Graco MARK V, Repair Manual

Page 1: ...locations 3300 psi 227 bar 22 7 MPa Maximum Working Pressure IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual and all related manuals Save these instructions ti18238a Mark V Premium Mark V Max 3A2333B EN Repair Mark V Premium and Mark V Max Electric Airless Sprayers Related Manuals 3A2243 309495 308491 310894 3A2245 ...

Page 2: ...p 9 5mm x 15m 6 4mm x 0 9m whip 3 8in x 100ft 1 4in x 6ft whip 9 5mm x 30m 6 4mm x 1 8m whip 24L993 Mark V MAX Europe 24L994 Mark V MAX MultiCord 24L995 Mark V MAX UK 24M001 Mark V Premium Europe 24M002 Mark V Premium MultiCord 24M003 Mark V Premium UK 24M004 Mark V Plus 16Y996 Mark V Max UK 20A ...

Page 3: ...al 12 110V Models 18 230V Models 19 Motor Control Board 21 Filter Board 23 Pressure Adjust Potentiometer 24 Pressure Control Transducer 25 Drive and Bearing Housing Replacement 27 Drive and Bearing Housing Replacement 28 Motor Replacement 29 Motor Replacement 30 Displacement Pump Replacement 31 Hose Reel 33 Fast Flush Switch Replacement 35 Wiring Diagram 36 230V Models 36 110V Models 37 Notes 38 N...

Page 4: ...n 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 com pletely understood or when in doubt as to whether the product is proper...

Page 5: ...turer 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 clean ing keep sprayer at least 20 feet 6 m away from explosive vapors SKIN INJECTION HAZARD High pressure spray is able to inject toxins into the body and cause serious bodily injury In the event that injection occurs...

Page 6: ...ng setup or usage of the system can cause electric shock Turn off and disconnect power cord before servicing equipment Connect only to grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors Wait five minutes after disconnecting power cord before servicing large capacitor units PRESSURIZED ALUMINUM...

Page 7: ...t Identification 12 10 13 1 2 4 5 6 7 9 3 11 ti18440a 1 Digital Display 2 ON OFF Switch 3 Pressure Control 4 Spray Prime Fast Flush 5 Filter 6 Pump 7 Trigger Lock 9 Drain Tube 10 Bearing Housing ProConnect 11 Gun 12 Unit Serial Tag 13 Hose Reel ...

Page 8: ... and other end to a true earth ground To maintain grounding continuity when flushing or relieving pressure hold metal part of spray gun firmly to side of a grounded metal pail Then trigger gun Thermal Overload Motor has a thermal overload switch to shut itself down if over heated If sprayer overheats allow approximately 45 minutes for sprayer to cool Once cool switch will close and sprayer will re...

Page 9: ...ntrol Mode see Operation manual Trigger gun to relieve pressure 6 Put drain tube in pail Turn prime valve down to DRAIN position This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Proce dure when you stop spraying and before cleaning checking or...

Page 10: ...clogged or dirty Clean filter see operation manual Prime valve leaking Relieve pressure Repair prime valve Verify pump does not continue to stroke when gun trigger is released Prime valve not leaking Service pump see pump manual Leaking around throat packing nut which may indicate worn or damaged packings Replace packings see pump manual Also check piston valve seat for hardened paint or nicks and...

Page 11: ...ee pump manual Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Cycle pump as slowly as possible during priming Tip is partially clogged Clear tip see pump manual Fluid supply is low or empty Refill fluid supply Prime pump see pump man ual Check fluid supply often to prevent running pump dry Pump is difficult to prime Air in pump or hose Check and tighten all ...

Page 12: ... TO CHECK HOW TO CHECK Sprayer does not run at all See flow chart page 17 Digital display is blank Control board status light never lights Sprayer does not run at all Check transducer or transducer connections 1 Make sure there is no pressure in the system see Pressure Relief Procedure page 9 Check fluid path for clogs such as clogged filter 2 Use airless paint spray hose with no metal braid 1 4 i...

Page 13: ...rol board socket Connect power set sprayer ON and control knob to 1 2 turn clockwise If sprayer does not run set sprayer to OFF and go to next step 5 Connect a confirmed working transducer to control board socket 6 Set sprayer ON and control knob to 1 2 turn clockwise If sprayer runs install new transducer Replace control board if sprayer does not run 7 Check transducer resistance with ohmmeter le...

