Graco Inc 309674M User Manual

Repair

WLD

Electric Airless Sprayers

- For the application of architectural paints and coatings -

Important Safety Instructions. Read all warnings and instructions in this manual. Save these instructions. See page 2 for model information.

3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure

Korean patent: 10-0579681

309674M

ti2399

Ultra

Ultimate NovaTM 395 Super Nova ST MaxTM 395/495/595

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

395/495/595

495/595

UltraMax II Ultimate MX II

ST Max II

490/495/595

Models

VAC Mod el

120

230 CEE

230

Europe

110 UK

230 Asia

100

Japan

Ultra 395

Ultimate Nova 395

Ultra 495

Super Nova 495

Ultra 595

Super Nova 595

Ultra Max II 490

Ultimate MX II 490

Ultra Max II 495

Ultimate MX II 495

Ultra Max II 595

Ultimate MX II 595

ST Max 395 Hopper 233955

ST Max 395 234176 258662

ST Max 495 233956 233970 233971

ST Max 595 248661 244437

ST Max II 490 Hopper 253011

ST Max II 490 249926 253012 253013

ST Max II 495 249928 253014 249978

ST Max II 595 253015 249930

ST Max 395 223963

ST Max 495 233957 233975

ST Max 595 244436

ST Max II 490 249927

ST Max II 495 249929 249979

ST Max II 595 249931

ST Max 395 223972

ST Max 495 233973 233975

ST Max 595 244436

ST Max II 490 249935

ST Max II 495 249936 249980

ST Max II 595 249937

Ultra 395 234180

Ultra 495 234183 234181 234182

Ultra 595 248660 244439

Ultra Max II 490 249932

Ultra Max II 495 249933 253104 253105

Ultra Max II 595 253107 249934

Ultra 495 234186 233974

UltraMax II 495 249938 253106

233960 826014

233966 826017

249911 825028

249915 825037

233961 233962

233967 826018

234490 826052

249913 825029

249916 825038

249918 825046

233968 826019

234435 826046

249914 825036

249917 825039

249919 825045

2 309674M

Warnings

The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.

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:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Sprayer 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.

• Keep work area free of debris, including solvent, rags, and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. Read Grounding instructions.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• 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.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

309674M 3

Warnings

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. Read Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or overbend hoses or use hoses to pull equipment.

• Comply with all applicable safety regulations.

• Keep children and animals away from work area.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, and/or 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/or property damage.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers and dispose of it according to applicable guidelines.

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 from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes, but is not limited to:

• Protective eye wear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

4 309674M

Component Identification

Model 233960 shown

Component Identification



FN Component

1 ON/OFF switch

2Prime tube

3 Siphon tube

4 Pressure control

5 Filter

6 Trigger lock

7Pump

8 Fluid outlet

9 Prime/Spray valve

10 Service Tag (below sprayer frame)

B

309674M 5

Installation

Grounding and Electric Requirements

The sprayer must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

The sprayer power cord

an appropriate grounding contact.

includes a grounding wire with

Power Requirements

• 100-120V units require 100-120VAC, 50/60 Hz, 15A, 1 phase

• 230V units require 230VAC, 50/60 Hz, 7.5A, 1 phase

• Never use an outlet that is not grounded or an adapter.

Only use an extension cord ground contact. If an extension cord is necessary, use a

3-wire, 12 AWG (2.5 mm

Smaller gauge or longer extension cords may reduce sprayer performance.

Spray gun

grounded fluid hose and pump.

Fluid supply container

: ground through connection to a properly

with an undamaged

) minimum.

: follow local code.

The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not use an adapter.

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Do not use the sprayer if the electrical cord has a damaged ground prong. Do not modify plug. If it will not fit in outlet, have a grounded outlet installed by a qualified electrician.

Solvent and oil-based fluids

only conductive metal pails, placed on a grounded surface such as concrete.

Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

Grounding the metal pail

pail by clamping one end to pail and other end to ground such as a water pipe.

Maintain grounding continuity relieving pressure: hold metal part of the spray gun

firmly to the side of a grounded metal pail, then trigger the gun.

: follow local code. Use

: connect a ground wire to the

when flushing or

6 309674M

Operation

Pressure Relief Procedure

To reduce risk of injury from injection, follow this procedure whenever you are instructed to relieve pressure, stop spraying, service equipment or install or clean spray tip. Read warnings, page 3.

