control knob to 1 2 turn clockwise If sprayer does not run set sprayer to OFF and go to next step Connect a confirmed working transducer to control board socket Set sprayer ON and control knob to 1 2 turn clockwise If sprayer runs install new transducer Replace control board if sprayer does not run Check transducer resistance with ohmmeter less than 9k ohm between red and black wires and 3 6k ohm between green and yellow wires 311365J Troubleshooting
11. tips in the case where the nozzle tip clogs while spraying follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit High pressure spray is able to inject toxins into the body and cause serious bodily injury In the event that injection occurs get immediate surgical treatment Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3300 psi Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections are secure before operating the unit Know how to stop the unit and bleed pressure quickly Be thoroughly familiar with the controls 311365J 311365J Warnings V NBUTNZININIe EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Always wear appropriate gloves eye protection and a respirator or mask when painting Do not operate or spray near children Keep children away from equipment at all times Do not overreach or stand on an unstable support Keep effective footing and balance at all times otay alert and watch what you are doing Do not operate the unit when fa
12. u 1H 255137 249678 4 311365J Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where appli cable 7 INAV NeININe GROUNDING This product must be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current This product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Improper installation of the grounding plug is able to result in a risk of electric shock When repair or replacement of the cord or plug is required do not connect the grounding wire to either flat blade terminal The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire Check with a qualified electrician or serviceman when the grounding instructions are not completely understood or when in doubt as to whether the product is properly grounded Do not modify the plug provided if it does not fit the outlet have the proper outlet installed by a qual ified e
13. 1365J 29 Pressure Control Board Pressure Adjust Potentiometer Removal Installation N 1 Install gasket 115 nut and potentiometer 82 on control panel 68 Torque nut to 30 35 in lb Relieve pressure page 9 Wait 5 minutes before 3 38 3 95 Nem servicing 1 Remove four screws 38 and cover 96 ti12998a 2 Install pressure control knob 34 Check pressure control knob alignment to etd potentiometer shaft Turn shaft fully clockwise 2 Disconnect potentiometer connector C from and attach knob in full ON position with a hex motor control board 95 wrench 34 ti12997a 3 Remove pressure control knob 34 with a hex wrench 3 Connect potentiometer connector C to motor control board 4 Remove gasket 115 nut and potentiometer 82 from control panel 68 4 ti13493a ti12998a 30 311365J Pressure Control Board Pressure Control Transducer Removal 4 Remove four screws 39 and control box 61 Allow control panel 68 to hang down freely Relieve pressure page 9 Wait 5 minutes before servicing 1 Remove four screws 38 and cover 96 ti13493a 5 Remove grommet 40 from control box then remove transducer 86 and o ring 20 from 2 Disconnect transducer connector E from filter base 67 motor control board 95 ti7260a ti13495a 95 ti12999a 6 Remove grommet 40 from transducer and 3 Disconnect
14. 99a 42 Displacement Pump Replacement 1095 1595 Mark V 6 Tighten latch and rotate latch lock into locked position TI6312a 7 Attach drain hose to sprayer ti7330a 8 Fill pump with Graco TSL until fluid flows onto top of seal 311365J Wiring Diagram Wiring Diagram 695 795 Lo Boy Series B 695 Hi Boy Series D 795 Hi Boy Series C 1095 1595 Mark V Series B Motor ti7346a green ground ON OFF Switch AL I La white Power 72 MD A Pressure us 2 BT Transducer LLS 14A 10A Switch 1595 MARK V Potentiometer Watchdog 311365J 43 Wiring Diagram Wiring Diagram 695 795 Lo Boy Series B 695 Hi Boy Series D 795 Hi Boy Series C 1095 1595 Mark V Series B Digital Display Motor Potentiometer Pressure Transducer E Black U D m Watchdog 20A 15A 1595 Switch ti12980a ON OFF Switch Black Power Plug green ground 311365 J Wiring Diagram Wiring Diagram UltraMax Il 695 795 Lo Boy Series B 695 Hi Boy Series D 795 Hi Boy Series C 1095 Mark V Series B Models with only TWO large capacitors on control board Motor ti7523a green ground ON OFF Switch ZU SSIT777 Digital Display Power Plug UD _ wur Pressure amp Transducer Qc Japan Taiwan Potentiometer Models 4 N Motor Digital Display Pressure Transducer Wa
