Repair Ultra® Max II/Ultimate Mx II 311365J - 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.
Table of Contents Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component Identification and Function . . . . . . . . . . . 8 General Repair Information . . . . . . . . . . . . . . . . . . . . 9 Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9 Grounding . . . . . . . . . . . . . . . . . .
Models Models Vac 120 North America Model Type Lo-Boy Hi-Boy 695 Standard 255130 249642 Premium 255131 249644 Standard 255132 249646 Premium 255133 249648 795 1095 1595 Standard 249651 Premium 249653 Standard 253060 Premium 253059 Mark V 120 North America 1595 249904 Standard 249658** Premium 249659** Mark V 695 795 Ultimate Mx II 1095 1595 Ultimate Mx II 1595 695 240 Europe 249903** Standard 826093 826067 Premium 826094 826069 Standard 826071 Premium 826072 S
Models Vac Model 240 Australia Type Lo-Boy Hi-Boy 695 255139 249685 795 255140 249687 1095 100 Japan & Taiwan 695 255136 249676 795 255137 249678 1095 4 249688 249680 311365J
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 applicable. WARNING GROUNDING This product must be grounded.
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 fumes.
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.
Component Identification and Function Component Identification and Function 14. 13. 12. 1. 2. 11. 3. 10. 4. 9. 5. 6. 7. 8.
General Repair Information General Repair Information Pressure Relief Procedure NOTICE To reduce risk of pressure control malfunction: 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.
Grounding Grounding 2. Do not alter ground prong or use adapter. ti2810a 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.
Troubleshooting Troubleshooting Mechanical/Fluid Flow Relieve pressure; page 9. TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check E=XX is displayed 1. Fault condition exists False tripping of WatchDog system. EMPTY is displayed. Pump does not run. Pump output is low 1. Operating conditions out of WatchDog parameters. Pump output is low, see below. 1. Spray tip worn 2. Spray tip clogged 3. Paint supply 4. Intake strainer clogged 5.
Troubleshooting WHAT TO CHECK If check is OK, go to next check TYPE OF PROBLEM Pump output is low 14. O-ring in pump is worn or damaged 15. Intake valve ball is packed with material 16. Pressure setting is too low 17. Motor runs but pump does not stroke 1. 2. 3. Excessive paint leakage into 1. throat packing nut 2. 3. Fluid is spitting from gun 1. 2. 3. Pump is difficult to prime 1. 2. 3. 4. No display, sprayer operates 1. 12 WHAT TO DO When check is not OK, refer to this column 14.
Troubleshooting Electrical Symptom: Sprayer does not run or stops running. WARNING Relieve pressure; page 9. • Plug sprayer into correct voltage, grounded outlet • Set power switch OFF for 30 seconds and then ON again. This ensures sprayer is in normal run mode.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=03 Control board status light blinks 3 times repeatedly 14 WHAT TO CHECK Check transducer or transducer connections (control board is not detecting a pressure signal). HOW TO CHECK 1. Set sprayer to OFF and disconnect power to sprayer. 2. Check transducer and connections to control board. 3. Disconnect transducer from control board socket. Check to see if transducer and control board contacts are clean and secure.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=05 Control board status light blinks 5 times repeatedly WHAT TO CHECK HOW TO CHECK Control is commanding motor to run 1. but motor shaft does not rotate. Possibly locked rotor condition, an open connection exists between 2. motor and control, there is a problem with motor or control board, or motor amp draw is excessive. 3. Remove pump and try to run sprayer.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=05 Control board status light blinks 5 times repeatedly WHAT TO CHECK Control is commanding motor to run 6. 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 7. motor amp draw is excessive. HOW TO CHECK Perform Field Short Test: Test at large 4-pin motor field connector.
Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK NOTE: Motor must be cooled down for the test. Allow sprayer to cool. If sprayer runs when cool, correct cause of 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 board socket. Make sure contacts are clean and secure.
Troubleshooting Sprayer Will Not Shut Off 1. Relieve Pressure, page 9. Leave prime valve open and power switch OFF. 2. Remove control box cover so the control board status light can be viewed if available. Troubleshooting Procedure Plumb pressure gauge into paint hose, plug sprayer in, and turn power switch ON. Does sprayer reach or exceed its maximum pressure? NO Mechanical problem: See the proper fluid pump manual for the sprayer for further trouble shooting procedures.
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 Once Normal operation Light on Control board Continuously commanding motor to run Flashing See Step 1. Do you have over 100 AC volts? NO See Step 2. Do you have over 100 AC volts? NO Repair or replace power cord. YES See Error Code section for further troubleshooting Replace the ON/OFF switch. YES See Step 3.
Pressure Control Board Pressure Control Board 100 - 120 Vac North American and Japan/Taiwan Motor Control Board Removal Relieve pressure; page 9. Wait 5 minutes before servicing. 1. Remove four screws (38) and cover (96). Installation 1. Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar. 2. Apply thermal compound: a.
Pressure Control Board 3. Install six screws (27), two screws (102) and motor control board. 9. Connect transducer connector (E) to motor control board. 4. Install and torque two screws (102) to values in illustration. Install motor control board (52) with six screws (27). Torque to 9-11 in-lb (1.02 1.24 N•m). 10. Connect 15/20A switch (178) (1595 model only). 5. Connect motor connectors, (F, G and H) to motor control board. 12. Connect WatchDog (49) switch connector (X) to motor control board. 6.
Pressure Control Board 100 - 120 Vac North American and Japan/Taiwan F 81 88 87 H G 69 Tighten 2 screws to 14-17 in-lb 27 102 Y 88 61 A 178 B F C A 52 E 40 96 38 33 D E 39 86 20 49 82 C 67 82 34 115 X 68 39 49 ti12994b 22 311365J
Pressure Control Board 240 Vac Motor Control Board Removal 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). Installation 1.
