Graco Inc. 311365G Paint Sprayer User Manual
Contents
1. Digital Display ON OFF Switch U m o x Pressure Transducer Brown UK Models SCR Watchdog 311365G 41 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 Thermal Switch Digital Display rj BBBBE e Potentiometer Pressure Transducer Jal e C Sm Black AutoClean gt ul O Motor Leads Watchdog DI 0000 green ground ti13484a ON OFF Switch L Japan Taiwan Models gt green ground Thermal Switch Wiring Diagram Digital Display Potentiometer P F Pressure l Transducer O E Black Ga AutoClean Motor rf Leads Watchdog S Al GR 0000 S amp S fk Black Blue dh g UK Models Gc m e Co ti13485a Brown ON OFF Switch Ne Brown green ground Power Plug 311365G Graco Standard Warranty Graco Standard Warrant2. lt gt NALE 311365G 39 Wiring Diagram Wiring Diagram 695 795 Lo Boy Series A 695 Hi Boy Series A C 795 Hi Boy Series A B 1095 1595 Mark V Series A Digital Display Potentiometer Motor Pressure Transducer Watchdog 20A 15A 1595 Switch ti12980a 8 green ground ON OFF Black Switch green ground 40 311365G Wiring Diagram Wiring Diagram UltraMax Il 695 795 Lo Boy Series A 695 Hi Boy Series A C 795 Hi Boy Series A B 1095 Mark V Series A Models with only TWO large capacitors on control board Motor ti7523a green ground ON OFF Switch N o l Digital Display T o 2 I Pressure Transducer Japan Taiwan Models Potentiometer S WA ded TN Blue a 175 Blue Motor ti7347a Black green ground Ca
3. RA 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 Stay alert and watch what you are doing Do not operate the unit when fatigued 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 AN 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 A 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 a MOVING PARTS HAZARD E Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipme
4. 44 Verify retaining spring 43 is in groove of connecting rod 85 3 Push pump up until pump threads engage 4 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 onto top of seal ti7169a 35 Displacement Pump Replacement 1095 1595 Mark V Displacement Pump Replacement 1095 1595 Mark V Removal 1 Flush pump 2 Stop pump with piston rod in its lowest position Ac Read Skin Injection Hazard page 5 3 Do Pressure Relief page 9 4 Separate drain hose from sprayer ti7326a ti6370a 36 7 Ratchet open pump door a Ratchet pump door forward ti6373a b Twist latch u bolt out of pump door recess c 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 f Place u bolt on pump door protrusion ti6375a 311365G Displacement Pump Replacement 1095 1595 Mark V 8 Ratchet pump door forward Installation ti6377a 1 Adjust piston rod with
5. 52 CAUTION To reduce risk of motor control board failure do not overtighten screws 102 which can damage the elec tric components 2 Install six screws 27 two screws 102 and control board 3 Install motor control board 52 with five screws 27 torque to 9 11 in Ib 1 02 1 24 Nem Install and torque three screws 102 to values in illustration on page 23 4 Connect motor connectors F G and H to motor control board 5 Reconnect wiring and install onto baffle Install motor shroud 6 Connect transducer connector E to motor control board 7 Connect motor control board power connectors K to filter board 146 Install control box 61 with top two screws 39 eo 9 Connect filter board power connectors J and power cord connectors D to ON OFF switch 33 10 Connect potentiometer connector C to motor control board 11 Connect WatchDog switch X to motor control board 12 Install control panel 68 with two screws 39 13 Connect display connector A to motor control board 52 14 Install cover 96 with four screws 38 311365G We Pressure Control Board 240 Vac Filter Board Installation Relieve pressure page 9 Removal 1 2 Remove four screws 38 and cover 96 Disconnect display connector A from motor control board 52 Remove bottom two screws 39 disconnect potentiometer connector C from motor control boa
6. Disconnect thermal device connector from control 4 Reconnect thermal device connector to control 2 Disconnect motor position sensor and inspect for 3 Reconnect sensor 4 Turn power ON If error continues replace motor NOTE Motor must be cooled down for the test Check thermal device connector yellow wires at control board board socket Make sure contacts are clean and secure 3 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 E DODO ti13140a Resistance Table 695 0 ohms 795 2k ohms 1095 3 9k ohms MARK V 3 9k ohms board socket Connect power turn sprayer ON and control knob 1 2 turn clockwise If sprayer does not run replace control board 1 Turn power OFF damage at connectors Sprayer does not run at all Digital display shows E 10 Es if EI Control board status light blinks 10 times repeatedly Check to see if control board is over heating 2 Make sure fan has not failed 3 Make sure control board is properly connected 4 Replace control board 5 Replace motor 1 Make sure motor air intake is not blocked to back plate and that conductive thermal paste is used on power components 311365G 17 Sprayer Will Not Shut Of
