Graco 309941J User's Manual
Contents
1. 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 e Turn off and disconnect power cord before servicing equipment Wait 5 minutes after disconnecting from power source before servicing motor control Use only grounded electrical outlets Use only 3 wire extension cords 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 Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves 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 309941 3 Component Identification and Function B ti2377a V J K H T N er ti4281a U D Fig 1 Er A Motor DC motor permanent magnet totally e2. Remove grommet 40 from transducer and save for reuse Installation 1 Install o ring 20 and transducer 86 in filter base 67 Torque to 35 45 ft Ib 47 61 N m Install grommet 40 onto transducer 86 Connect transducer connector E to motor control board Install control box 61 and control panel 68 with four screws 39 Connect potentiometer connector C to motor control board Install cover 96 with four screws 38 309941 15 Drive and Bearing Housing Replacement CAUTION 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 Ne a DA Relieve pressure page 5 2 16 Remove screw 31 two nuts 24 pail hanger 55 and pump rod cover 108 Remove pump 91 Displacement Pump Re placement page 20 Fig 6 Remove two screws 158 and shroud 72 Remove four screws 158 and front cover 51 Remove four screws 14 and washers 12 to remove bearing housing 83 and connecting rod 85 309941 7 Remove five screws 6 and pull drive housing 90 off motor 84 Assembly Fig 7 Make sure gear 89 and thrust washers 28 30 90a 36 are in place Brush grease onto gear teeth 1 Fig 6 Push drive housing 90 onto motor 84 and install with five screws 6 Torgue to 190 210 in Ib 21 23 N m 2 Install bearing housing 83 with four screws 14 and washers
3. 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 injec tion splashing fluid or moving parts follow Pres sure Relief Procedure whenever you e are instructed to relieve pressure e stop spraying check or service any system equipment e orinstall or clean spray tip 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 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 proce dures These parts are not normally pro
4. the threads of the drive housing will be damaged 1 Fig 10 Extend pump piston rod 1 5 in Apply grease to top of pump rod at A or inside connect ing rod ti4258a Fig 10 2 Install pump pin 44 Verify retaining spring 43 is in groove of connecting rod 85 3 Push pump up until pump threads engage 20 309941 4 Screw in pump until threads are flush with drive housing opening Align pump outlet to back 5 Fig 9 Install washers o rings and suction tube 76 and hose 94 6 Fig 11 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 approxi mately 75 5 ft lb 102 N m Fig 11 7 Fig 8 Install pump rod shield 108 with screw 31 8 Fig 12 Fill packing nut with Graco TSL until fluid flows onto top of seal ti4258a Fig 12 Technical Data Model 100 120V 220 240V Generator Motor HP W Cycles per Maximum Maximum Fluid Outlet A Hz A Hz Minimum gallon liter Delivery gom Tip size npsm W Ipm 1 Gun E Guns 695 14 50 60 9 50 60 5000 1 75 1300 243 64 0 75 2 8 0 027 N A 1 4 in 795 15 50 60 10 50 60 15000 2 00 1490 195 52 0 95 3 6 0 031 0 021 1 4 in 1095 15 50 60 10 50 60 5000 2 20 1640 123 33 1 1 4 1 0 033 0 023 1 4 in Mark V N A 10 50 60 5000 2 20 1640 110 29 1 2 4 3 0 035 0
5. 12 Torque to 25 30 ft Ib 34 40 N m 3 Install front cover 51 with four screws 31 4 Install shroud 72 with two screws 31 5 Install pump 41 Displacement Pump Replace ment page 20 6 Install pump rod cover 108 and pail hanger 55 with screw 31 and two nuts 24 108 Fig 6 17 309941 Motor Replacement Installation Removal 1 N JN Relieve pressure page 5 WI Wait 5 minutes before servicing 2 Remove pump 91 Displacement Pump Re placement page 20 CAUTION Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing 3 Remove drive housing 89 Drive Housing Re placement page 16 4 Fig 7 Remove four screws 38 and control cover 96 5 Remove bottom two screws 39 and and allow control panel 68 to hang down freely 6 Disconnect all three motor connectors from motor control board 95 7 Remove top two screws 39 and control housing 61 8 Remove strain relief 29 from motor wires and power bar plate 69 9 Remove two screws 23 and nuts 19 on side opposite control 10 Loosen two nuts 19 on side near control and remove motor 84 from cart frame 62 18 309941 10 Slide new motor 84 under two screws 23 in cart frame 62 near control Install two screws 23 and nuts 19 on motor side opposite control Tighten all four screws