Pressure Control Board 3. Install two screws (102), six screws (27) and control board. 9. Install control box (61) with top two screws (39). 4. Install and torque two screws (102) to values in illustration on page 25. Install motor control board (52) with six screws (27). Torque to 9-11 in-lb (1.02 - 1.24 N•m). 10. Connect filter board power connectors (J) and power cord connectors (D) to ON/OFF switch (33). 5. Connect motor connectors (F, G and H) to motor control board. 6.
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 control board (52). 2. Connect motor control board power connectors (K) to filter board (146). 3. Remove bottom two screws (39). disconnect potentiometer connector (C) from motor control board (52).
Pressure Control Board 110 Vac U.K. Motor Control Board Removal Relieve pressure; page 9. Wait 5 minutes before servicing. Installation 1. Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar. 2. Apply thermal compound: a. For 2 capacitor boards and 6 capacitor 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.
Pressure Control Board 3. Install two screws (102), six screws (27) and control board. 9. Connect transducer connector (E) to motor control board. 4. Install and torque two screws (102) to values in illustration. Install motor control board (52) with six screws (27). Torque to 9-11 in-lb (1.02 1.24 N•m). 10. Connect 15/20A switch (178) (1595 model only). 5. Connect motor connectors, (F, G and H) to motor control board. 12. Connect WatchDog (49) switch connector (X) to motor control board. 6.
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). 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 filter board connector (J) and power cord connector (D) from ON/OFF switch (33). Remove control panel (68). 4.
Pressure Control Board 110 Vac U.K. Tighten 2 screws to 14-17 in-lb (1.58-1.
Pressure Control Board Pressure Adjust Potentiometer Removal Installation 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-lb (3.38 - 3.95 N•m). 68 1. Remove four screws (38) and cover (96). 82 96 82 115 38 ti13493a 2. Disconnect potentiometer connector (C) from motor control board (95). ti12998a 2.
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). 68 39 ti13494a 61 96 38 ti13493a 2. Disconnect transducer connector (E) from motor control board (95). 5. Remove grommet (40) from control box then remove transducer (86) and o-ring (20) from filter base (67).
Pressure Control Board Installation 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. 3. Install control box (61) and control panel (68) with four screws (39). ti7458a 40 67 ti7447a 39 61 ti13494a 68 86 20 4. Connect potentiometer connector (C) to motor control board. ti13496a 2. Connect transducer connector (E) to motor control board (95). C E ti12997a 95 5.
Notes Notes 311365J 33
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; see page 29) are in place. Brush grease onto gear teeth. Relieve pressure; page 9. 1. Remove screw (31), two nuts (24), pail hanger (55) and pump rod cover (108). 2.
Drive and Bearing Housing Replacement 72 158 84 51 90 6 31 85 12 14 83 24 31 108 55 91 ti13000a 311365J 35
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. Relieve pressure; page 9. 1. Remove pump (91); see Displacement Pump Replacement, page 38 (695/795) page 40 (1095/1595/Mark V). 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. 2.
Motor Replacement 158 62 58 84 36 61 19 90a 90 28 158 51 96 89 39 6 30 12 14 31 68 23 19 90 6 12 14 91 ti13001a 311365J 37
Displacement Pump Replacement for 695/795 Displacement Pump Replacement for 695/795 See pump manual 310643 or 310894 for pump repair instructions. OFF and unplug power cord. Push up retaining ring (43) and push pump pin out. 44 See manual 311362, 311363, or 311364 for applicable sprayer part number references. ti7168a Removal 43 Relieve pressure; page 9. Wait 5 minutes before servicing. 4. Remove suction tube (76), hose (94) and any washers and o-rings. 1. Flush pump. 2.
Displacement Pump Replacement for 695/795 Installation 2. Install pump pin (44). Verify retaining spring (43) is in groove of connecting rod (85). 3. Push pump up until pump threads engage. 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. 4. Screw in pump until threads are flush with drive housing opening. Align pump outlet to back. 5.
Displacement Pump Replacement 1095/1595/Mark V Displacement Pump Replacement 1095/1595/Mark V Removal 7. Ratchet open pump door. a. 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. Do Pressure Relief, page 9. 4. Separate drain hose from sprayer. b. Twist latch u-bolt out of pump door recess. ti7326a 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.
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. ti6325a 9. Open pump door. ti7331a ti5492a 3. Slide pump into connecting rod. Push pump pin until it is fully retained. Note: Pin will snap into position. ti6378a 10.
Displacement Pump Replacement 1095/1595/Mark V 4. Close pump door and rotate latch into position. Do not tighten latch. 6. Tighten latch and rotate latch lock into locked position. ti7329a ti6313a ti6204a TI6312a 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.
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 Power Plug white Black green/ground Pressure Transducer 14A 10A Switch 1595/MARK V Potentiometer Watchdog 311365J 43
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 ON Black Dip Switch Watchdog 20A 15A 1595 Switch ti12980a green/ground ON/OFF Switch Black white Black + Power Plug green/ground 44 311365J
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 Power Plug white green/ground Japan/Taiwan Models Pressure Transducer Potentiometer Watchdog Motor ti7347a Black green/ground Blue 175 Blue Brown Blue ON/OFF Switch UK Models Digital Display green/ground Black Pressure Transducer Brown
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 ON Dip Switch AutoClean Motor Leads Watchdog Motor Sensor Leads green/ground ON/OFF Switch Black white ti13484a Black + Power Plug green/ground Japan/Taiwan Models Thermal Switch Digital Display Potentiometer Pressure Transducer Motor
Notes Notes 311365J 47
Graco Standard Warranty 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.