Page 14: ... clean and secure continue to step 4 4 Set sprayer to OFF and spin motor fan 1 2 turn Restart sprayer If sprayer runs replace control board If sprayer does not run continue to step 5 5 Perform Spin Test Test at large 4 pin motor field connector Disconnect fluid pump from sprayer Test motor by placing a jumper across pins 1 2 Rotate motor fan at about 2 revolutions per second A cogging resistance t...

Page 15: ...ld Short Test Test at large 4 pin motor field connector There should not be continuity from pin 4 the ground wire and any of the remaining 3 pins If motor field connector tests fail replace motor 7 Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each unit see table below Digital display shows E 05 Control board status light blinks 5 tim...

Page 16: ... ON and control knob 1 2 turn clockwise If sprayer does not run replace control board Digital display shows E 06 Control board status light blinks 6 times repeatedly Sprayer does not run at all Check the connections Control is not receiving a motor position sensor signal 1 Turn power OFF 2 Disconnect motor position sensor and inspect for damage at connectors 3 Reconnect sensor 4 Turn power ON If e...

Page 17: ...sducer to the board Does the motor run Replace potentiometer See Step 3 Is the proper reading present through the thermal switch wires Replace the ON OFF switch See step 4 Does the motor run See Step 1 Do you have over 100 AC volts 220 for 230V units See Step 2 Do you have over 100 AC 220 for 230 VAC units Repair or replace power cord If motor is hot let cool and retest If Step 3 still shows incor...

Page 18: ...ard and on off switch Turn meter to AC Volts Black Black Black Black On Off Switch Control Board White Power Cord Control Board On Off Switch Power Cord White 100k ohm STEP 3 Check motor thermal switch Unplug yellow wires Meter should read according to Resistance Table on page 16 NOTE Motor should be cool during reading STEP 4 Plug power cord in and turn switch ON Disconnect potentiometer Yellow B...

Page 19: ... cord in and turn switch ON Connect probes to on off switch Turn meter to AC Volts 100k ohm STEP 3 Check motor thermal switch Unplug yellow wires Meter should read according to Resistance Table on page 16 NOTE Motor should be cool during reading STEP 4 Plug power cord in and turn switch ON Disconnect potentiometer Yellow Black Control Board Control Board Thermal Switch Motor ...

Page 20: ...ailable Troubleshooting Procedure Plumb pressure gauge into paint hose plug sprayer in and turn power switch ON Does sprayer reach or exceed its maximum pressure Unplug the transducer from control board Does motor stop running Bad transducer Replace and test with a new one Replace the control board Mechanical problem See the proper fluid pump manual for the sprayer for further trouble shooting pro...

Page 21: ...r from motor control board 7 Disconnect motor control board power connectors from filter board 146 8 Remove top two screws 39 and control box 61 9 Disconnect transducer connector E from motor control board 10 Disconnect motor connectors 11 Remove six screws 27 two screws and control board Installation NOTE See Wiring Diagram page 36 for locations of wire connections 1 Use acetone or equivalent cle...

Page 22: ...all control box 61 with top two screws 39 10 Connect filter board power connectors and power cord connectors D to ON OFF switch 33 11 Connect potentiometer connector to motor control board 12 Connect Fast Flush switch connector to motor con trol board 13 Install control panel 68 with two screws 39 14 Connect display connector A to motor control board 52 15 Install cover 96 with four screws 38 16 I...

Page 23: ...r board 146 7 Remove four screws from filter board 146 Installation NOTE See Wiring Diagram page 36 for locations of wire connections 1 Install filter board 146 with four screws 163 2 Connect motor control board power connectors to filter board 146 3 Connect filter board power connectors J to top two terminals of ON OFF switch 33 and power cord con nectors D to bottom two terminals of ON OFF switc...

Page 24: ...d potentiometer 82 from control panel 68 Installation 1 Install gasket 115 nut and potentiometer 82 on control panel 68 Torque nut to 30 35 in lb 3 25 4 0 N m 2 Rotate new potentiometer shaft to highest pressure setting fully clockwise and install knob 34 Use allen wrench to tighten two screws on knob 3 Connect potentiometer connector C to motor con trol board 4 Install control panel and tighten t...

Page 25: ...Disconnect potentiometer connector C and Fast Flush switch connector from motor control board 5 Remove four screws 39 control panel 68 and control box 61 Allow control panel 68 to hang down freely 6 Remove grommet 40 from control box then remove transducer 86 and o ring 20 from filter base 67 7 Remove grommet 40 from transducer and save for reuse 38 96 ti13493b E 95 ti12999a C ti13722b 39 61 68 ti...

