Graco 309674M Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

309674M

Repair

Electric Airless Sprayers

- For the application of architectural paints and coatings -

3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure

Korean patent: 10-0579681

Important Safety Instructions. Read all warnings and instructions

in this manual. Save these instructions. See page 2 for model

information.

ti2399

WLD

UltraTM 395/495/595

UltraMax IITM 490/495/595

Ultimate MX IITM 490/495/595

ST Max IITM 490/495/595

Ultimate Nova

395

ST MaxTM 395/495/595

Super NovaTM 495/595

Models

2309674M

Models

VAC Model

120

Ultra 395

Ultimate Nova 395

233960

826014

233961 233962

Ultra 495

Super Nova 495

233966

826017

233967

826018

233968

826019

Ultra 595

Super Nova 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

249916

825038

249917

825039

Ultra Max II 595

Ultimate MX II 595

249918

825046

249919

825045

230 CEE

ST Max 395 Hopper 233955

ST Max 395 234176 258662

ST Max 495 233956 233970 233971

ST Max 595 248661 244437

ST Max II 490 Hopper 253011

ST Max II 490 249926 253012 253013

ST Max II 495 249928 253014 249978

ST Max II 595 253015 249930

230

Europe

ST Max 395 223963

ST Max 495 233957 233975

ST Max 595 244436

ST Max II 490 249927

ST Max II 495 249929 249979

ST Max II 595 249931

110 UK

ST Max 395 223972

ST Max 495 233973 233975

ST Max 595 244436

ST Max II 490 249935

ST Max II 495 249936 249980

ST Max II 595 249937

230 Asia

Ultra 395 234180

Ultra 495 234183 234181 234182

Ultra 595 248660 244439

Ultra Max II 490 249932

Ultra Max II 495 249933 253104 253105

Ultra Max II 595 253107 249934

100

Japan

Ultra 495 234186 233974

UltraMax II 495 249938 253106

Warnings

309674M 3

Warnings

The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment.

Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols

appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the

manual, refer back to these pages for a description of the specific hazard.

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:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

• 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.

• Keep work area free of debris, including solvent, rags, and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. Read Grounding instructions.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

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.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just

a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

Warnings

4309674M

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. Read Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, request MSDS from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco

replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or overbend hoses or use hoses to pull equipment.

• Comply with all applicable safety regulations.

• Keep children and animals away from work area.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, and/or other halogenated hydrocarbon solvents or

fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemi-

cal reaction and equipment rupture, and result in death, serious injury, and/or property damage.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers and dispose of it according to applicable guidelines.

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

Component Identification

309674M 5

Component Identification

Model 233960 shown

B



FN Component

1 ON/OFF switch

2Primetube

3 Siphon tube

4 Pressure control

5 Filter

6 Trigger lock

7Pump

8 Fluid outlet

9 Prime/Spray valve

10 Service Tag (below sprayer frame)

Installation

6309674M

Installation

Grounding and Electric

Requirements

The sprayer must be grounded. Grounding reduces the

risk of static and electric shock by providing an escape

wire for the electrical current due to static build up or in

the event of a short circuit.

The sprayer power cord includes a grounding wire with

an appropriate grounding contact.

The plug must be plugged into an outlet that is properly

installed and grounded in accordance with all local

codes and ordinances. Do not use an adapter.

Do not use the sprayer if the electrical cord has a dam-

aged ground prong. Do not modify plug. If it will not fit in

outlet, have a grounded outlet installed by a qualified

electrician.

Power Requirements

• 100-120V units require 100-120VAC, 50/60 Hz,

15A, 1 phase

• 230V units require 230VAC, 50/60 Hz, 7.5A, 1

phase

• Never use an outlet that is not grounded or an

adapter.

Only use an extension cord with an undamaged

ground contact. If an extension cord is necessary, use a

3-wire, 12 AWG (2.5 mm2) minimum.

Spray gun:ground through connection to a properly

grounded fluid hose and pump.

Fluid supply container:follow local code.

Solvent and oil-based fluids: follow local code. Use

only conductive metal pails, placed on a grounded sur-

face such as concrete.

Do not place the pail on a nonconductive surface, such

as paper or cardboard, which interrupts grounding conti-

nuity.

Grounding the metal pail: connect a ground wire to the

pail by clamping one end to pail and other end to ground

such as a water pipe.

Maintain grounding continuity when flushing or

relieving pressure: hold metal part of the spray gun

firmly to the side of a grounded metal pail, then trigger

the gun.

TIC

Smaller gauge or longer extension cords may

reduce sprayer performance.

Operation

309674M 7

Operation

Pressure Relief Procedure

To reduce risk of injury from injection, follow this proce-

dure whenever you are instructed to relieve pressure,

stop spraying, service equipment or install or clean

spray tip. Read warnings, page 3.

1. Turn power switch OFF and unplug power cord.

2. Turn pressure to lowest setting. Hold gun to side of

grounded metal flushing bucket. Trigger gun to

relieve pressure, turn prime valve down.

3. Engage gun trigger lock if unit is being shut down or

left unattended.