7. Fluid Flow Relieve pressure page 9 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK If check is OK go to next check When check is not OK refer to this column WHAT TO DO E XX is displayed 1 Fault condition exists 1 Determine fault correction from table page 13 False tripping of WatchDog system EMPTY is dis played Pump does not run Operating conditions out of WatchDog parameters Pump output is low see below Turn pressure down Refer to operation manual for adjusting Operate without WatchDog active see operation manual Pump output is low Spray tip worn 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 pri
8. 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 ti6325a 9 Open pump door ti7331a TA tib492a N 3 Slide pump into connecting rod Push pump pin until it is fully retained Note Pin will snap into position ti7328a 311365G 37 Displacement Pump Replacement 1095 1595 Mark V 4 Close pump door and rotate latch into 6 Tighten latch and rotate latch lock into position Do not tighten latch locked position ti7329a TI6312a 5 Rotate pump to align with paint hose Connect paint hose and hand tighten to 70 in Ib ti6299a ti7330a 8 Fill pump with Graco TSL until fluid flows onto top of seal 38 311365G Wiring Diagram Wiring Diagram 695 795 Lo Boy Series A 695 Hi Boy Series A C 795 Hi Boy Series A B 1095 1595 Mark V Series A Motor CA ti7346a ON OFF NS Switch LA ie Black NS YAY o Digital Display o L white J Power Plug DIL E green ground Pressure AA 1 Transducer ET 20A 15A Switch i 1595 MARK V Potentiometer
9. repeatedly Control is commanding motor to run but motor shaft does not rotate Possibly locked rotor condition an open connection exists between motor and control there is a problem with motor or control board or motor amp draw is excessive Perform Field Short Test Test at large 4 pin motor field connector There should not be continuity from pin 4 the ground wire and any of the remaining 3 pins If motor field connector tests fail 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 N ogogo Resistance Table 695 0 ohms 795 2k ohms 1095 3 9k ohms MARK V 3 9k ohms 16 311365G Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 06 En LILA om Control board status light blinks 6 times repeatedly Sprayer does not run at all Digital display shows E 09 I du EL LJ Control board status light blinks 9 times repeatedly Allow sprayer to cool If sprayer runs when cool correct cause of overheating Keep sprayer in cooler location with good ventilation Make sure motor air intake is not blocked If sprayer still does not run follow Step 1 Check the connections Control is not receiving a motor position sensor signal 2
10. 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 i i 1 Remove four screws 38 and cover 96 n ti13493a 5 Remove grommet 40 from control box 2 Disconnect transducer connector E from then remove transducer 86 and o ring motor control board 95 20 from filter base 67 AE gt 40 ti12999a 6 Remove grommet 40 from transducer and 3 Disconnect potentiometer connector C save for reuse from motor control board 28 311365G Pressure Control Board Installation 3 Install control box 61 and control panel 68 with four screws 39 1 2 Connect transducer connector E to motor Install o ring 20 and transducer 86 in filter base 67 Torque to 35 45 ft Ib 47 61 Nem Install grommet onto transducer 86 and transducer into control box 40 4 Connect potentiometer connector C to ti13496a motor control board control board 95 ti12997a 5 ti13493a 311365G 29 Drive and Bearing Housing Replacement 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 DO Relieve pressure page 9 1 Remove screw 31 two nuts 24 pail hanger 55 and pump rod cover 10
