Graco ultra max ii Repair Manual
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Graco ultra max ii Repair Manual

Portable airless spraying of architectural coatings and paints
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Repair
®
Ultra
Max II/Ultimate Mx II
- For Portable Airless Spraying of Architectural Coatings and Paints. For professional use only.
Not for use in explosive atmospheres.-
3300 psi (22.8 MPa, 227 bar) Maximum Working Pressure
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information, including maximum working pressure and approvals.
Korean patent 10-0579681
ti13450a
ti13461a
695/795 HI
MARK V
ti13459a
695/795 LOW
ti13460a
1095/1595 HI
311365H
ENG

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  • Page 1 Repair ® Ultra Max II/Ultimate Mx II 311365H - For Portable Airless Spraying of Architectural Coatings and Paints. For professional use only. Not for use in explosive atmospheres.- 3300 psi (22.8 MPa, 227 bar) Maximum Working Pressure IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual.

  • Page 2: Table Of Contents

    Notes ........47 Graco Standard Warranty ....48...

  • Page 3: Models

    Models Models Model Type Lo-Boy Hi-Boy Standard 255130 249642 Premium 255131 249644 Standard 255132 249646 Premium 255133 249648 North America 1095 Standard 249651 Premium 249653 1595 Standard 253060 Premium 253059 Mark V 249904 1595 Standard 249658** Premium 249659** North America Mark V 249903** Standard...
  • Page 4 Models Model Type Lo-Boy Hi-Boy 255139 249685 Australia 255140 249687 1095 249688 255136 249676 Japan & Taiwan 255137 249678 1095 249680 311365H...

  • Page 5: Warnings

    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.
  • Page 6 • Check hoses and parts for signs of damage. Replace any damaged hoses or parts. • This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated a minimum of 3300 psi. • Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
  • Page 7 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.

  • Page 8: Component Identification And Function

    Component Identification and Function Component Identification and Function ti13451a English 1 Premium Digital Display 2 ON/OFF switch 3 Pressure control 4 Prime / Spray valve 5 Filter 6 AutoClean ™ 7 Siphon tube 8 Pump 9 Bearing Housing / ProConnect ™...

  • Page 9: General Repair Information

    General Repair Information General Repair Information Pressure Relief Procedure NOTICE To reduce risk of pressure control malfunction: • Use needle-nose pliers to disconnect wire. System pressure must be manually relieved to pre- Never pull on wire, pull on connector. vent system from starting or spraying accidentally. •...

  • Page 10: Grounding

    1. Ultra Max II 695, 795 and 1095 100-200 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. Ultra Max II 1595/Mark V 3.

  • Page 11: Troubleshooting

    Troubleshooting Troubleshooting Mechanical/Fluid Flow Relieve pressure; page 9. WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK, refer to this column E=XX is displayed 1. Fault condition exists 1.
  • Page 12 Troubleshooting WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK, refer to this column Pump output is low 14. O-ring in pump is worn or dam- 14. Replace o-ring; see pump manual 310643 aged or 310894.

  • Page 13: Electrical

    Troubleshooting Electrical Symptom: Sprayer does not run or stops running. WARNING Relieve pressure; page 9. To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting, wait 30 seconds • Plug sprayer into correct voltage, grounded outlet after unplugging power cord for stored electricity to dissi- •...
  • Page 14 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Check transducer or transducer Set sprayer to OFF and disconnect power to sprayer. connections (control board is not Digital display shows E=03 Check transducer and connections to control board. detecting a pressure signal).
  • Page 15 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run Remove pump and try to run sprayer. If motor runs, but motor shaft does not rotate. check for locked or frozen pump or drive train. Digital display shows E=05 Possibly locked rotor condition, an If sprayer does not run, continue to step 2.
  • Page 16 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run Perform Field Short Test: Test at large 4-pin motor but motor shaft does not rotate. field connector. There should not be continuity from Digital display shows E=05 Possibly locked rotor condition, pin 4, the ground wire, and any of the remaining...
  • Page 17 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Allow sprayer to cool. If sprayer runs NOTE: Motor must be cooled down for the test. when cool, correct cause of Digital display shows E=06 Check thermal device connector (yellow wires) overheating.
  • Page 18 Troubleshooting Sprayer Will Not Shut Off 1. Relieve Pressure, page 9. Leave prime valve open 2. Remove control box cover so the control board and power switch OFF. status light can be viewed if available. Troubleshooting Procedure Plumb pressure gauge into paint Mechanical problem: See the proper hose, plug sprayer in, and turn power fluid pump manual for the sprayer for...
  • Page 19 Troubleshooting 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). No light See Step 1. Do See Step 2. Do Repair or you have over you have over replace...

