Graco 311365G Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this manual.
Save these instructions.
311365G
Ultra
®
Max II/Ultimate Mx II
Korean patent10-0579681
- For Portable Airless Spraying of Architectural Coatings and Paints -
Repair
ti13450a
695/795 HI
ti13459a
695/795 LOW
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MARK V
ti13460a
1095/1595 HI

Table of Contents
2311365G
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification and Function . . . . . . . . 7
General Repair Information . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drive and Bearing Housing Replacement . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Displacement Pump Replacement for 695/795 . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Displacement Pump Replacement
1095/1595/Mark V . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Models
311365G 3
Models
Vac Model Type Lo-Boy Hi-Boy
120
North America
695 Standard 255130 249642
Premium 255131 249644
795 Standard 255132 249646
Premium 255133 249648
1095 Standard 249651
Premium 249653
1595 Standard 253060
Premium 253059
Mark V 249904
120
North America
1595 Standard 249658**
Premium 249659**
Mark V 249903**
Ultimate Mx II 695 Standard 826093 826067
Premium 826094 826069
795 Standard 826071
Premium 826072
1095 Standard 826073
Premium 826074
1595 Standard 826082
Premium 826081
Ultimate Mx II 1595 Standard 826075
Premium 826076
240
Europe
695 255134 249663
795 249666
256165
1095 249667
Mark V 249905
256166
240
Europe Multi-cord
695 255135 249668
795 249671
1095 249672
Mark V* 249907
110
UK
695 249673
795 249674
1095 249675
Mark V 249906
240
Asia
695 255138 249681
795 249683
1095 249684
*Also for Asia and Australia;
**Not ETL Approved
All models not available in all
countries.

Models
4311365G
240
Australia
695 255139 249685
795 255140 249687
1095 249688
100
Japan & Taiwan
695 255136 249676
795 255137 249678
1095 249680
Vac Model Type Lo-Boy Hi-Boy

Warnings
311365G 5
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.
WARNING
GROUNDING
• 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.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• 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.
• 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.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
Extension Cords:
• 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 mm2) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.
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Warnings
6311365G
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 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.
• Fire extinguisher equipment shall be present and working.
• 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) away 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.
• 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.
• 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.
• 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.
• 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.
WARNING

Warnings
311365G 7
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 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
Improper grounding, setup, or usage of the system can cause electric shock.
• 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
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.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• 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
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 eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
WARNING

Component Identification and Function
8311365G
Component Identification and Function
English
1 Premium Digital Display
2 ON/OFF switch
3 Pressure control
4 Prime / Spray valve
5Filter
6AutoClean2™
7 Siphon tube
8Pump
9Bearing Housing / ProConnect™
10 Fluid Outlet
11 Drain tube
12 Trigger Lock
13 Model/serial tag
14 WatchDog™Switch (not Mark V)
5. 6. 7. 8.
9.
10.
11.
12.
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General Repair Information
311365G 9
General Repair Information
Pressure Relief Procedure
SKIN INJECTION HAZARD
System pressure must be manually relieved to
prevent system from starting or spraying
accidentally. Fluid under high pressure can be
injected through skin and cause serious injury.
To reduce risk of injury from injection, splashing
fluid, or moving parts, follow Pressure Relief
Procedure whenever you:
• are instructed to relieve pressure
• stop spraying
• check or service any system equipment
• install 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. Then clear tip or hose
obstruction.
1. Keep all screws, nuts, washers, gaskets,
and electrical fittings removed during repair
procedures. These parts are not normally
provided with replacement assemblies.
ELECTRIC SHOCK HAZARD
MOVING PARTS HAZARD
HOT SURFACE HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or electrical
parts with fingers or tools while testing repair.
Shut off and unplug sprayer when inspection is
complete. Install all covers, guards, gaskets,
screws, washers and shroud before operating
sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was
done correctly. If necessary, see
Troubleshooting, page 11, for other
possible solutions.
CAUTION
To reduce risk of pressure control malfunction:
• 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.

Grounding
10 311365G
Grounding
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 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 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.
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.
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