11. 8 2 Remove pump 91 see Displacement Pump Replacement page 34 695 795 page 36 1095 1595 Mark V 3 Remove two screws 158 and shroud 72 4 Remove four screws 31 and front cover 51 5 Remove four screws 14 and washers 12 to remove bearing housing 83 and connecting rod 85 6 Remove five screws 6 and pull drive housing 90 off motor 84 30 Assembly Make sure gear 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 2 Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft Ib 34 40 Nem 3 Install front cover 51 with four screws 31 4 Install shroud 72 with two screws 158 5 Install pump 91 see Displacement Pump Replacement page 34 695 795 page 36 1095 1595 Mark V 6 Install pump rod cover 108 and pail hanger 55 with screw 31 and two nuts 24 311365G Drive and Bearing Housing Replacement 158 ti13000a eee ee ee ee ee ee 311365G 31 Motor Replacement Motor Replacement Removal NA Relieve pressure page 9 1 Remove pump 91 see Displacement Pump Replacement page 34 695 795 page 36 1095 1595 Mark V CAUTION Do not drop gear cluster 89 when removing drive housing
12. 90 Gear cluster may stay engaged in motor front end bell or drive housing 2 Remove drive housing 90 see Drive Housing Replacement page 30 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 7 Disconnect motor leads 8 Remove top two screws 39 and control housing 61 9 Remove strain relief 29 from motor wires and power bar plate 69 10 Remove motor wires from baffle 278075 and remove baffle 32 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 Ib 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 7 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 h
13. HAZARD System pressure must be manually relieved to prevent system from starting or spraying accidentally Fluid under high pressure can be e Mate wire connectors properly Center flat blade of insulated male connector in female connector injected through skin and cause serious injury Route wires carefully to avoid interference To reduce risk of injury from injection splashing with other connections of pressure control fluid or moving parts follow Pressure Relief Do not pinch wires between cover and Procedure whenever you control box e are instructed to relieve pressure 1 Keep all screws nuts washers gaskets Stop spraying and electrical fittings removed during repair e check or service any system equipment procedures These parts are not normally e install or clean spray tip provided with replacement assemblies 1 Turn pressure control knob to zero HO v zl 2 Turn ON OFF switch to OFF 3 Unplug power supply cord ELECTRIC SHOCK HAZARD 4 MOVING PARTS HAZARD HOT SURFACE HAZARD To reduce risk of serious injury including electric shock do not touch moving or electrical 6 Open prime valve Leave prime valve open parts with fingers or tools while testing repair until ready to spray again Shut off and unplug sprayer when inspection is complete Install all covers guards gaskets screws washers and shroud before operating sprayer Hold metal part of gun firmly to grounded me
14. Repair x GRACO Ultra Max Il Ultimate Mx Il Korean patent10 0579681 311365G For Portable Airless Spraying of Architectural Coatings and Paints Gatti A IMPORTANT SAFETY INSTRUCTIONS poo Read all warnings and instructions in this manual E Save these instructions 1095 1595 HI PROVEN QUALITY LEADING TECHNOLOGY WERT ERE Graco Inc P O Box 1441 Minneapolis MN 55440 1441 ID C Pe Liste Copyright 2005 Graco Inc is registered to I S EN ISO 9001 HO03 Table of Contents Models 24 42 32424 Aa a 3 Warnings cum REIR aan aan sn 5 Component Identification and Function 7 General Repair Information 8 Pressure Relief Procedure 8 Grounding eese sees 9 Troubleshooting 10 Mechanical Fluid FloW 10 Electrical 22x a a a 12 Electrical xvii od e a aed 13 Electrical 5e cale aaa 14 Notes ou lA o EIS A 15 Pressure Control Board 16 100 120 Vac North American and Japan Taiwan Motor Control Board 16 240 Vac Motor Control Board 18 240 Vac Filter Board 19 110 Vac U K Motor Control Board 20 110 Vac U K Filter Board 20 Pressure Adjust Potentiometer 22 Pressure Control Transducer 23 Notes Dia pria 25 Drive and Bearing Housing Replacement 26 Disassembly eria ery rus sen e
15. al display shows E 03 Control board status light blinks 3 times repeatedly Check transducer or transducer connections control board is not detecting a pressure signal _ Set 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 14 311365G Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 05 L FUL L od Control board status light blinks 5 times repeatedly Control is commanding motor to run but motor shaft does not rotate Possibly locked rotor condition an open connection exists between motor and control there is a problem with motor or control board or motor amp draw is excessive Remove pump and try t