15. Repair G GRACO Ultra Max Il Ultimate Mx II 311365 For Portable Airless Spraying of Architectural Coatings and Paints For professional use only Not for use in explosive atmospheres 3300 psi 22 8 MPa 227 bar Maximum Working Pressure IMPORTANT SAFETY INSTRUCTIONS e Read all warnings and instructions in this manual Save these instructions See page 3 for model information including maximum working pressure and approvals Korean patent 10 0579681 1095 1595 HI m Ce Intertek PROVEN QUALITY LEADING TECHNOLOGY Table of Contents Table or COMICS 3 2252 wiwa conn e eat he RI RA 2 Mer Pc 3 Warming s ssd hi RUD dti abd hi RARE KA 5 Component Identification and Function 8 General Repair Information 9 Pressure Relief Procedure 9 GIOUNAINA d re dad ee A kawa BJ dake 10 Troubleshooting aaaaaaaaaa aaa aaa ai 11 Mechanical Fluid Flow 05 11 Eleclfical wi baie ze Beach Racine Se ea XS 13 Pressure Control Board aaaaa41111 20 100 120 Vac North American and Japan Taiwan Motor Control Board 20 240 Vac Motor Control Board 23 240 Vac Filter Board 25 110 Vac U K Motor Control Board 26 110 Vac U K Filter Board 28 Pressure Adjust Potentiometer 30 Pressure Control Transducer 31 Meum P prp WRA ae ET 33 Drive and Bearing Ho
16. any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may
17. craper so an even layer is 10 Remove motor shroud Disconnect and remove remaining in the pocket wiring from baffle 9 Disconnect motor connectors F G and H from motor control board 11 Remove nut and screw 88 and disconnect ground wire 87 Disconnect coil connector Y Remove coil 81 12 Remove top two screws 39 and control box 61 13 Remove six screws 27 two screws 102 and control board NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 20 311365J Install six screws 27 two screws 102 and motor control board Install and torque two screws 102 to values in illustration Install motor control board 52 with six screws 27 Torque to 9 11 in lb 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect and install wiring in baffle Install motor shroud Install control box 61 with top two screws 39 Install coil 81 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 311365J 10 11 12 13 14 16 Pressure Control Board Connect transducer connector E to motor control board Connect 15 20A switch 178 1595 model only Connect motor control board power lead s D to ON OFF switch 33 Connect WatchDog 49 switch connector X to motor control board Connect potentiometer connector C to
18. e valve open until ready to spray again NOTE If suspected that spray tip or hose is com pletely clogged or that pressure has not been fully relieved after following steps above VERY SLOW LY loosen tip guard retaining nut or hose end cou pling to relieve pressure gradually then loosen completely Then clear tip or hose obstruction 311365J General Repair Information NOTICE To reduce risk of pressure control malfunction e Use needle nose pliers to disconnect 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 1 Keep all screws nuts washers gaskets and electrical fittings removed during repair procedures These parts are not normally provided with replacement assemblies 77 o reduce risk of serious injury including electric hock do not touch moving or electrical parts with ingers or tools while testing repair Shut off and un4 plug sprayer when inspection is complete Install all overs guards gaskets screws washers and hroud 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 11 for other possible solutions
19. i Green Blue Red Black 4 3 il Green Blue Red Black 311365J 15 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run 6 Perform Field Short Test Test at large 4 pin motor Digital display shows E 05 but motor shaft does not rotate field connector There should not be continuity from Possibly locked rotor condition pin 4 the ground wire and any of the remaining EE ae an open connection exists between 3 pins If motor field connector tests fail l j B motor and control there is a problem replace motor l with motor or control board or um ap motor amp draw is excessive Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper Control board status light blinks 9 resistance for each model see table below 5 times repeatedly Resistance Table gt gt e ess So esA 16 311365J Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Allow sprayer to cool If sprayer NOTE Motor must be cooled down for the test Digital display shows E 06 runs when cool correct cause of overheating Keep sprayer in cooler location with good ventilation Make sure motor air intake is not blocked 2 Disconnect thermal device connector from control If sprayer still does not run follow board socket Make sure contacts are clean and Control board
20. include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer 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 FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco o
