Graco ULTRA MAX 695 Instructions-Parts List Manual Download

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309067

Rev. A

First choice when

quality counts.

232915

232918

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309067

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Displacement Pump

308815

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Fluid Filter

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Spray Gun

309091

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Spray Tip

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232917

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232919
232914

9659A

9660A

INSTRUCTIONS-PARTS LIST

INSTRUCTIONS

This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.

ULTRA

MAX

695

Airless Paint Sprayer

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

230 VAC

232918, A

Hi-boy sprayer with hoses, gun,
RAC IV

DripLess

Tip Guard and SwitchTip

240 VAC

232914, A

Hi-boy sprayer with hoses, gun,
RAC IV

DripLess

Tip Guard and SwitchTip

232915, A

Lo-boy sprayer with hoses, gun,
RAC IV

DripLess

Tip Guard and SwitchTip

120 VAC

232919, A

Hi-boy sprayer with hoses, gun,
RAC IV

DripLess

Tip Guard and SwitchTip

120 VAC

232910 – 232913, A

232911 Hi–boy & 232913 Lo–boy sprayers with hoses, gun,
RAC IV

DripLess

Tip Guard and SwitchTip

232910 Hi–boy & 232912 Lo–boy sprayers

100 VAC

232916, A; 232917, A

Basic Hi-boy sprayer; Basic Lo-boy sprayer

Table of Contents

Component Function and Identification

. . . . . . . . . . . . . . . . .

General Repair Information

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Brushes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Control Board

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Cord

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On/Off Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Adjusting Potentiometer

. . . . . . . . . . . . . . . . . . . . .

Drive Housing, Connecting Rod, Crankshaft

. . . . . .

Pressure Transducer

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Transducer Seal

. . . . . . . . . . . . . . . . . . . . . .

Drain Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete Sprayer Parts

. . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Phone Number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GRACO INC.

P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

Graco Inc. is registered to I.S. EN ISO 9001

Summary of Contents for ULTRA MAX 695

Page 1: ...Hi boy sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip 120 VAC 232910 232913 A 232911 Hi boy 232913 Lo boy sprayers with hoses gun RAC IV DripLess Tip Guard and SwitchTip 232910 Hi boy 232912 Lo boy sprayers 100 VAC 232916 A 232917 A Basic Hi boy sprayer Basic Lo boy sprayer Table of Contents Component Function and Identification 2 General Repair Information 3 Grounding 4 Troublesho...

Page 2: ...sprayed from source through spray gun J 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends K RAC IV Tip Guard Reverse A Clean RAC tip guard reduces the risk of fluid injection injury L Contractor Gun High pressure spray gun with gun safety latch M RAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip without removing tip from spray...

Page 3: ...ossible solutions WARNING EXPLOSION HAZARD Motor and drive housing are very hot during operation and could burn skin if touched Flammable materials spilled on hot bare motor could cause fire or explosion Have motor shield in place during operation to reduce risk of burns fire or explosion CAUTION Do not run sprayer dry for more than 30 seconds to avoid damaging pump packings 4 Install motor shield...

Page 4: ...p is still clogged relieve pressure refer to separate gun or tip instruction manual for tip cleaning Clean or replace filter element See manual 308249 Mechanical 1 Frozen or hardened paint in pump 18 Use a screwdriver and carefully rotate fan at back of motor See page 12 1 Thaw sprayer if water or water based paint has frozen in sprayer Place spray er in warm area to thaw Do not start sprayer unti...

Page 5: ...t 8 Motor control board 22a by performing motor control board diagnostics on page 13 If diagnostics indicate sub stitute with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board 8 Replace board See page 13 9 Power cord 30 232918 232915 232914 Disconnect brown and blue power cord terminals connect volt meter to ...

Page 6: ...y then release and engage safety latch Relieve pressure turn off and unplug sprayer 2 Service pump See page 11 3 Release gun trigger Observe resting position of pump rod 222 3 If pump consistently comes to rest with rod 222 fully extended the piston packings and or piston valve may be worn Service pump See page 11 4 Electrical supply with volt meter Meter must read 90 110 VAC for 232916 232917 Met...

Page 7: ...hardened paint or nicks and replace if necessary Tighten packing nut 6 Release gun trigger Observe resting position of pump rod 222 6 If pump consistently comes to rest with rod 222 fully extended piston packings and or piston valve may be worn Service pump See page 11 No output motor runs but pump does not stroke 1 Displacement pump connecting rod pin 14 See Fig 9 page 11 1 Replace pin if missing...

Page 8: ...d cause a short 2 Correct faulty conditions 3 Motor armature for shorts Use an armature tester growler or perform motor test See page 9 Inspect windings for burns 3 Replace motor See page 12 4 Motor control board 22a by performing motor control board diagnostics on page 13 If diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor arma ture is determined to ...