6. a Turn pressure control knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise position Try a new pressure transducer Motor runs but pump does not 1 Displacement pump pin 32 damaged or miss 1 Replace pump pin if missing Be sure re stroke ing page 20 tainer spring 31 is fully in groove all around connecting rod page 20 2 Connecting rod assembly 43 damaged 2 Replace connecting rod assembly page 16 page 16 3 Gears or drive housing damaged page 16 3 Inspect drive housing assembly and gears for damage and replace if necessary page 16 6 309941 Troubleshooting Electrical Symptom Sprayer does not run or stops running e UN W WA Relieve pressure page 5 e Plug sprayer into correct voltage grounded outlet e Set power switch OFF for 30 seconds and then ON again This ensures sprayer is in normal run mode e Turn pressure control knob clockwise 1 2 turn e View digital display No power to control board Blinks once and No RUN command stops to control board 4 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 If no digital display is available use control board status light to troublesho
7. 023 se in 1595 20 15 N A 5000 2 5 1860 110 29 1 25 4 7 0 037 0 025 14 in 50 60 BE ERE Ee 2 5 1860 110 29 1 25 4 7 0 037 0 025 50 60 Basic Sprayer Wetted Parts Noise Level zinc and nickel plated carbon steel nylon stainless Sound power 91 dBa steel PTFE Acetel leather UHMWPE aluminum Sound pressure 82 dBa tungsten carbide PEEK brass per ISO 3744 measured at 3 1 feet 1 m Dimensions Model Weight Ib kg Height in cm Length Width To Boy Firboy To Boy Ai Boy in cm V cm 26 5 67 3 Handle down 28 5 72 4 Handle down 38 8 98 6 Handle up 38 75 98 4 Handle up 795 98 45 98 45 26 5 67 3 Handle down 28 5 72 4 Handle down 25 20 5 38 8 98 6 Handle up 38 75 98 4 Handle up 63 5 52 1 1095 N A 120 55 N A 29 5 74 9 Handle down 26 66 122 5 38 5 97 8 Handle up 57 2 1595 N A 125 57 N A 29 5 74 9 Handle down 26 66 22 5 38 5 97 8 Handle up 57 2 Mark V N A 130 59 N A 29 5 74 9 Handle down 26 66 122 5 38 5 97 8 Handle up 57 2 309941 21 Graco Standard Warranty Graco warrants all eguipment 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 by an authorized Graco distributor to the original purchaser for use With the exception of any special extended or limi
8. 23 and nuts 19 Torque nuts to 115 135 in Ib 13 15 N m Install strain relief 29 onto motor wires and into power bar plate 69 Install control housing 61 with top two screws 39 Connect all three motor connectors to motor control board 95 Install control panel 68 with two screws 39 Install control cover 96 with four screws 38 Install drive housing 42 Drive Housing Re placement page 16 Install pump 13 Displacement Pump Replace ment page 20 Fig 7 19 309941 Displacement Pump Replacement See manual 310643 for pump repair instructions See manual 309943 309944 or 309951 309954 for applicable sprayer part number references Removal 1 Flush pump 13 2 IN A w WA Relieve pressure page 5 3 Fig 8 Remove screw 31 and slide pump rod shield 108 forward ti4258a Fig 8 4 Fig 10 Cycle pump in JOG mode until pump pin 44 is in position to be removed Turn power switch OFF and unplug power cord Push up retaining ring 43 and push pump pin out 5 Fig 9 Remove suction tube 76 hose 94 and any washers and o rings 6 Loosen pump jam nut 56 Unscrew pump 76 SI N 4 a ti4258a Installation 4 WARNING 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 prop erty damage CAUTION If the pump jam nut loosens during operation
9. 8035 tan 249029 N N 249030 RAS e NI d G d iG gt H E SES 248043 e Hi Boy Lo Boy oe ENNL M A WARNING FIRE AND EKPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre veni fire and explosion e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc 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 See Grounding instructions Use only conductive hoses Hold gun firmly to side of grounded pail when triggering into pail 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 e Do not point the 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying
10. 9941 5 Troubleshooting Relieve pressure page 5 Mechanical Fluid Flow TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Low or No Fluid Pressure Out 1 Spray tip worn 1 Follow Pressure Relief Procedure Warn put 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 are not seating 5 Remove intake valve and clean Check properly balls and seats for nicks replace if neces sary page 20 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 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 9 Service pump See page 20 gun trigger is released Prime valve not leak ing 10 Leaking around throat packing nut which may 10 Replace packings page 20 Also check indicate worn or damaged packings See page piston valve seat for hardened paint or 20 nicks and replace if necessary Tighten packing nut wet cup 11 Pump rod damage 11 Repair pump page 20 12 Low stall pressure 12 Do either or both
11. ADA 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 reconnais sent 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 procedures concern es TO PLACE AN ORDER OR FOR SERVICE 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 This manual contains English GN 309941 MM 309941 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN USA 309941J 12 2003 Rev 4 2005 22 309941