21. ith the powerbar 7 Disconnect transducer connector E from shown in Fig 2 below apply a small motor control board amount of thermal compound 15U114 or 110009 5 into both pockets of the Power bar 69 and scrape across the pocket with the provided scraper so an even layer is 8 Disconnect motor connectors F G and H from motor control board 9 Hemove motor shroud disconnect and remove wiring from baffle 10 Remove six screws 27 two screws 102 and control board NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 311365J 23 24 Install two screws 102 six screws 27 and control board Install and torque two screws 102 to values in illustration on page 25 Install motor control board 52 with six screws 27 Torque to 9 11 in Ib 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect wiring and install onto baffle Install motor shroud Connect transducer connector E to motor control board Connect motor control board power connectors K to filter board 146 9 10 11 12 13 14 15 Pressure Control Board Install control box 61 with top two screws 39 Connect filter board power connectors J and power cord connectors D to ON OFF switch 33 Connect potentiometer connector C to motor control board Connect WatchDog switch X
22. lace pressure trans ducer 13 Piston packings are worn or 13 Replace packings see pump manual damaged 310643 or 310894 311365J 11 Troubleshooting WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK go to next check When check is not OK refer to this column Pump output is low 14 O ring in pump is worn or dam 14 Replace o ring see pump manual 310643 aged or 310894 15 Intake valve ball is packed with 15 Clean intake valve see pump manual material 310643 or 310894 16 Pressure setting is too low 16 Increase pressure see pump manual 310643 or 310894 17 Large pressure drop in hose with 17 Use larger diameter hose and or reduce heavy materials overall length of hose Use of more than 100 ft of 1 4 in hose significantly reduces performance of sprayer Use 3 8 in hose for optimum performance 50 ft minimum Motor runs but pump does 1 Displacement pump pin 32 Replace pump pin if missing Be sure not stroke damaged or missing see pump retainer spring 31 is fully in groove all manual 310643 or 310894 around connecting rod see pump manual 310643 or 310894 2 Connecting rod assembly 43 Replace connecting rod assembly see damaged see pump manual pump manual 310643 or 310894 310643 or 310894 3 Gears or drive housing dam 3 Inspect drive housing assembly and gears aged page 34 for damage and replace if necessary see pump manual 310643 or 310894 Excessive paint leakage in
23. lectrician This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illus trated in the figure below 1 lf ti9164a Only connect the product to an outlet having the same coniiguration as the plug Do not use an adapter with this product Extension Cords Use only a 3 wire extension cord that has a 3 blade grounding plug and a 3 slot receptacle that accepts the plug on the product Make sure your extension cord is not damaged If an extension cord is necessary use 12 AWG 2 5 mm minimum to carry the current that the product draws An undersized cord results in a drop in line voltage and loss of power and overheating 311365J 5 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes motors and electrical equipment Paint or solvent flowing through the equipment is able to result in static electricity Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes All parts of the spray sys tem including the pump hose assembly spray gun and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless paint sp
24. oard 52 8 Install cover 96 with four screws 38 ti12995b 25 Pressure Control Board 110 Vac U K Motor Control Board Removal Installation 1 Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar Relieve pressure page 9 Wait 5 minutes before servicing 2 Apply thermal compound a For 2 capacitor boards and 6 capacitor 1 Remove four screws 38 and cover 96 boards with the Powerbar shown in Figure 2 Disconnect display connector A from motor 1 below apply a small amount of thermal control board compound 15U114 or 110009 5 to shaded component areas on rear of motor control 3 Remove bottom two screws 39 and allow board 52 control panel 68 to hang down freely 4 Disconnect control board power lead s D BS s 5 from ON OFF switch 33 and motor control U board 52 5 Disconnect potentiometer connector C from motor control board 6 Disconnect WatchDog 49 switch connector X from motor control board 7 Disconnect 15 20A switch 178 1595 model only 8 Disconnect transducer connector E from motor control board ti17334a Figure 1 b For 6 capacitor boards with the powerbar shown in Fig 2 below apply a small amount of thermal compound 15U114 or 9 Disconnect motor connectors F G and H 110009 5 into both pockets of the Power from motor control board bar 69 and scrape across the pocket with 10
