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Graco Inc. 309674M manual

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  • Page 1

    Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2002, Graco Inc. is r egistered to I. S. EN ISO 9001 309674M Repair Electr ic Air less Spr a y ers - For the application of ar chit ectural paints and coatings - 3300 psi (227 bar , 22.7 MP a) Maxim um Wo rking Pressure Korean patent: 10-0579681 Important Safety Instructions. Read all wa[...]

  • Page 2

    Models 2 309674M Models VA C M o d e l 120 Ultra 395 Ultimate Nova 395 233960 826014 233961 233962 Ultra 495 Super Nov a 495 233966 826017 233967 826018 233968 826019 Ultra 595 Super Nov a 595 234490 826052 234435 826046 Ultra Max II 490 Ultimate MX II 490 249911 825028 249913 825029 249914 825036 Ultra Max II 495 Ultimate MX II 495 249915 825037 2[...]

  • Page 3

    Warnings 309674M 3 Wa r n i n g s The f ollowing ar e general w ar nings related to the set up , use, gro unding, maintenance , and repair of this equipmen t. Additional, more specific warnings ma y be found through out the bo dy of this manual where applicab le. Symbols appearing in the body of the man ual ref er to these gen eral w ar nings. When[...]

  • Page 4

    Warnings 4 309674M EQUIPMENT MISUSE HAZARD Misuse can ca use death or serious injury . • Do not exceed the maximum w ork in g pressure or temperature rating of the low est rated system component. Read T echnical Data in all equipment manual s. • Use fluids and solv ents th at are compatib le with equipment w etted par ts. Read T echnical Data i[...]

  • Page 5

    Component Identi fication 309674M 5 Component Identification Model 233960 shown 6 1 8 9 5 4 3 2 7 B  FN Component 1 ON/OFF s witch 2P r i m e t u b e 3 Siphon tube 4 Pressure c ontrol 5 Filter 6 T r igger loc k 7P u m p 8 Fluid outlet 9 Prime /Spra y valv e 10 Ser vice T ag (below spray er frame)[...]

  • Page 6

    Installation 6 309674M Installation Gr ounding and Electric Requirements The spra yer must be gr ounded. Grounding reduces the risk of static and electric shock by pro viding an escape wire f or the electrical current due to static b uild up or in the e v ent of a short circuit. The spra yer po wer cord include s a grounding wire with an appropriat[...]

  • Page 7

    Operation 309674M 7 Operation Pressure Relief Pr ocedure T o reduce risk of injur y from injection, f ollow this proce- dure whene ver y ou are instructed to relie v e pressure, stop spra ying, ser vice equipment or install or clean spra y tip . Read w arnings, page 3. 1. T urn pow er s witch OFF an d unplug po wer co rd. 2. T urn pressure to low e[...]

  • Page 8

    General Repair Information 8 309674M General Repair Inf ormation Flammable materials spilled o n hot, bare motor could cause fire or ex plosion. To re duce risk of bur ns, fire or explosion, d o not oper ate sprayer with cover removed. • K eep all scre ws, nuts, washers , gaske ts, and el ectri- cal fittings remo v ed during repair procedures . T[...]

  • Page 9

    Troubleshooting 309674M 9 T r oubleshooting T ype of Prob lem What to Check (if chec k is OK, go to nex t) What to Do (When chec k is not OK, ref er to this column) Basic fluid pressure pro blems Pressure control knob setting. Motor will not run if at minimum setting (fully counter- clock wise). Slowly increase pressure to see if motor star ts . Sp[...]

  • Page 10

    Troubleshooti ng 10 309674M Basic Electrical Problems Electric supply . Meter must read: • 210-255 V AC f or 220- 240V models • 85-130 V AC f or 100-120V models. Reset b uilding circuit breake r . Replace b uilding fuse. T r y another outlet. Extension cord. Ch eck e x tension cord continuity with volt meter . Replace e xtension cord . Spra yer[...]

  • Page 11

    Troubleshooting 309674M 11 Note: f or the follo wing electr ic prob- lems, ref er to wir ing diagr am, page 22, 23, and 24 to ident ify T est P oints (TP). P ower supply cord. Connect volt meter betw een TP1 (neutr al) and TP2. Plug in spra yer . Meter must read: • 210-255 V AC f or 220- 240V models • 85-130 V AC f or 100-1 20V models. Unplug s[...]