  • Page 20: Pressure Control Board

    Pressure Control Board Pressure Control Board 100 - 120 Vac North American and Japan/Taiwan Motor Control Board Removal Installation 1. Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar. Relieve pressure; page 9. Wait 5 minutes before servicing.
  • Page 21 Pressure Control Board 3. Install six screws (27), two screws (102) and 9. Connect transducer connector (E) to motor motor control board. control board. 4. Install and torque two screws (102) to values in 10. Connect 15/20A switch (178) (1595 model illustration.
  • Page 22 Pressure Control Board 100 - 120 Vac North American and Japan/Taiwan Tighten 2 screws to 14-17 in-lb $XWR  0$5. 9 ti12994b 311365H...

  • Page 23: 240 Vac Motor Control Board

    Pressure Control Board 240 Vac Motor Control Board Removal Installation 1. Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar. Relieve pressure; page 9. Wait 5 minutes before servicing. 2. Apply thermal compound: For 2 capacitor boards and 6 capacitor 1.
  • Page 24 Pressure Control Board 3. Install two screws (102), six screws (27) and 9. Install control box (61) with top two screws (39). control board. 10. Connect filter board power connectors (J) and 4. Install and torque two screws (102) to values in power cord connectors (D) to ON/OFF switch illustration on page 25.

  • Page 25: 240 Vac Filter Board

    Pressure Control Board 240 Vac Filter Board Relieve pressure; page 9. Removal Installation 1. Remove four screws (38) and cover (96). 1. Install filter board (146) with four screws (163). 2. Disconnect display connector (A) from motor 2. Connect motor control board power connectors control board (52).

  • Page 26: 110 Vac U.k. Motor Control Board

    Pressure Control Board 110 Vac U.K. Motor Control Board Removal Installation 1. Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar. Relieve pressure; page 9. Wait 5 minutes before 2. Apply thermal compound: servicing.
  • Page 27 Pressure Control Board 3. Install two screws (102), six screws (27) and 9. Connect transducer connector (E) to motor control board. control board. 10. Connect 15/20A switch (178) (1595 model 4. Install and torque two screws (102) to values in only).

  • Page 28: 110 Vac U.k. Filter Board

    Pressure Control Board 110 Vac U.K. Filter Board Relieve pressure; page 9. Wait 5 minutes before servicing. Removal Installation 1. Remove four screws (38) and cover (96). 1. Connect motor control board power connectors (K) to filter board (146). Connect filter 2.
  • Page 29 Pressure Control Board 110 Vac U.K. Tighten 2 screws to 14-17 in-lb (1.58-1.92 N ‚Ä¢ ti12996b 311365H...

  • Page 30: Pressure Adjust Potentiometer

    Pressure Control Board Pressure Adjust Potentiometer Removal Installation 1. Install gasket (115), nut and potentiometer (82) on control panel (68). Torque nut to 30-35 in-lb (3.38 - 3.95 N•m). Relieve pressure; page 9. Wait 5 minutes before servicing. 1. Remove four screws (38) and cover (96). ti12998a 2.

  • Page 31: Pressure Control Transducer

    Pressure Control Board Pressure Control Transducer Removal 4. Remove four screws (39) and control box (61). Allow control panel (68) to hang down freely. Relieve pressure; page 9. Wait 5 minutes before servicing. ti7458a 1. Remove four screws (38) and cover (96). ti13494a 5.
  • Page 32 Pressure Control Board Installation 3. Install control box (61) and control panel (68) with four screws (39). 1. Install o-ring (20) and transducer (86) in filter base (67). Torque to 35-45 ft-lb (47-61 N•m). Install grommet onto transducer (86) and transducer into control box.

  • Page 33: Notes

    Notes Notes 311365H...