25. ol board and power switch OFF status light can be viewed if available Troubleshooting Procedure Plumb pressure gauge into paint hose plug sprayer in and turn power Mechanical problem See the proper fluid pump manual for the sprayer for further trouble shooting procedures switch ON Does sprayer reach or ex ceed its maximum pressure YES Unplug the transducer from control NO Replace the control board board Does motor stop running YES Bad transducer Replace and test with a new one 18 311365J Sprayer Will Not Run See following page for steps Remove control box cover Turn sprayer ON Observe control board status light on control board see page 13 Normal operation Light on Control board Continuously commanding motor to run Flashing See Error Code section for further troubleshooting you have over 100 AC volts See Step 1 Do YES See Step 3 Is the proper reading pres ent through the ther mal switch wires Troubleshooting See Step 2 Do Repair or you have over replace 100 AC volts power cord YES Replace the ON OFF switch If motor is hot let cool and re test If Step 4 still shows incor rect resistance replace motor The motor has a defective thermal device YES See step 4 Does the motor run YES Replace potentiometer Pressure switch 311365J Connect a test transducer to the boa
26. onto top of seal ti7169a 39 Displacement Pump Replacement 1095 1595 Mark V Displacement Pump Replacement 1095 1595 Mark V Removal 7 Ratchet open pump door a Ratchet pump door forward 8 See Skin Injection Hazard page 6 Flush pump Stop pump with piston rod in its lowest position Do Pressure Relief page 9 ti6373a Oo I xt Separate drain hose from sprayer b Twist latch u bolt out of pump door recess m Place u bolt on pump door outer edge d If pump door is stuck do steps e f and 8 otherwise go to step 9 e Twist latch u bolt back from pump door outer edge ti6374a ti6300a Place u bolt on pump door protrusion ti6375a 40 311365J Displacement Pump Replacement 1095 1595 Mark V 8 Ratchet pump door forward Installation ti6377a 1 Adjust piston rod with pin holder to pull out piston rod Tap piston rod on hard surface to push in piston rod 2 Push pump collar flush with bearing housing ledge to be able to close pump door 9 Open pump door ti7331a tib492a 3 Slide pump into connecting rod Push pump pin until it is fully retained Note Pin will snap into position ti7328a 311365J 41 4 Close pump door and rotate latch into position Do not tighten latch ti7329a A er 9 5 Qe E Y i Sl SU NJ LF O 5 Rotate pump to align with paint hose Connect paint hose and hand tighten to 70 in lb ti62
27. r otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 311365 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2005 Graco Inc is registered to ISO 9001 WWW graco com Revised J August 2014
28. rayer hoses Verify that all containers and collection systems are grounded to prevent static discharge Connect to a grounded outlet and use grounded extensions cords Do not use a 3 to 2 adapter Do not use a paint or a solvent containing halogenated hydrocarbons Keep spray area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not spray pump assembly Do not smoke in the spray area Do not operate light switches engines or similar spark producing products in the spray area Keep area clean and free of paint or solvent containers rags and other flammable materials Know the contents of the paints and solvents being sprayed Read all Material Safety Data Sheets MSDS and container labels provided with the paints and solvents Follow the paint and solvents manufacturer s safety instructions Fire extinguisher equipment shall be present and working oprayer generates sparks When flammable liquid is used in or near the sprayer or for flushing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors SKIN INJECTION HAZARD Do not aim the gun at or spray any person or animal Keep hands and other body parts away from the discharge For example do not try to stop leaks with any part of the body Always use the nozzle tip guard Do not spray without nozzle tip guard in place Use Graco nozzle tips Use caution when cleaning and changing nozzle
29. rd Does the motor run Replace the control board Replace the transducer 19 Pressure Control Board Pressure Control Board 100 120 Vac North American and Japan Taiwan Motor Control Board Removal Installation 2 1 Use Acetone or equivalent solvent to thoroughly remove thermal paste from the Relieve pressure page 9 Wait 5 minutes before pockets of tne Powerbar servicing 2 Apply thermal compound a For 2 capacitor boards and 6 capacitor boards with the Powerbar shown in Figure Remove four screws 38 and cover 96 2 Disconnect display connector A from motor 1 below apply a small amount of thermal control board compound 15U114 or 110009 5 to shaded component areas on rear of motor control 3 Remove bottom two screws 39 and allow control panel 68 to hang down freely board 52 s 4 Disconnect control board power lead s D a from ON OFF switch 33 and motor control I board 52 52 5 Disconnect potentiometer connector C from motor control board 6 Disconnect WatchDog 49 switch connector X from motor control board ti17334a 7 Disconnect 15 20A switch 178 1595 model ANIE only b For 6 capacitor boards with the Powerbar 8 Disconnect transducer connector E from shown in Figure 2 below apply a small motor control board amount of thermal compound 15U114 or 110009 5 into both pockets of the Power bar 69 and scrape across the pocket with the provided s