16. ctive 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 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
17. emove coil 81 12 Remove top two screws 39 and control box 61 13 Remove six screws 27 two screws 102 and control board 14 Remove five screws 27 three screws 102 and motor control board 20 Installation 1 Apply small amount of thermal compound 15U114 or 110009 5 to shaded component areas on rear of motor control board 52 CAUTION To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 2 Install five screws 27 three screws 102 and motor control board 3 Install motor control board 52 with five screws 27 Torque to 9 11 in Ib 1 02 1 24 Nem Install and torque three screws 102 to values in illustration 4 Connect motor connectors F G and H to motor control board 5 Reconnect and install wiring in baffle Install motor shroud 6 Install control box 61 with top two screws 39 7 Install coil 81 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 8 Connect transducer connector E to motor control board 9 Connect 15 20A switch 178 1595 model only 10 Connect motor control board power lead s D to ON OFF switch 33 11 Connect WatchDog 49 switch connector X to motor control board 12 Connect potentiometer connector C to motor control board 13 Install control panel 68 with two screws 39 14 Connect display connec
18. est If Step 4 still shows present through the NO incorrect resistance replace thermal switch motor The motor has wires a defective thermal device YES Y Connect a test See step 4 Does NO transducer to the the motor run INY board Does the motor run NO YES YES Replace the control board Replace potentiometer Pressure switch Y Replace the transducer 19 Pressure Control Board Pressure Control Board 100 120 Vac North American and Japan Taiwan Motor Control Board Removal DS Relieve pressure page 9 Wait 5 minutes before servicing 1 Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 3 Remove bottom two screws 39 and allow control panel 68 to hang down freely 4 Disconnect control board power lead s D from ON OFF switch 33 and motor control 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 9 Disconnect motor connectors F G and H from motor control board 10 Remove motor shroud Disconnect and remove wiring from baffle 11 Remove nut and screw 88 and disconnect ground wire 87 Disconnect coil connector Y R
19. f 1 Relieve Pressure page 9 Leave prime valve open and power switch OFF Troubleshooting Procedure Plumb pressure gauge into paint hose plug sprayer in and turn power NO Troubleshooting 2 Remove control box cover so the control board status light can be viewed if available switch ON Does sprayer reach or exceed its maximum pressure Y Unplug the transducer from control NO Mechanical problem See the proper fluid pump manual for the sprayer for further trouble shooting procedures board Does motor stop running Y Bad transducer Replace and test with a new one 18 Replace the control board 311365G 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 Continuously No light Once Normal operation Light on Control board commanding motor to run Flashing See Error Code section for further troubleshooting 311365G See Step 1 Do you have over 100 AC volts No Troubleshooting See Step 2 Do you have over 100 AC volts Repair or replace power cord NO YES r Replace the ON OFF switch See Step 3 Is the proper reading If motor is hot let cool and ret
20. hose significantly reduces performance of sprayer Use 3 8 in hose for optimum performance 50 ft minimum Motor runs but pump does not stroke Displacement pump pin 32 damaged or missing see pump manual 310643 or 310894 Replace pump pin if missing Be sure retainer spring 31 is fully in groove all around connecting rod see pump manual 310643 or 310894 2 Connecting rod assembly 43 2 Replace connecting rod assembly see damaged see pump manual pump manual 310643 or 310894 310643 or 310894 3 Gearsor drive housing damaged 3 Inspect drive housing assembly and gears page 30 for damage and replace if necessary see pump manual 310643 or 310894 Excessive paint leakage into 1 Throat packing nut is loose 1 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 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 Tipis 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