If you suspect the spray tip or hose is clogged or that

pressure has not been fully relieved after following the

steps above, VERY SLOWLY loosen tip guard retaining

nut or hose end coupling to relieve pressure gradually,

then loosen completely. Clear hose or tip obstruction.

ti2707a

ti2718a

Leave Spray - Prime/Drain valve in the

PRIME/DRAIN position until you are ready to spray

again.

ti2614a

FLUSH

ti2599a

ti2

General Repair Information

8309674M

General Repair Information

Flammable materials spilled on hot, bare motor could

cause fire or explosion. To reduce risk of burns, fire or

explosion, do not operate sprayer with cover removed.

• Keep all screws, nuts, washers, gaskets, and electri-

cal fittings removed during repair procedures. These

parts usually are not provided with replacement kits.

• Test repairs after problems are corrected.

• If sprayer does not operate properly, review repair

procedure to verify you did it correctly. See Trouble-

shooting, page 9.

• Install motor shroud before operation of sprayer and

replace if damaged. Motor shroud directs cooling air

around motor to prevent overheating. It can reduce

risk of burns, fire or explosion, or cut fingers.

To reduce risk of serious injury, including electric shock:

• Do not touch moving or electric parts with fingers or

tools while testing repair.

• Unplug sprayer when power is not required for test-

ing.

• Install all covers, gaskets, screws and washers

before you operate sprayer.

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 or pressure control. Do not

pinch wires between cover and control box.

CAUTION

• Do not run sprayer dry for more than 30 seconds.

Doing so could damage pump packings.

• Protect the internal drive parts of this sprayer from

water. Openings in the cover allow for air cooling of

the mechanical parts and electronics inside. If

water gets in these openings, the sprayer could

malfunction or be permanently damaged.

• Prevent pump corrosion and damage from freezing.

Never leave water or water-base paint in sprayer

when its not in use in cold weather. Freezing fluids

can seriously damage sprayer. Store sprayer with

Pump Armor to protect sprayer during storage.

Troubleshooting

309674M 9

Troubleshooting

Type of Problem

What to Check

(if check is OK, go to next)

What to Do

(When check is not OK, refer to this

column)

Basic fluid pressure problems Pressure control knob setting. Motor

will not run if at minimum setting (fully

counter-clockwise).

Slowly increase pressure to see if

motor starts.

Spray tip or fluid filter may be

clogged.

Relieve pressure, page 7 and clear

clog, or clean filter; refer to separate

gun or tip instruction manual.

Basic Mechanical Problems Pump frozen or paint hardened in

pump.

Thaw sprayer if water or water-based

paint has frozen in sprayer. Place

sprayer in warm area to thaw. Do not

start sprayer until thawed completely.

If paint hardened (dried) in sprayer,

replace pump packings. See page

15, Displacement Pump Replace-

ment.

Displacement pump connecting rod

pin must be completely pushed into

connecting rod and retaining spring

must be firmly in groove of pump pin.

See page 15.

Push pin into place and secure with

spring retainer.

Motor. Remove drive housing assem-

bly. See page 17. Try to rotate fan by

hand.

Replace motor if fan won’t turn. See

page 19.

Motor control board. Board shuts

down and displays error code.

See Motor Control Board Diagnos-

tics, page 27.

Troubleshooting

10 309674M

Basic Electrical Problems Electric supply. Meter must read:

• 210-255 VAC for 220-240V

models

• 85-130 VAC for 100-120V

models.

Reset building circuit breaker.

Replace building fuse. Try another

outlet.

Extension cord. Check extension

cord continuity with volt meter.

Replace extension cord.

Sprayer power supply cord. Inspect

for damage such as insulation or

wires.

Replace power supply cord, page 24.

Motor leads are securely fastened

and properly mated.

Replace loose terminals; crimp to

leads. Be sure terminals are firmly

connected.

Clean circuit board terminals.

Securely reconnect leads.

Basic Electrical Problems - These

problems only apply to Ultra, Nova

and STMax 395/495/595 model

sprayers with brush motors. They do

not apply to UltraMax II, Ultimate

MX II and ST Max II 490/495/595

model sprayers.

Motor armature for shorts using

armature tester (growler) or perform

spin test. See page 18.

Replace motor. See page 29.

For loose motor brush lead connec-

tions and terminals.

Tighten terminal screws. Replace

brushes if leads are damaged.

Brush length which must be 1/2 in.

minimum. NOTE: Brushes do not

wear at the same rate on both sides

of motor. Check both brushes.

Replace brushes, page 20.

Broken or misaligned motor brush

springs. Rolled portion of spring must

rest squarely on top of brush.

Replace spring if broken. Realign

spring with brush.

Motor brushes may be binding in

brush holders.

Clean brush holders. Remove carbon

with small cleaning brush. Align

brush leads with slot in brush holder

to assure free vertical brush move-

ment.

Motor armature commutator for burn

spots, gouges or extreme roughness.

Remove motor and have motor shop

resurface commutator if possible.

See page 29.

Type of Problem

What to Check

(if check is OK, go to next)

What to Do

(When check is not OK, refer to this

column)

This manual suits for next models

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