Page 26: ...sducer into control box 2 Connect transducer connector E and Fast Flush switch connector to control board 95 3 Install control box 61 and control panel 68 with four screws 39 4 Connect potentiometer connector C and Fast Flush switch connector to control board 5 Install cover 96 with four screws 38 ti7447a 40 67 20 86 ti13496a E 95 ti12999a 39 61 ti13494a 68 C ti13722b 38 96 ti13493b ...

Page 27: ...nd pull drive housing 90 off motor 84 Installation Make sure gear and thrust washers are in place Brush grease onto gear teeth 1 Push drive housing 90 onto motor 84 and install with five screws 6 Torque to 190 210 in lb 21 23 N m 2 Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft lb 34 40 N m 3 Install front cover 51 with four screws 31 4 Install shroud 72 with two ...

Page 28: ...Drive and Bearing Housing Replacement 28 3A2333B Drive and Bearing Housing Replacement 72 158 84 51 6 90 31 85 83 12 14 91 ti14892b ...

Page 29: ...e near control and remove motor 84 from cart frame Installation 1 Slide new motor 84 under two screws 23 in cart frame near control 2 Install two screws 23 and nuts 19 on motor side opposite control 3 Tighten all four screws 23 and nuts 19 torque nuts to 200 230 in lb 25 6 29 0 N m 4 Install baffle 5 Connect all three motor connectors to motor and route through baffle 6 Install drive housing 90 se...

Page 30: ...Motor Replacement 30 3A2333B Motor Replacement 58 158 96 61 39 39 23 23 19 19 91 14 12 90 6 51 158 89 30 28 28 90a 36 19 84 ti14893b ...

Page 31: ... 5 minutes before servicing 4 Separate drain hose from sprayer 5 Disconnect hose from pump 6 Raise latch lock Push latch open 7 Ratchet pump door forward 8 Twist latch u bolt out of pump door recess 9 Place u bolt on pump door protrusion 10 Ratchet pump door forward 11 Open pump door 12 Pull out pump pin and place in pin holder ti18433a ti18428a ti18432a ti18431a ti6377a ti18429a ti18430a ...

Page 32: ...pump door 4 Close pump door and rotate latch into position Do not tighten latch 5 Rotate pump to align with paint hose Connect hose and tighten to 8 N m 70 in lb 6 Tighten latch and rotate latch lock into locked posi tion 7 Attach drain hose to sprayer 8 Fill pump with Graco TSL until fluid flows onto top of seal If pump pin is not inserted properly it could work loose parts could break off and pr...

Page 33: ...ivel cap and completely remove hose 2 Remove cap from swivel 3 Remove E clip from swivel shaft 4 Remove swivel 5 Remove snap ring 6 Remove hose reel Be sure to keep your head clear of hose reel while winding up hose ti18437a ti13675a ti13538a ti13543a ti13542a ti18434a ...

Page 34: ...lace C clamp on reel and frame to allow snap ring to fit into place Install snap ring 4 Install swivel 5 Install E clip and swivel cap 6 Install hose to swivel Make sure to route hose through side arm of hose reel 7 Turn hose reel clockwise to wrap up hose Make sure hose is routed through hose guide ti13537a ti13545a ti18436a ti13543a ti13538a ti18437a ti13504a ...

Page 35: ...control board 5 Unscrew Fast Flush switch from control panel Installation 1 Apply thread sealant to end of Fast Flush switch Hand tighten Fast Flush switch until it is tight against control panel 2 Add thread sealant and tighten jam nut against threaded bus 3 Connect Fast Flush switch to control board 4 Replace control panel and tighten two screws 5 Replace display cover and tighten four screws ti...

Page 36: ...Wiring Diagram 36 3A2333B Wiring Diagram 230V Models 3UHVVXUH 7UDQVGXFHU 3RWHQWLRPHWHU LJLWDO LVSOD 21 2 6ZLWFK 3RZHU 3OXJ 0RWRU DVW OXVK 0RWRU HDGV 0RWRU 6HQVRU HDGV 7KHUPDO 6ZLWFK LS 6ZLWFK ti13486d ...

Page 37: ...Wiring Diagram 3A2333B 37 110V Models 3UHVVXUH 7UDQVGXFHU LJLWDO LVSOD 21 2 6ZLWFK 3RZHU 3OXJ 0RWRU 3RWHQWLRPHWHU DVW OXVK 0RWRU HDGV 0RWRU 6HQVRU HDGV 7KHUPDO 6ZLWFK LS 6ZLWFK ti13485c ...

Page 38: ...Notes 38 3A2333B Notes ...

Page 39: ...Notes 3A2333B 39 Notes ...

Page 40: ...equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and bu...