21. ll coil 31 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 8 Connect transducer connector E to motor control board 9 Connect 15 20A switch 178 1595 model only 10 Connect motor control board power lead s D to ON OFF switch 33 11 Connect WatchDog 49 switch connector X to motor control board 12 Connect potentiometer connector C to motor control board 13 Install control panel 68 with two screws 39 14 Connect display connector A to motor control board 15 Install cover 96 with four screws 38 311365G 110 Vac U K Removal Relieve pressure page 9 We Wait 5 minutes before servicing 1 2 3 Remove four screws 38 and cover 96 Disconnect display connector A from motor control board 52 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 Disconnect motor board control power connectors K from filter board 146 Disconnect filter connector L from power cord connector L Remove four screws 163 from filter board 146 311365G 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 In
22. me 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 Also nut which may indicate worn or check piston valve seat for hardened paint damaged packings 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 replace pressure trans ducer 13 Piston packings are worn or 13 Replace packings see pump manual damaged 310643 or 310894 311365G 11 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK If check is OK go to next check WHAT TO DO When check is not OK refer to this column Pump output is low 14 O ring in pump is worn or dam aged 14 Replace o ring see pump manual 310643 or 310894 15 Intake valve ball is packed with material Clean intake valve see pump manual 310643 or 310894 16 Pressure setting is too low Increase pressure see pump manual 310643 or 310894 17 Large pressure drop in hose with heavy materials Use larger diameter hose and or reduce overall length of hose Use of more than 100 ft of 1 4 in
23. nt 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 D 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 e Protective eye wear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 311365G 7 Component Identification and Function English Premium Digital Display ON OFF switch Pressure control Prime Spray valve Filter AutoClean Siphon tube Pump Bearing Housing ProConnect Fluid Outlet Drain tube Trigger Lock Model serial tag WatchDog Switch not Mark V Component Identification and Function 311365G General Repair Information General Repair Information Pressure Relief Procedure CAUTION AD To reduce risk of pressure control malfunction e Use needle nose pliers to disconnect wire Never pull on wire pull on connector SKIN INJECTION
24. o run sprayer If motor runs check for locked or frozen pump or drive train If sprayer does not run continue to step 2 Set sprayer to OFF and disconnect power to sprayer 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 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 8 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 AN 123 4 EYY Green Blue Red Black vor JJJ 1234 var Green Blue Red Black 2 3 E STEP 3 i a 311365G 15 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 05 l I IL L 77 LJ 4 Control board status light blinks 5 times
25. 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 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 a la suite de ou en rapport directement ou indirectement avec les proc dures concern es TO PLACE AN ORDER OR FOR SERVICE contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor This manual contains English Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com 12 2005 Rev 4 2009 311365G 43
26. ousing 90 see Drive Housing Replacement page 30 12 Install pump 91 see Displacement Pump Replacement page 34 695 795 page 36 1095 1595 Mark V 311365G Motor Replacement 33 311365G Displacement Pump Replacement for 695 795 Displacement Pump Replacement for 695 795 See pump manual 310643 or 310894 for pump repair instructions See manual 311362 311363 or 311364 for applicable sprayer part number references Removal 1 Flush pump Relieve pressure page 9 2 Remove screw 31 and slide pump rod shield 108 forward 31 ti7170a 3 Cycle pump in JOG mode until pump pin 44 is in position to be removed Turn power switch OFF and unplug power cord 34 Push up retaining ring 43 and push pump pin out ti7168a 4 Remove suction tube 76 hose 94 and any washers and o rings 5 Loosen pump jam nut 56 Unscrew pump 311365G Installation 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 property damage CAUTION 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 1 5 in ti7171a 311365G Displacement Pump Replacement for 695 795 Install pump pin