  • Page 12

    Troubleshooti ng 12 309674M Low Output Leads from motor to pressure control circuit board f or damaged or loose wires or connectors . Inspect wiring insulation and terminals fo r signs of ov erheating . Be sure male terminal blade s are centered a nd fir mly co nnected to f emale terminals. Replace any loose ter minal or damaged wir ing. Secur ely [...]

  • Page 13

    Troubleshooting 309674M 13 Motor runs but pump does not strok e Displacement pump pin damaged or missing. Replace pump pin if missing. Be sure retainer spring is fully in groov e all around conn ecting rod, pag e 15. Connecting rod assemb ly damaged. Replace connecting rod assemb ly . See pump manu al. Gears or drive ho using, page 17. Inspe ct dri[...]

  • Page 14

    Troubleshooti ng 14 309674M ON/OFF s witch. See page 22. Be sure spra yer is unplug ged! Disconnect wires from switch. Chec k switch with ohmmeter . Reading must be infinity with ON/OFF switch OFF , and zero when switch is ON. Replace ON/OFF s witch. See page 22. F or damaged or pinched wir es in pressure cont rol. See page 26. Replace dam aged par[...]

  • Page 15

    Displacement Pump Replacement 309674M 15 Displacement Pump Replacement See manual 309053 for pump repair instructions. Re m ova l 1. Flush pump (13). 1. Relieve pressure , page 7. 2. (Style A) Loosen scre ws (12) and rotate cov er (70). Note: Style A is shown in most illustrations . (Style B) Loosen scre ws (12). Push co ver (70) up and pull off sp[...]

  • Page 16

    Displacement Pump Replacement 16 309674M Installation 1. Extend pu mp piston r od full. Apply grease to top of pump rod at (A) or inside connecting rod (4 3). Install jam nut (29) on pump th reads. 2. Install pump rod (A) into co nnecting rod (43). 3. Install p ump pin (3 2). Slide reta iner spr ing (31) down in to groo ve ov er pump pin. 4. Push p[...]

  • Page 17

    Drive Housing Replacement 309674M 17 Drive Housing Replacement Re m ova l 1. Relieve pressure , page 7. 2. Disconnect po wer cord from outlet . 3. Remove scre ws (12) an d pump rod cover (70). 4. Remov e pump (41) , Displacement Pump Replace- ment , page 15 5. Remov e scre ws (12) from shroud (23). 6. Remove screws (12) from front cov er (22). 7. R[...]

  • Page 18

    Motor Diagnostics 18 309674M Motor Diagnostics Spin T est *Note: Motors used in th e UltraMax II, Ultimat e MX II and S T Max II 490/49 5/595 mode l spra yers are brus hless. The f ollowing brush inf ormation and instructions apply to Ultra , Nov a and ST Max 395/495/595 mod el spra yers only . Chec k for electrical continuity in motor armature, wi[...]

  • Page 19

    Fan Replacement 309674M 19 F an Replacement Re m ova l 1. Relieve pressure , page 7. Disco nnect pow er cord from outlet . 2. Remove f our screws (12) an d shroud ( 23). 3. Loosen tensioning scr ew (126) on fan (125). 4. Pull off f an (77). Installation 1. Slide new f an (125) in place on bac k of motor . Be sure bla des of f an f ace motor as show[...]

  • Page 20

    Motor Brush Replacement 20 309674M Motor Brush Replacement Note: Motors used i n the UltraMax II, Ultimate MX II an d ST Max II 490 /495/595 model spr ay ers are brushless. The f ollowing brush inf ormation and instructions apply to Ultra , Nov a and ST Max 395/495/595 mod el spra yers only . The Utlra, Nova and ST Max 395/ 495/595 sprayer’s moto[...]

  • Page 21

    Motor Brush Replacement 309674M 21 Motor Brush Installation 1. Install ne w brush (G) with lead into br ush holder (D). 2. Slide brush lead (E) onto terminal (F). 3. Install spr ing clip (B). Push down to set hook (C) into brush holder (D). 4. Repeat f or other side . 5. T est br ushes. a. Remove pump . Displacement P ump Replace- ment , page 15. b[...]

  • Page 22

    On/Off Switch Replacement 22 309674M On/Off Switch Replacement 100/120 V A C Ultra and ST 395/495/595 models Re m ova l 1. Relieve pressure , page 7. 2. Remove f our screws (12) and pressure c ontrol cov er (50). 3. Disconnect two wire s (A) from ON/OFF s witch (58). 4. Remov e toggle boot (30) and lock ing ring. Remov e ON/OFF s witch (58). Instal[...]

