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Repair
®
Ultra Max II/Ultimate Mx II
Korean patent10-0579681
311365G
- For Portable Airless Spraying of Architectural Coatings and Paints -
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this manual.
Save these instructions.
ti13459a
695/795 LOW
ti13450a
695/795 HI
ti13460a
1095/1595 HI
ti13461a
MARK V
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
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Table of Contents Table of Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component Identification and Function . . . . . . . . 7 General Repair Information . . . . . . . . . . . . . . . . . . 8 Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . .
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Models Models Vac Model Type Lo-Boy Hi-Boy 695 Standard 255130 249642 Premium 255131 249644 795 Standard 255132 249646 120 Premium 255133 249648 North America 1095 Standard 249651 Premium 249653 1595 Standard 253060 Premium 253059 Mark V 249904 1595 Standard 249658** 120 Premium 249659** North America Mark V 249903** 695 Standard 826093 826067 Ultimate Mx II Premium 826094 826069 795 Standard 826071 Premium 826072 *Also for Asia and Australia; 1095 Standard 826073 **Not ETL Approved All models n
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Models Vac Model Type Lo-Boy Hi-Boy 695 255139 249685 240 Australia 795 255140 249687 1095 249688 695 255136 249676 100 Japan & Taiwan 795 255137 249678 1095 249680 4 311365G
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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
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Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: � Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment. � Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk of fire or explosion in the presence of paint or solvent fum
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Warnings WARNING EQUIPMENT MISUSE HAZARD 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 k
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Component Identification and Function Component Identification and Function 12. 11. 10. ti13451a 9. 5. 6. 7. 8. English 1 Premium Digital Display 2 ON/OFF switch 3 Pressure control 4 Prime / Spray valve 5Filter ™ 6 AutoClean 2 7 Siphon tube 8Pump ™ 9 Bearing Housing / ProConnect 10 Fluid Outlet 11 Drain tube 12 Trigger Lock 13 Model/serial tag ™ 14 WatchDog Switch (not Mark V) 8 311365G
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General Repair Information General Repair Information Pressure Relief Procedure CAUTION To reduce risk of pressure control malfunction: � Use needle-nose pliers to disconnect wire. Never pull on wire, pull on connector. SKIN INJECTION HAZARD � Mate wire connectors properly. Center flat System pressure must be manually relieved to blade of insulated male connector in prevent system from starting or spraying female connector. accidentally. Fluid under high pressure can be injected through sk
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Grounding Grounding 2. Do not alter ground prong or use adapter. ti2810a WARNING Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death. 3. 120 Vac: A 12 AWG, 3 wires with grounding 1. Ultra Max II 695, 795 and 1095 100-200 prong, 300 ft (90 m) extension cord may be Vac models require a 50/60 Hz, 15A circuit used. 220-240 Vac: You may use a 3-wire, with a grounding receptacle. Ultra Max II 1.0
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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. Determine fault correction from table, page 13. False tripping of WatchDog 1. Operating conditions out of 1. Turn pressure down. Refer to operation system. EMPTY is dis- WatchDog parameters. Pump manual for adjusting. Operate without played. Pump does n
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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. 15. Intake valve ball is packed with 15. Clean intake valve; see pump manual material 310643 or 310894. 16. Pressure setting is too low 16. Increase pressure; see pump manual 310643 or 310894. 17. Large pressure drop in hose with 17. Use larger diame
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Troubleshooting Electrical Symptom: Sprayer does not run or stops running. Relieve pressure; page 9. WARNING 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- � Set power switch OFF for 30 seconds and then ON pate. Keep clear of electrical and moving parts during again. This ensures sprayer is in normal run mode. troubl
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Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Check transducer or transducer 1. Set sprayer to OFF and disconnect power to sprayer. connections (control board is not Digital display shows E=03 2. Check transducer and connections to control board. detecting a pressure signal). 3. Disconnect transducer from control board socket. Check to see if transducer and control board contacts are clean and secure. Control board status light blinks 4. Reconnect t
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Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run 1. 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. open connection exists between 2. Set sprayer to OFF and disconnect power to sprayer. motor and control, there is a problem with m
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Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Control is commanding motor to run 6. 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 an open connection exists between 3 pins. If motor field connector tests fail, motor and control, there is a problem repla
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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 1. Check thermal device connector (yellow wires) overheating. Keep sprayer in cooler at control board. location with good ventilation. Make sure motor air intake is not blocked. 2. Disconnect thermal device connector from control If sprayer still does not run, follow
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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 NO fluid pump manual for the sprayer for switch ON. Does sprayer reach or further trouble shooting procedures. exceed its maximum pressure? YES Unplug the t
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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 NO you have over NO you have over replace Once Normal operation 100 AC volts? 100 AC volts? power cord. Light on Control board Continuously commanding motor to run YES Flashing See Error Code section for further troubleshooting Replace the YES ON/OFF switch. If m
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Pressure Control Board Pressure Control Board 100 - 120 Vac North American and Japan/Taiwan Motor Control Board Removal Installation 1. Apply small amount of thermal compound 15U114 or 110009 (5) to shaded component areas on rear of motor control board (52). CAUTION Relieve pressure; page 9. Wait 5 minutes before To reduce risk of motor control board failure, do servicing. not overtighten screws (102) which can damage 1. Remove four screws (38) and cover (96). the electric components. 2. D
