Graco 309941J User Manual

Repair

Ultrar Max II 695/795/1095/1595t TexSprayt Mark V Airless Sprayers

– For Portable Airless Spraying of Architectural Coatings and Paints –

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

Models: See page 2

309941J

ti4281a

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Table of Contents

Component Function and Identification 4. . . . .

General Repair Information 5. . . . . . . . . . . . . . .

Grounding 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical/Fluid Flow 6. . . . . . . . . . . . . . . .

Electrical 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Repair 10. . . . . . . . . . . . . . . .

Models

Vac Model Type Lo-Boy Hi-Boy

695 Standard 248037 248036

Premium 248031 248030

120 795 Standard 248308 248038

North America Premium 248033 248032

1095 Standard 248039

Premium 248034

1595

Mark V 249029**

240 695 248042 248041

Europe 795 248043

1095 248044

Mark V 249031

240 695 248046 248045

Europe Multi-cord 795 248047

1095 248048

Mark V* 249178

110 695 248049

UK 795 248050

1095 248051

Mark V 249072

240 695 248058 248057

Asia 795 248059

1095 248060

240 695 248593 248592

Australia 795 249431 248594

1095 248595

100 695 248053 248052

Japan & Taiwan 795 248055 248054

1095 248056

Standard 248747

248040**

Premium 248746

248035**

249030

Drive and Bearing Housing Replacement 16. .

Motor Replacement 18. . . . . . . . . . . . . . . . . . . . .

Displacement Pump Replacement 20. . . . . . . .

Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 22. . . . . . . . . . . . . . .

ti4281a

Hi-Boy

ti4278a

Lo-Boy

Also for Asia and Australia;

Not ETL Approved

All models not available in all countries.

2 309941

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:

D Use equipment only in well ventilated area.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static arc).

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

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

D Ground equipment and conductive objects in work area. See Grounding instructions.

D Use only conductive hoses.

D Hold gun firmly to side of grounded pail when triggering into pail.

D If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

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 medical attention.

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

D Do not put your hand over the spray tip.

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

D Do not spray without tip guard and trigger guard installed.

D Engage trigger lock when not spraying.

D Follow the Pressure Relief Procedure on page 5 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

ELECTRIC SHOCK HAZARD

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

D Turn off and disconnect power cord before servicing equipment. Wait 5 minutes after disconnecting

from power source before servicing motor control.

D Use only grounded electrical outlets.

D Use only 3-wire extension cords.

D Ensure ground prongs are intact on sprayer and extension cords.

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:

D Protective eyewear

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

D Gloves

D Hearing protection

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.

3309941

Component Identification and Function

Fig. 1

ti2377a

ti4281a

A Motor DC motor, permanent magnet, totally enclosed, fan cooled

B Drive Assembly Transfers power from DC motor to displacement pump

D Displacement Pump Transfers fluid to be sprayed from source through spray gun

E Fluid Outlet Fluid hose is connected here

F Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open

G Fluid Filter Final filter of fluid to spray gun

H Pressure Control Knob Controls fluid outlet pressure

J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump

outlet. Works with pressure adjusting knob.

K ON/OFF Switch Power switch that controls main power to sprayer

M 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends

N Spray Gun High pressure spray gun with gun safety latch

P Spray Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun

R HandTitet Tip Guard Tip guard reduces risk of injection injury

S Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun. Contractor II gun

shown. Refer to your gun manual to properly set your gun safety latch.

T Hose Rack Holds wrapped hose for storage

U Suction Tube Transfers fluid to be sprayed from source to pump

V Drain Tube Fluid outlet used to drain and prime the sprayer

W AutoClean Reverse flush system

4 309941

General Repair Information

Pressure Relief Procedure

WARNING

INJECTION HAZARD

System pressure must be manually relieved to prevent system from starting

or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres- sure Relief Procedure whenever you:

D are instructed to relieve pressure, D stop spraying, D check or service any system equipment, D or install or clean spray tip.

CAUTION

To reduce risk of pressure control malfunction:

D Use needle nose pliers to disconnect wire. Never

pull on wire, pull on connector.