12. N gt c a 2 e T e 2L 52 o c N FN cr 5 et S S CS IR o N O LU 82 N RG Ps LO NA U U CA 309941 Fig 5 14 Pressure Adjust Potentiometer Installation Removal A 3 x Relieve pressure page 5 Wait 5 minutes before servicing 1 4 Install gasket 115 nut and potentiometer 82 on control panel 68 Torgue nut to 30 35 in Ib 3 38 3 95 N m Install pressure control knob 34 Check pressure control knob alignment to potentiometer shaft Turn shaft fully clockwise and attach knob in full ON position with a hex wrench Connect potentiometer connector C to motor control board Install cover 96 with four screws 38 Pressure Control Transducer 2 Fig 3 4 or 5 Remove four screws 38 and cover 96 3 Disconnect potentiometer connector C from motor control board 95 4 Remove pressure control knob 34 with a hex wrench 5 Remove gasket 115 nut and potentiometer 82 from control panel 68 Removal 1 N JN Relieve pressure page 5 WI Wait 5 minutes before servicing 2 Fig 3 or 5 Remove four screws 38 and cover 96 3 Disconnect transducer connector E from motor control board 95 4 Disconnect potentiometer connector C from motor control board 5 Remove four screws 39 and control box 61 Allow control panel to hang down freely 6 Remove transducer 86 and o ring 20 from filter base 67 T
13. Repair GRACO Ultra Max Il 695 795 1095 1595 TexSpray Mark V Airless Sprayers 309941J For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi 227 bar 22 7 MPa Maximum Working Pressure Models See page 2 PROVEN QUALITY LEADING TECHNOLOGY GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2004 Graco Inc is registered to I S EN ISO 9001 2 Table of Contents Component Function and Identification General Repair Information Grounding Troubleshooting Mechanical Fluid Flow Electrical Pressure Control Repair Models Drive and Bearing Housing Replacement 16 MotorReplacemenit 18 Displacement Pump Replacement 20 TechnicalData 21 Dimensions 21 Graco Standard Warranty 22 Vac Type Lo Boy Hi Boy EE Sens ee North America 1595 Standard S nd MERE NUR Europe Multi cord Ce 110 6 U 2 C E umi EEE ad i FE E Mel Ee i EM K E 95 95 95 95 2 6 7 E Australia Japan amp Taiwan Also for Asia and Australia Not ETL Approved All models not available in all countries 95 95 95 95 95 95 5 309941 248747 248040 ED gt 248746 Mes 24
14. abor 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 mak ing 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 or otherwise FOR GRACO CAN
15. ard 95 4 Remove bottom two screws 39 Disconnect potentiometer connector C from motor control board 95 Disconnect power cord connectors D and filter board connectors J from ON OFF switch 33 and remove control panel 68 5 Disconnect motor control board power connectors K from filter board 146 6 Remove four screws 163 from filter board 146 1 Fig 4 Install filter board 146 with four screws 163 Connect motor control board power connectors K to filter board 146 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 Connect potentiometer connector C to motor control board 95 Install control panel 68 with two screws 39 Connect display connector A to motor control board 95 Install cover 96 with four screws 38 309941 11 240 Vac to 14 17 in Ib 1 58 1 92 Nem 3 o m o a c i E gt RK KI YA UNS Ay NA V Tighten 2 screws 7 10 in Ib 79 1 13 Nem ti4345a 82 Fig 4 309941 12 110 Vac U K Motor Control Board Removal 1 N TN Relieve pressure page 5 WI Wait 5 minutes before servicing Installation 1 Fig 5 Apply small amount of thermal compound 110009 5 to shaded areas on rear of motor control board 95 CAUTION To reduce risk of motor control board failure do not overtighten
16. control board temperature Blinks 12 x repeat edly 06 07 09 10 11 12 High Current 13 E E E E E E Blinks 13 x repeat E ediy Ni E EMPTY on digital display indicates a loss of paint to the pump or a severe loss in pressure Blinks 9 x repeat Motor sensor failure edly Model not selected 1 Check motor wiring connections 2 Check for locked or frozen pump or drive train 3 Ifall motor wiring connections are OK and pump drive train are not locked up replace motor Check all wire connections from motor to control board If connections are all ok allow sprayer to cool If sprayer runs when cool correct cause of overhea ting Keep sprayer in cooler location with good ventilation Make sure motor air intake is not blocked This error only occurs in flush timer mode 1 Make sure prime valve and gun are open 2 Make sure no flow obstructions or clogged filter Make sure motor sensor resolver is connected to the control board and check wiring for damage 1 Make sure the motor air intake is not blocked 2 Make sure control board is properly connected to the back plate and that conductive thermal paste is used on the power components Fig 3 Blinks 11 x repeat Excessive motor Check for damaged gears or disconnected pump edly speed 1 Check for locked or frozen pump or drive train 2 Check for possible short circuits in wiring 3 Check pressure output and replace transducer if pressu