27. 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 9 Disconnect motor connectors F G and H from motor control board 10 Remove motor shroud Disconnect and remove wiring from baffle 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 14 Remove five screws 27 three screws 102 and motor control board 24 Installation 1 Apply small amount of thermal compound 15U114 or 110009 5 to shaded component areas on rear of motor control board 52 CAUTION To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 2 Install five screws 27 three screws 102 and motor control board 3 Install motor control board 52 with five screws 27 Torque to 9 11 in Ib 1 02 1 24 Nem Install and torque three screws 102 to values in illustration 4 Connect motor connectors F G and H to motor control board 5 Reconnect and install wiring in baffle Install motor shroud 6 Install control box 61 with top two screws 39 7 Insta
28. 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 3 Pump packings are worn 3 Replace pump packings see pump man ual 310643 or 310894 4 Paint is too thick 4 Thin the paint according to the supplier s recommendations No display sprayer operates Display is damaged or has bad connection Check connections Replace display 12 311365G Electrical Symptom Sprayer does not run or stops running Relieve pressure page 9 TINO 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 Troubleshooting ATEN 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 pate Keep clear of electrical and moving parts during troubleshooting procedures If no digital display is available use control board status light to troubleshoot prob lems Turn ON OFF switch OFF remove control cover and then turn power back ON Observe sta
29. rd 52 Disconnect power cord connectors D and filter board connectors J from ON OFF switch 33 and remove control panel 68 Disconnect WatchDog switch connector X from motor control board Disconnect motor control board power connectors K from filter board 146 Remove four screws 163 from filter board 146 240 Vac 311365G 1 m em DI 99 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 52 Connect WatchDog switch X 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 ti12995a gt 23 Pressure Control Board 110 Vac U K Motor Control Board Removal Relieve pressure page 9 AS Relieve pressure page 9 Wait 5 minutes before servicing 1 Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 3 Remove bottom two screws 39 and allow control panel 68 to hang down freely 4 Disconnect control board power lead s D from ON OFF switch 33 and motor control board 52 5 Disconnect
30. rnennen 26 Assembly aisi ipa a edi 26 Motor Replacement 28 Removal iia a ke 28 Installati n seese asuda ee 28 Displacement Pump Replacement for 695 795 30 Removal iia a ehe 30 Installation synest as ii 31 Displacement Pump Replacement 1095 1595 MarkV 32 Removal viii es 32 Installation o ooo oooooooo ooo 33 Notes a a 35 Graco Standard Warranty 36 2 Table of Contents 311365G Models Vac Model Type Lo Boy Hi Boy 695 Standard 255130 249642 Premium 255131 249644 120 795 Standard 255132 249646 North America Premium 255133 249648 BERG 1095 Standard 249651 qu Premium 249653 c 1595 Standard 253060 or Premium 253059 Mark V 249904 120 1595 Standard 249658 North America Premium 249659 Mark V 249903 695 Standard 826093 826067 en Premium 826094 826069 m 795 Standard 826071 IJ Premium 826072 nia 1095 Standard 826073 Premium 826074 1595 Standard 826082 Premium 826081 Ultimate Mx II 1595 Standard 826075 Premium 826076 695 255134 249663 249666 Cad 2 256165 C 1095 249667 249905 Mark V 256166 240 695 255135 249668 Europe Multi cord 795 249671 1095 249672 Mark V 249907 110 695 249673 UK 795 249674 1095 249675 C Mark V 249906 240 695 255138 249681 Asia 795 249683 1095 249684 311365G Model
31. s Also for Asia and Australia Not ETL Approved All models not available in all countries Vac Model Type Lo Boy Hi Boy 240 695 255139 249685 Australia 795 255140 249687 1095 249688 100 695 255136 249676 Japan amp Taiwan 795 255137 249678 1095 249680 Models 311365G 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 Grounding Instructions 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 Ah WARNING GROUNDING e 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 e The wire with insulation having an outer surface that is green with or without