D Mate wire connectors properly. Center flat blade of

insulated male connector in female connector.

D 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.

WARNING

1. Turn pressure control knob to zero.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open prime valve. Leave prime valve open until ready to spray again.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above, VERY SLOWLY loosen tip

guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

Grounding

WARNING

ELECTRIC SHOCK HAZARD MOVING PARTS HAZARD HOT SURFACE HAZARD

To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, guards, gaskets, screws, washers and shroud 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, pages 6 – 9, for other possible solutions.

Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.

1. Fig. 2. Ultra Max II 695, 795 and 1095 100–120 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. Ultra Max II 1595 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.

2. Do not alter ground prong or use adapter.

Grounding Plug

Fig. 2

3. 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.

Grounded Outlets

5309941

Relieve pressure; page 5.

Mechanical/Fluid Flow

Troubleshooting

TYPE OF PROBLEM

Low or No Fluid/Pressure Output

WHAT TO CHECK

If check is OK, go to next check

1. Spray tip worn 1. Follow Pressure Relief Procedure Warn-

2. Spray tip clogged 2. Relieve pressure. Check and clean spray

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 are not seating properly

6. Suction hose connections 6. Tighten any loose connections. Check for

7. Filter clogged 7. Relieve pressure. Check and clean filter.

8. Prime valve leaking 8. Relieve pressure. Repair prime valve.

9. Verify pump does not continue to stroke when gun trigger is released. (Prime valve not leaking.)

10. Leaking around throat packing nut which may indicate worn or damaged packings. See page

20.

WHAT TO DO

When check is not OK refer to this column

ing, then replace tip. See your separate gun or tip manual.

tip.

5. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 20. Strain paint before using to remove particles that could clog pump.

missing or damaged seals.

9. Service pump. See page 20.

10.Replace packings, page 20. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

Motor runs but pump does not stroke

11. Pump rod damage 11.Repair pump, page 20

12.Low stall pressure 12. Do either or both: a. Turn pressure control knob fully

clockwise. Make sure pressure control knob is properly installed to allow full clockwise position.

b. Try a new pressure transducer.

1. Displacement pump pin (32) damaged or miss-

ing, page 20

2. Connecting rod assembly (43) damaged,

page 16

3. Gears or drive housing damaged, page 16 3. Inspect drive housing assembly and gears

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod, page 20.

2. Replace connecting rod assembly, page 16

for damage and replace if necessary, page 16

6 309941

Troubleshooting

Electrical

Symptom: Sprayer does not run or stops running

D Plug sprayer into correct voltage, grounded outlet

D Set power switch OFF for 30 seconds and then ON

again. This ensures sprayer is in normal run mode.

D Turn pressure control knob clockwise 1/2 turn.

D View digital display

Relieve pressure; page 5.

WARNING

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 dissipate. Keep clear of electrical and moving parts during troubleshooting procedures.

D If no digital display is available, use control board

status light to troubleshoot problems: Turn ON/OFF switch OFF, remove control cover and then turn power back ON. Observe status light.

DIGITAL DISPLAY

Blank Never lights

–––– psi Blinks once and

CONTROL BOARD STATUS LIGHT

LED 100

stops

INDICATION

No power to control board

No RUN command to control board.

WHAT TO DO

1. Verify required voltage is present

2. Check wiring connections to control board

3. Perform continuity check on power cord and switch. Replace power cord or switch as needed.

4. If steps 1 – 3 are ok, replace control board

1. Make sure prime valve is open and there is no pressure in the system

2. Turn pressure control knob clockwise

3. Check potentiometer connection to control board

4. Check pressure control knob alignment to potentiometer shaft. Turn shaft fully clockwise and attach knob in full ON position.

5. Unplug potentiometer. Short out center pin of control board potentiometer connector to each outer pin (one at a time). If sprayer runs, replace potentiometer, page 15.

6. Check transducer connection

7. Disconnect and reconnect transducer plug to ensure good connection with control board socket. Check that transducer contacts are clean.

8. Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON. Replace transducer If sprayer runs. Replace control board If sprayer does not run.

7309941

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