17. ect transducer connector E from motor control board 8 Disconnect motor connectors F G and H from motor control board 9 Remove five screws 27 three screws 102 and motor control board Removal 1 N NN Relieve pressure page 5 WI Wait 5 minutes before servicing Fig 5 Remove four screws 38 and cover 96 Disconnect display connector A from motor control board 95 Remove bottom two screws 39 Disconnect potentiometer connector C from motor control board 95 Disconnect filter board connector J and power cord connector D from ON OFF switch 33 Remove control panel 68 Disconnect motor control board power connectors K from filter board 146 Disconnect filter con nector L from power cord connector L Remove four screws 163 from filter board 146 Installation 1 Fig 5 Connect motor control board power connec tors K to filter board 146 Connect filter con nector L to power cord connector L 2 Install filter board 146 with four screws 163 3 Fig 5 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 95 5 Install control panel 68 with two screws 39 Connect display connector A to motor control board 95 7 Install cover 96 with four screws 38 309941 13 110 Vac U K tib015a 7 10 in Ib 79 1 13 Nem o z o O o E
18. educe risk of motor control board failure do not overtighten screws 102 which can damage the electric components 11 Tighten 1 screw to 14 17 in Ib 5 Install motor control board 95 with five screws 27 Torque to 9 11 in Ib 1 02 1 24 N m Install and torque three screws 102 to values in Fig 3 Connect motor connectors F G and H to motor control board Install control box 61 with top two screws 39 Connect transducer connector E to motor control board Connect 15 20A switch 178 1595 Connect motor control board power lead s D to ON OFF switch 33 Connect potentiometer connector C to motor control board Install control panel 68 with two screws 39 Connect display connector A to motor control board Install cover 96 with four screws 38 Tighten 2 screws to 7 10 in Ib ti4289b 240 Vac Motor Control Board Removal i A 2 x Relieve pressure page 5 Wait 5 minutes before servicing Installation Fig 4 Apply small amount of thermal compound 110009 5 to shaded areas on rear of motor control board 95 CAUTION 1 To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 10 11 Install motor control board 95 with five screws 27 Torque to 9 11 in Ib 1 02 1 24 N m Install and torque three screws 102 to values shown in Fig 5 Connect motor connect
19. nclosed 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 Vave 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 ONOFF Swiich Power switch that controls main power to sprayer M SOR 5m Main Hose 1 4 n 1D grounded nylon hose with spring guards on both en 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 Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun Contractor Il gun shown Refer to your gun manual to properly set your gun safety latch T Holds wrapped hose for storage Suction Tube Transfers fluid to be sprayed from source to pump U V Drain Tube Fluid outlet used to drain and prime the sprayer w AutoClean Reverse flush system 4 309941 General Repair Information CAUTION To reduce risk of pressure control malfunction Pressure Relief Procedure 4 WARNING INJECTION HAZARD System pressure must be manually
20. ors F G and H to motor control board Connect transducer connector E to motor control board Connect motor control board power connectors K to filter board 146 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 Install control panel 68 with two screws 39 Connect display connector A to motor control board 95 Install cover 96 with four screws 38 240 Vac Filter Board Installation 2 Fig 4 Remove four screws 38 and cover 96 3 Disconnect display connector A from motor control board 95 4 Remove bottom two screws 39 Disconnect potentiometer connector C from motor control board 95 Disconnect power cord connectors D and filter board connectors J from ON OFF switch 33 and remove control panel 68 5 Disconnect motor control board power connectors K from filter board 146 6 Remove top two screws 39 and control box 61 7 Disconnect transducer connector E from motor control board 8 Disconnect motor connectors F G and H from motor control board 9 Remove five screws 27 three screws 102 and motor control board Removal 1 N JN Relieve pressure page 5 WI Wait 5 minutes before servicing 2 Fig 4 Remove four screws 38 and cover 96 3 Disconnect display connector A from motor control bo
21. ot problems Turn ON OFF switch OFF remove control cover and then turn power back ON Observe status light Verify reguired voltage is present Check wiring connections to control board Perform continuity check on power cord and switch Replace power cord or switch as needed If steps 1 3 are ok replace control board Make sure prime valve is open and there is no pres sure in the system Turn pressure control knob clockwise Check potentiometer connection to control board Check pressure control knob alignment to potentiom eter shaft Turn shaft fully clockwise and attach knob in full ON position 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 Check transducer connection Disconnect and reconnect transducer plug to ensure good connection with control board socket Check that transducer contacts are clean 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 309941 7 Electrical DIGITAL CONTROL BOARD INDICATION WHAT TO DO DISPLAY STATUS LIGHT Improper pressure signal to control Displays high pressure when prime valve is open and there is no pressure in sprayer Blinks 2 x repeat ediy Blinks 3 x repeat ediy 8 309941 Troubleshooting Cont