  • Page 34: Drive And Bearing Housing Replacement

    Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement NOTICE Do not drop gear cluster (89) when removing drive housing (90). Gear cluster may stay engaged in motor front end bell or drive housing. Disassembly Assembly Make sure gear (89) and thrust washers (28, 30, 90a, 36;...
  • Page 35 Drive and Bearing Housing Replacement ti13000a 311365H...

  • Page 36: Motor Replacement

    Motor Replacement Motor Replacement Removal 10. Remove motor wires from baffle 278075 and remove baffle. 11. Remove two screws (23) and nuts (19) on side opposite control. 12. Loosen two nuts (19) on side near control and Relieve pressure; page 9. remove motor (84) from cart frame (62).
  • Page 37 Motor Replacement ti13001a 311365H...

  • Page 38: Displacement Pump Replacement For 695/795

    Displacement Pump Replacement for 695/795 Displacement Pump Replacement for 695/795 See pump manual 310643 or 310894 for pump OFF and unplug power cord. Push up retaining repair instructions. ring (43) and push pump pin out. See manual 311362, 311363, or 311364 for applicable sprayer part number references.

  • Page 39: Installation

    If the pump jam nut loosens during operation, 7. Install pump rod shield (108) with screw (31). the threads of the drive housing will be 8. Fill packing nut with Graco TSL until fluid flows damaged. onto top of seal.

  • Page 40: Displacement Pump Replacement 1095/1595/Mark V

    Displacement Pump Replacement 1095/1595/Mark V Displacement Pump Replacement 1095/1595/Mark V Removal 7. Ratchet open pump door. Ratchet pump door forward. See Skin Injection Hazard; page 6. 1. Flush pump. 2. Stop pump with piston rod in its lowest position. ti6373a 3.

  • Page 41: Installation

    Displacement Pump Replacement 1095/1595/Mark V 8. Ratchet pump door forward. Installation ti6377a 1. Adjust piston rod with pin holder to pull out piston rod. Tap piston rod on hard surface to push in piston rod. 2. Push pump collar flush with bearing housing ledge to be able to close pump door.
  • Page 42 7. Attach drain hose to sprayer. 5. Rotate pump to align with paint hose. Connect paint hose and hand tighten to 70 in-lb. ti6299a ti7330a 8. Fill pump with Graco TSL until fluid flows onto top of seal. ti5493a 311365H...

  • Page 43: Wiring Diagram

    Wiring Diagram Wiring Diagram 695/795 Lo-Boy Series B; 695 Hi-Boy Series D; 795 Hi-Boy Series C; 1095/1595/Mark V Series B Motor ti7346a green/ground ON/OFF Switch Black + Digital Display white Power Plug Black green/ground Pressure Transducer 14A 10A Switch 1595/MARK V Potentiometer Watchdog 311365H...

  • Page 44: Wiring Diagram

    Wiring Diagram Wiring Diagram 695/795 Lo-Boy Series B; 695 Hi-Boy Series D; 795 Hi-Boy Series C; 1095/1595/Mark V Series B Digital Display Potentiometer Motor Pressure Transducer Black Dip Switch Watchdog 20A 15A 1595 Switch ti12980a green/ground ON/OFF Switch Black white Black + Power Plug green/ground...

  • Page 45: Wiring Diagram

    Wiring Diagram Wiring Diagram UltraMax II: 695/795 Lo-Boy Series B; 695 Hi-Boy Series D; 795 Hi-Boy Series C; 1095/Mark V Series B (Models with only TWO large capacitors on control board) Motor ti7523a green/ground ON/OFF Switch Black + Digital Display white Power Plug green/ground...

  • Page 46: Wiring Diagram

    Wiring Diagram Wiring Diagram UltraMax II: 695/795 Lo-Boy Series B; 695 Hi-Boy Series D; 795 Hi-Boy Series C, 1095/Mark V Series B (Models with SIX large capacitors on control board) Potentiometer Thermal Switch Digital Display Pressure Transducer Motor Black Dip Switch AutoClean Motor Leads...

  • Page 47: Notes

    Notes Notes 311365H...

  • Page 48: Graco Standard Warranty

    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 manual is also suitable for:

Ultimate mx ii

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