  • Page 23

    On/Off Switch Replacement 309674M 23 110/240 V A C Ultra, Nov a, and ST Max 395/495/595 models Re m ova l 1. Relie v e pressure, pag e 7. 2. Remov e f our scre ws (12) and pressur e control co ver (50). 3. Remove displa y connect or (B) from plug (C). 4. Disconnect f our wires (A) from ON/ OFF switch ( 58). 5. Remov e toggle boot (30) and lock ing [...]

  • Page 24

    On/Off Switch Replacement 24 309674M UltraMax II, Ultimate MX II an d ST Max II 490/495/595 models ON/OFF Switch/P ower Cor d Boar d Kit Re m ova l 1. Relieve pressure , page 7. 2. Remov e f our scre ws (12) and contr ol box co ve r (50). Po w e r C o rd 3. Remov e gree n ground scre w (19) and disconnect ground chok e coil and black lea ds. 4. Sli[...]

  • Page 25

    On/Off Switch Replacement 309674M 25 Wiring Diagram 02725 WLD ON/OFF Switch Ground Black Ref 30 Power Plug Ref 56 White Black Pressure Transducer Ref 38 Potentiometer Ref 37 J11 J12 Black Green 210 211[...]

  • Page 26

    Pressure Control Repair 26 309674M Pressure Contr ol Repair Motor Contr ol Boar d Ultra, No va, and ST Max 395/495/595 Models Ref er to wiring diagram f or your spra yer sho wn on pages 22, and 23. Re m ova l 1. Relieve pressure , page 7, and unplug sp ra ye r . 2. Remov e scre ws (12) and co v er (50). 3. Disconnect all leads to motor control bo a[...]

  • Page 27

    Pressure Control Repair 309674M 27 Motor Contr ol Board Diagnostics NO TE: • K eep a ne w tran sducer on hand to use f or test. • No displa y does not mean the spr a yer is not pres- surized. Bef ore repair , relieve pressure , pa ge 7. 1. F or spra yers with digital displa y , see Digital Displa y Messages . 2. Remove scre ws (12) and cover (5[...]

  • Page 28

    Pressure Control Repair 28 309674M Pressure Contr ol T ransducer Re m ova l 1. Relieve pressure , page 7. 2. Remov e scre ws (12) and co v er (50). 3. Disconnect tr ansducer lead from motor co ntrol board (49). 4. Slide transduce r grommet (20) out of control bo x (48). 5. Remov e pressure control transdu cer (38) and o- ring (3) from filter housin[...]

  • Page 29

    Motor Replacement 309674M 29 Motor Replacement Ultra, No va, and ST Max 395/495/595 Models Only Re m ova l 1. Relieve pressure , page 7. 2. Remove pump (41); Displaceme nt Pump Re place- ment , page 15 3. Remov e drive hou sing (42); Drive Housing Replacement , page 17 . 4. Remove screws (12) from cover (50). 5. Disconnect all leads from boar d (49[...]

  • Page 30

    Motor Replacement 30 309674M UltraMax II, Ultimate II, and ST Max II 490/495/595 Models Only Re m ova l 1. Relieve pressure , page 7. 2. Remove f our screws (12) an d shroud ( 23). 3. Remov e two screws (12) and fr ont cov er (22) 4. Remove pump (41); Displaceme nt Pump Re place- ment , page 15 5. Remov e drive ho using (42); Drive Housing Replacem[...]

  • Page 31

    Technical Data 309674M 31 Te c h n i c a l D a t a Basic Sprayer Wetted Parts: zinc-plated carbon ste el, nylon, stainless stee l, PTFE , acetal, chrome pla ting, leather, UHMWPE, alumin um, tungsten carbide Noise Le vel: Sound power . . . . . . . . . . 100 dBa* Sound pres sure . . . . . . . . . 90 dBa* *Measured 3 fe et (1 meter) from equipment. D[...]

  • Page 32

    Graco Standard Warranty 32 309674M Graco Standar d W arranty Graco warrants all equipment ref erenced in th is document which is manuf actured by Graco and bearing its name to be free from de fe c t s i n material and workmanship on the date of sale to the origin al purch aser for use. With the e xception of any special, e xtended, or limited warra[...]