32. stall filter board 146 with four screws 163 Connect filter board power connector J and power cord connector D to ON OFF switch 33 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 Install cover 96 with four screws 38 25 Pressure Control Board 110 Vac U K 5 gt Tighten 1 screw ko to 14 17 in Ib 3 1 58 1 92 N c 26 311365G Pressure Control Board Pressure Adjust Potentiometer Removal Installation We Relieve pressure page 9 Wait 5 minutes before servicing 1 Install gasket 115 nut and potentiometer 82 on control panel 68 Torque nut to 30 35 in Ib 3 38 3 95 Nem 1 Remove four screws 38 and cover 96 82 115 9 2 Install pressure control knob 34 Check pressure control knob alignment to ti13493a potentiometer shaft Turn shaft fully clockwise and attach knob in full ON position with a hex wrench ti12998a 2 Disconnect potentiometer connector C from motor control board 95 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 ti13493a ti12998a 311365G 27 Pressure Control Board Pressure Control Transducer Removal
33. 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 sprayer 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 e Fire extinguisher equipment shall be present and working e 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 a
34. tal pail Trigger gun to relieve pressure 5 Lock gun safety latch 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 2 Test repair after problem is corrected retaining nut or hose end coupling to 3 relieve pressure gradually then loosen completely Then clear tip or hose obstruction 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 311365G 9 Grounding Grounding mw 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 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 2 Do not alter ground prong or use adapter ti2810a S N wt PP al 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 M 311365G Troubleshooting Mechanical
35. tor A to motor control board 15 Install cover 96 with four screws 38 311365G Pressure Control Board 100 120 Vac North American and Japan Taiwan Tighten 1 screw to 14 17 in Ib Tighten 2 screws to 11 14 in Ib 311365G 21 Pressure Control Board 240 Vac Motor Control Board Removal AS Relieve pressure page 9 Wait 5 minutes before servicing 1 Remove all 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 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 motor shroud disconnect and remove wiring from baffle 10 Remove five screws 27 three screws 102 and motor control board 11 Remove six screws 27 two screws 102 and control board 22 Installation 1 Apply a small amount of thermal compound 15U114 or 110009 5 to shaded areas on rear of motor control board
36. tus 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 Eon 0 LIL Control board status light blinks 2 times repeatedly lights Sprayer does not run at all Check transducer or transducer 1 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 2 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 3 Setsprayerto OFF and disconnect power to sprayer 4 Check transducer and connections to control board 5 Disconnect transducer from control board socket Check that transducer and control board contacts are clean and secure 6 Reconnect transducer to control board socket Connect power 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 7 Install new transducer Connect power set sprayer ON and control knob 1 2 turn clockwise Replace control board if sprayer does not run properly 311365G 13 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digit
37. way 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 e Use Graco nozzle tips Use caution when cleaning and changing nozzle 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 e 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 e Check hoses and parts for signs of damage Replace any damaged hoses or parts e 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 e 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 311365G Warnings A WARNING EQUIPMENT MISUSE HAZARD
38. y 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 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 defe
39. yellow stripes is the grounding wire e 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 electrician e 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 ti9164a e Only connect the product to an outlet having the same configuration as the plug Donotuse an adapter with this product Extension Cords e 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 e An undersized cord results in a drop in line voltage and loss of power and overheating 311365G 5 Warnings Ah WARNING PE POS 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 e Paint or solvent flowing through the equipment is able to result in
Download Pdf Manuals
Related Search