22. re is excessive Control board identity resistors must be properly clipped to identify model type manual 310657 1 Check for empty paint condition clogged inlet strainer failed pump or severe leak Turn pressure control knob to zero to restart sprayer 2 WatchDog W DOG feature can be deactivated See Operation Manual 309935 309941 9 Pressure Control Repair 100 120 Vac North American and Japan Taiwan Motor Control Board Removal 1 2 3 e Relieve pressure page 5 Wi Wait 5 minutes before servicing Fig 3 Remove four screws 38 and cover 96 Disconnect display connector A from motor control board 95 Remove bottom two screws 39 and allow control panel 68 to hang down freely Disconnect control board power lead s D from ON OFF switch 33 and motor control board 95 Disconnect potentiometer connector C from motor control board Disconnect 15 20A switch 178 1595 Disconnect transducer connector E from motor control board Disconnect motor connectors F G and H from motor control board 10 Remove top two screws 39 and control box 61 11 Remove five screws 27 three screws 102 and motor control board 100 120 Vac North American and Japan Taiwan 39 P K Fig 3 10 309941 Installation Fig 3 Apply small amount of thermal compound 110009 5 to shaded component areas on rear of motor control board 95 CAUTION 1 To r
23. rol board is re ceiving excessive pressure signal from transducer Transducer may be damaged or fluid flow path may be clogged Transducer or transducer connec tion error Open prime valve Connect a known good trans ducer in place of the sprayer transducer Set sprayer ON Replace transducer If sprayer runs Replace control board If sprayer does not run Check fluid path for clogs such as a clogged filter Open prime valve and gun if running AutoClean 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 Replace transducer if fluid path is not clogged and proper hose is used Check transducer connection Disconnect and reconnect transducer plug to ensure good connection with control board socket Check that transducer contacts are ok 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 Troubleshooting Electrical DIGITAL CONTROL BOARD JINDICATION WHAT TO DO DISPLAY STATUS LIGHT Possible locked pump or drive May be motor connection or wiring error Blinks 5 x repeat edly Motor is too hot or motor thermal de vice connection may be bad Blinks 6 x repeat edly Blinks 7 x repeat edly Exceeded 2000 psi during timed flush cycle Blinks 10 x repeat edly High
24. screws 102 which can damage the electric components 2 Install motor control board 95 with five screws 27 Torque to 9 11 in Ib 1 02 1 24 N m Install and torque three screws 102 to values shown in Fig 5 3 Connect motor connectors F G and H to motor control board Connect transducer connector E to motor control board 5 Connect motor control board power connectors K to filter board 146 Connect filter connector L to power cord connector L gt Install control box 61 with top two screws 39 7 Fig 5 Connect filter board power connector J and power cord connector D to ON OFF switch 33 8 Connect potentiometer connector C to motor control board Install control panel 68 with two screws 39 10 Connect display connector A to motor control board 95 11 Install cover 96 with four screws 38 110 Vac U K Filter Board 2 Fig 5 Remove four screws 38 and cover 96 3 Disconnect display connector A from motor control board 95 4 Remove bottom two screws 39 Disconnect potentiometer connector C from motor control board 95 Disconnect filter board connector J and power cord connector D from ON OFF switch 33 Remove control panel 68 5 Disconnect motor control board power connectors K from filter board 146 Disconnect filter con nector L from power cord connector L 6 Remove top two screws 39 and control box 61 7 Disconn
25. ted 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 inadeguate or improper maintenance negligence accident tampering or sub stitution 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 include the costs of parts l
26. vided with replacement assemblies A 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 spray er when inspection is complete Install all covers guards gaskets screws wash 4e ers 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 Grounding A WARNING 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 Il 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 recep tacle 2 Do not alter ground prong or use adapter Grounding Plug 9 Grounded Outlets 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 30
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