Graco Ultra max ii Operating instructions

311365H

ENG

Ultra

Max II/Ultimate Mx II

- 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

See page 3 for model information, including maximum working pressure and approvals.

Korean patent 10-0579681

IMPORTANT SAFETY INSTRUCTIONS

Read all warnings and instructions in this

manual. Save these instructions.

MARK V

ti13461a

ti13460a

1095/1595 HI

ti13459a

695/795 LOW

695/795 HI

ti13450a

Repair

Table of Contents

2 311365H

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 ................................10

Troubleshooting ............................11

Mechanical/Fluid Flow ...................11

Electrical ..............................13

Pressure Control Board ......................20

100 - 120 Vac North American and

Japan/Taiwan Motor Control Board .........20

240 Vac Motor Control Board ..............23

240 Vac Filter Board .....................25

110 Vac U.K. Motor Control Board ..........26

110 Vac U.K. Filter Board .................28

Pressure Adjust Potentiometer .............30

Pressure Control Transducer ..............31

Notes ....................................33

Drive and Bearing Housing Replacement ........34

Disassembly ...........................34

Assembly .............................34

Motor Replacement .........................36

Removal ..............................36

Installation .............................36

Displacement Pump Replacement for 695/795 ....38

Removal ..............................38

Installation .............................39

Displacement Pump Replacement

1095/1595/Mark V ..........................40

Removal ..............................40

Installation .............................41

Wiring Diagram ............................43

Wiring Diagram ............................44

Wiring Diagram ............................45

Wiring Diagram ............................46

Notes ....................................47

Graco Standard Warranty ....................48

Models

311365H 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

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

4 311365H

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

311365H 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.

WARNING

GROUNDING

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.

• 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.

ti9164a

Warnings

6 311365H

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

311365H 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

8 311365H

Component Identification and Function

English

1 Premium Digital Display

2 ON/OFF switch

3 Pressure control

4 Prime / Spray valve

5 Filter

6AutoClean2™

7 Siphon tube

8 Pump

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.

10.

11.

12.

13.14.

ti13451a

General Repair Information

311365H 9

General Repair Information

Pressure Relief Procedure

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.

NOTE: If suspected that spray tip or hose is com-

pletely clogged, or that pressure has not been fully

relieved after following steps above, VERY SLOW-

LY loosen tip guard retaining nut or hose end cou-

pling 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.

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.

System pressure must be manually relieved to pre-

vent system from starting or spraying accidentally.

Fluid under high pressure can be injected through

skin and cause serious injury. To reduce risk of in-

jury 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

NOTICE

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.

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 un-

plug sprayer when inspection is complete. Install all

covers, guards, gaskets, screws, washers and

shroud before operating sprayer.

Grounding

10 311365H

Grounding

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.

Improper installation or alteration of grounding

plug results in risk of electric shock, fire or

explosion that could cause serious injury or

death.

ti2810a

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