1. Turn power switch OFF and unplug power cord.

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2. Turn pressure to lowest setting. Hold gun to side of grounded metal flushing bucket. Trigger gun to relieve pressure, turn prime valve down.

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3. Engage gun trigger lock if unit is being shut down or left unattended.

Leave Spray - Prime/Drain valve in the PRIME/DRAIN position until you are ready to spray again.

If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.

FLUSH

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309674M 7

General Repair Information

Flammable materials spilled on hot, bare motor could cause fire or explosion. To reduce risk of burns, fire or explosion, do not operate sprayer with cover removed.

CAUTION

To reduce risk of pressure control malfunction:

• 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 or pressure control. Do not pinch wires between cover and control box.

• Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts usually are not provided with replacement kits.

• Test repairs after problems are corrected.

• If sprayer does not operate properly, review repair procedure to verify you did it correctly. See Trouble- shooting, page 9.

To reduce risk of serious injury, including electric shock:

• Do not touch moving or electric parts with fingers or tools while testing repair.

• Unplug sprayer when power is not required for testing.

• Install all covers, gaskets, screws and washers before you operate sprayer.

CAUTION

• Do not run sprayer dry for more than 30 seconds. Doing so could damage pump packings.

• Protect the internal drive parts of this sprayer from water. Openings in the cover allow for air cooling of the mechanical parts and electronics inside. If water gets in these openings, the sprayer could malfunction or be permanently damaged.

• Prevent pump corrosion and damage from freezing. Never leave water or water-base paint in sprayer when its not in use in cold weather. Freezing fluids can seriously damage sprayer. Store sprayer with Pump Armor to protect sprayer during storage.

• Install motor shroud before operation of sprayer and replace if damaged. Motor shroud directs cooling air around motor to prevent overheating. It can reduce risk of burns, fire or explosion, or cut fingers.

8 309674M

Troubleshooting

What to Check

Type of Problem

Basic fluid pressure problems Pressure control knob setting. Motor

Basic Mechanical Problems Pump frozen or paint hardened in

(if check is OK, go to next)

will not run if at minimum setting (fully counter-clockwise).

Spray tip or fluid filter may be clogged.

pump.

Displacement pump connecting rod pin must be completely pushed into connecting rod and retaining spring must be firmly in groove of pump pin. See page 15.

Motor. Remove drive housing assembly. See page 17. Try to rotate fan by hand.

Motor control board. Board shuts down and displays error code.

Troubleshooting

What to Do

(When check is not OK, refer to this

column)

Slowly increase pressure to see if motor starts.

Relieve pressure, page 7 and clear clog, or clean filter; refer to separate gun or tip instruction manual.

Thaw sprayer if water or water-based paint has frozen in sprayer. Place sprayer in warm area to thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer, replace pump packings. See page 15, Displacement Pump Replace-

ment.

Push pin into place and secure with spring retainer.

Replace motor if fan won’t turn. See page 19.

See Motor Control Board Diagnos- tics, page 27.

309674M 9

What to Check

Type of Problem

(if check is OK, go to next)

Basic Electrical Problems Electric supply. Meter must read:

• 210-255 VAC for 220-240V models

• 85-130 VAC for 100-120V models.

Extension cord. Check extension cord continuity with volt meter.

Sprayer power supply cord. Inspect for damage such as insulation or wires.

Motor leads are securely fastened and properly mated.

Basic Electrical Problems - These problems only apply to Ultra, Nova and STMax 395/495/595 model sprayers with brush motors. They do not apply to UltraMax II, Ultimate MX II and ST Max II 490/495/595 model sprayers.

Motor armature for shorts using armature tester (growler) or perform spin test. See page 18.

For loose motor brush lead connections and terminals.

Brush length which must be 1/2 in. minimum. NOTE: Brushes do not wear at the same rate on both sides of motor. Check both brushes.

Broken or misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.

Motor brushes may be binding in brush holders.

Motor armature commutator for burn spots, gouges or extreme roughness.

Troubleshooting

What to Do

(When check is not OK, refer to this

column)

Reset building circuit breaker. Replace building fuse. Try another outlet.

Replace extension cord.

Replace power supply cord, page 24.

Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.

Clean circuit board terminals. Securely reconnect leads.

Replace motor. See page 29.

Tighten terminal screws. Replace brushes if leads are damaged.

Replace brushes, page 20.

Replace spring if broken. Realign spring with brush.

Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.

Remove motor and have motor shop resurface commutator if possible. See page 29.

10 309674M

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