30. s and then ON pate Keep clear of electrical and moving parts during again This ensures sprayer is in normal run mode troubleshooting procedures e Turn pressure control knob clockwise 1 2 turn cs If no digital display is available use control e View digital display MON board status light to troubleshoot prob 010 lems Turn ON OFF switch OFF remove control cover and then turn power back ON Observe status light Blinking LED to tal count equals digital error code i e two blinks equals E 02 TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all See flow chart page 19 Digital display is blank Control board status light never lights Sprayer does not run at all Check transducer or transducer Make sure there is no pressure in the system see Digital display shows E 02 connections Pressure Relief page 9 Check fluid path for clogs such as clogged filter Use airless paint spray hose with no metal braid 1 4 in x 50 ft minimum Smaller hose or metal braid hose may result in high pressure spikes Set sprayer to OFF and disconnect power to sprayer Control board status light blinks 2 times repeatedly Check transducer and connections to control board Disconnect transducer from control board socket Check that transducer and control board contacts are clean and secure Reconnect transducer to control board socket Connect power
31. status light blinks Step 1 secure 6 times repeatedly 1 Check thermal device connector yellow wires at control board Measure resistance of the thermal device If reading is not correct replace motor Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each model see table below RANNE Table 3 9k ohms MARK V 3 9k ohms Reconnect thermal device connector to control board socket Connect power turn sprayer ON and control knob 1 2 turn clockwise If sprayer does not run replace control board Sprayer does not run at all Check the connections Control Turn power OFF Digital display shows E 09 oe TOC ee OO DOSIHON Disconnect motor position sensor and inspect for sensor signal damage at connectors Heconnect sensor Control board status light blinks Turn power ON If error continues replace motor 9 times repeatedly Sprayer does not run at all Check to see if control board is over 1 Make sure motor air intake is not blocked Make sure fan has not failed Make sure control board is properly connected to back plate and that conductive thermal paste is used on power components Control board status light blinks 10 times repeatedly Replace control board Replace motor 311365J 17 Troubleshooting Sprayer Will Not Shut Off 1 Relieve Pressure page 9 Leave prime valve open 2 Remove control box cover so the contr
32. t is low Spray tip worn 1 Follow Pressure Relief procedure Warn ing then replace tip See your separate gun or tip manual 2 Spray tip clogged 2 Relieve pressure Check and clean spray tip 3 Paint supply 3 Refill and reprime pump 4 Intake strainer clogged 4 Remove and clean then reinstall 5 Intake valve ball and piston ball 5 Remove intake valve and clean Check are not seating properly balls and seats for nicks replace if neces sary see pump manual 310643 or 310894 Strain paint before using to remove particles that could clog pump 6 Suction hose connections 6 Tighten any loose connections Check for missing or damaged seals 7 Fluid filter tip filter or tip is 7 Clean filter see operation manual clogged or dirty 8 Prime valve leaking 8 Relieve pressure Repair prime valve 9 Verify pump does not continue to 9 Service pump see pump manual 310643 stroke when gun trigger is or 310894 released Prime valve not leak ing 10 Leaking around throat packing 10 Replace packings see pump manual nut which may indicate worn or Also check piston valve seat for hardened damaged packings paint or nicks and replace if necessary Tighten packing nut wet cup 11 Pump rod damage 11 Repair pump See pump manual 310643 or 310894 12 Low stall pressure 12 Turn pressure knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise position If problem persists rep
33. tchdog 311365J 45 Wiring Diagram Wiring Diagram UltraMax Il 695 795 Lo Boy Series B 695 Hi Boy Series D 795 Hi Boy Series C 1095 Mark V Series B Models with SIX large capacitors on control board Potentiometer Switch Digital Display Pressure Transducer Dip Switch AutoClean MW D Mn ZZ a SM O z O OOO ti13484a Japan Taiwan Models Thermal Switch Digital Display Potentiometer Pressure Transducer Dip Switch AutoClean A gt Watchdog A O ZA UK Models green ground 46 311365J Notes 311365J Notes 47 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of
34. th two screws 39 Connect display connector A to motor control board Install cover 96 with four screws 38 27 110 Vac U K Relieve pressure page 9 Wait 5 minutes before servicing Removal 1 Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 52 3 Remove bottom two screws 39 Disconnect potentiometer connector C from motor control board 52 Disconnect filter board connector J and power cord connector D from ON OFF switch 33 Remove control panel 68 4 Disconnect motor board control power connectors K from filter board 146 Disconnect filter connector L from power cord connector L 5 Remove four screws 163 from filter board 146 28 Pressure Control Board Filter Board Installation 1 Connect motor control board power connectors K to filter board 146 Connect filter connector L to power cord connector L Install filter board 146 with four screws 163 Connect filter board power connector J and power cord connector D to ON OFF switch 33 4 Connect potentiometer connector C to motor control board 52 Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 7 Install cover 96 with four screws 38 Q N o u 311365J Pressure Control Board 110 Vac U K Tighten 2 screws to 14 17 in Ib 1 58 1 92 N Ac ti12996b 31
35. tigued or under the influence of drugs or alcohol Do not kink or over bend the hose Do not expose the hose to temperatures or to pressures in excess of those specified by Graco Do not use the hose as a strength member to pull or lift the equipment ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you
36. to 1 Throat packing nut is loose Remove throat packing nut spacer throat packing nut Tighten throat packing nut just enough to stop leakage 2 Throat packings are worn or 2 Replace packings see pump manual damaged 310643 or 310894 3 Displacement rod is worn or 3 Replace rod see pump manual 310643 or damaged 310894 Fluid is spitting from gun Air in pump or hose 1 Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming 2 Tip is partially clogged 2 Clear tip see tip guard manual 309640 3 Fluid supply is low or empty 3 Refill fluid supply Prime pump see pump manual 310643 or 310894 Check fluid supply often to prevent running pump dry Pump is difficult to prime 1 Airin pump or hose 1 Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming 2 Intake valve is leaking 2 Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve ual 310643 or 310894 recommendations connection 12 311365J Troubleshooting Electrical Symptom Sprayer does not run or stops running A o To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting wait 30 seconds after unplugging power cord for stored electricity to dissi e Plug sprayer into correct voltage grounded outlet e Set power switch OFF for 30 second
37. to motor control board Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 Install cover 96 with four screws 38 311365J Pressure Control Board 240 Vac Filter Board Relieve pressure page 9 Removal 1 Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 52 3 Remove bottom two screws 39 disconnect potentiometer connector C from motor control board 52 Disconnect power cord connectors D and filter board connectors J from ON OFF switch 33 and remove control panel 68 4 Disconnect WatchDog switch connector X from motor control board 5 Disconnect motor control board power connectors K from filter board 146 6 Remove four screws 163 from filter board 146 Tighten 2 screws 240 Vac to 14 17 in Ib 1 58 1 92 N A 102 311365J Installation 1 Install filter board 146 with four screws 163 2 Connect motor control board power connectors K to filter board 146 3 Connect filter board power connectors J to top two terminals of ON OFF switch 33 and power cord connectors D to bottom two terminals of ON OFF switch 4 Connect potentiometer connector C to motor control board 52 5 Connect WatchDog switch X to motor control board 6 Install control panel 68 with two screws 39 7 Connect display connector A to motor control b
38. using Replacement 34 Disassembly leeren 34 ASSOImDIV ze dd A 2 umi del a os sk 34 Motor Replacement 2222222 36 REMOVAL sud 3 500 decease Beet UWAG 36 Installation llle 36 Displacement Pump Replacement for 695 795 38 Removal uua acs eee EHE RC oai w 38 Installation ue uo ie e CE e ded Sca 39 Displacement Pump Replacement 1095 1595 MarkV llle 40 IHGIOVdl e sasz Stosa d HR RES 40 Iristallatlori ex as ER RE Saw Go ee exa 41 Wiring Diagram llle 43 WIRING DIAGQKAIN peia arrea pede ee Y ro deeds 44 Wiring Diagram llle 45 Wining Diagramm zusenden 46 peu dec Lm 47 Graco Standard Warranty 00005 48 2 Table of Contents 311365J Models Models ME xm North America NE Premium 253059 om NENNEN nn c EI US Liste Intertek Mv me jemu wre HE wa Premium 826072 Also for Asia and Australia NJ us Premium 826074 All models not available in all Premium 826081 Ultimate Mx I 1595 Standard 826075 ERE Premium 8206 pes EM 2460 249666 240 249666 Europe 256165 ce meer w Mew Co EEE 24968 ce er Mae or X m er ce er mv 248806 we 1 26M 311365J 3 Models Australia es dg 255140 249687 i JEN u 100 E NNNM 255136 249676 Japan amp Taiwan
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