Page 9: ...fore coming to complete stop If motor does not spin freely armature is shorted and motor must be replaced See page 12 Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Fig 4 Connect red and black motor leads C together with a test lead Turn motor fan by hand at about two revolutions per second 80 green with yellow stripe 8386A Fig 4 77 67 30 78 C 22a 96 D E black green white black r...

Page 10: ...clip F at a slight angle slide spring clip into brush holder and hook it over end of holder See Fig 7 Pull on spring clip to be sure it stays in place Connect brush lead to blade con nector E 8 Repeat for other side 9 Test brushes a Remove pump connecting rod pin 14 WARNING ELECTRIC SHOCK HAZARD Do not touch the brushes leads springs or brush holders while the sprayer is plugged in to reduce the r...

Page 11: ...ring 15 up and push out pin 14 7 Loosen screws 17 Remove pump 18 Repairing pump See manual 308815 for displacement pump repair instructions and parts Installing pump See Fig 8 and 9 14 201 15 Fig 9 202 7840A 1 Lightly grease or oil transducer 67 See Fig 15 Guide pump over alignment pins and pressure transducer Tap it into position with a soft hammer Tighten screws 17 to 50 ft lb 68 N m 2 Align hol...

Page 12: ...6 Turn displacement pump rod 222 so pin hole aligns with bottom drive housing screw 16 See Fig 11 Remove three drive housing screws and lockwashers 16 4 See Fig 11 and 12 7 Remove two motor screws and lockwashers 3 4 8 Tap lower rear of drive housing 2 with a plastic mallet to loosen motor Pull drive housing straight off motor while guiding pressure transducer wire A from motor Do not allow gear 1...

Page 13: ...ol board 22a See Fig 12 3 Turn ON OFF switch ON 4 Observe LED operation and reference following table LED BLINKS SPRAYER OPERATION INDICATES WHAT TO DO Once Sprayer runs Normal operation Do nothing Twice Sprayer runs Normal operation Do nothing Two times repeatedly Sprayer shuts down and LED continues to blink two times repeatedly Run away pressure Pressure greater than 4500 psi Replace motor cont...

Page 14: ...ires from ON OFF switch 80 and remove switch See Fig 4 5 Install switch so internal tab of anti rotation ring 81 engages with vertical groove in threads of switch and external tab engages with slot of junction box See page 20 6 Powder inside of rubber boot 82 with talcum then shake excess out of boot Install nut and rubber boot and tighten 7 Reconnect black white brown and blue wires to ON OFF swi...

Page 15: ...e usually stay in the gear re cesses but could be dislodged If the balls are not in place the bearings will wear prematurely 7 Tap lower rear of drive housing 2 with a plastic mallet to loosen motor Pull drive housing straight off motor 8 Remove and inspect crankshaft 5 and connecting rod 12 Replace all damaged or worn parts 9 Install connecting rod 10 Lubricate inside of connecting rod bearing wi...

Page 16: ...t the hole in the drive housing 2 Pass a spacer 68 over harness connector A and down into position at bottom of transducer 67 3 Guide harness up through leg and notch of drive housing 2 Secure guide wire over connector 4 While pulling guide wire out through bottom of motor guide harness through drive housing and motor castings 5 Place grommet 65 over harness and push into position in drive housing...

Page 17: ...al minutes CAUTION Excess pressure from the probes or fingernails will damage the packing and cause subsequent leakage 3 Use a blunt wooden or plastic probe and install seal 69 into recess in manifold 229 Be careful not to cause kinks or bends in packing during installation 4 Lightly grease or oil transducer 67 and install pump 18 See page 11 229 Fig 16 69 9666A ...

Page 18: ...at area 2 If replacing gasket 55 or seat 56 pry out gas ket NOTE Whenever gasket 55 is removed replace it with a new one 3 Place seat 56 in drain valve assembly 51 so lapped side is toward ball Apply a small amount of grease to new gasket 55 and install it in drain valve assembly NOTE The gasket will protrude from the end of the valve until the valve is tightened into pump which correctly seats th...

Page 19: ...le spraying with a 017 tip per ISO 3744 Wetted Parts Zinc plated carbon steel Aluminum Stainless steel Polyethylene Delrin Leather Tungsten carbide Chrome plating Polyurethane NOTE and Delrin are trademarks of the DuPont Company Dimensions 232912 232913 232915 232917 232910 232911 232914 232916 232918 232919 Weight dry w o packaging 69 lb 31 kg Length handle collapsed 27 in 686 mm Width 19 5 in 49...

Page 20: ... 14 18 114 2a 5 6 8 2 9 7 41 13 25 22 22a 20 23 99 42 26 95 24 21 75 40 39 70 37 31 32 57 4 3 85 9 105 197 60 103 47 Ref 50 Ref 44 73 72 74 126 71 22a 107 108 78 80 119 96 30 27 82 28 81 77 80 76 78 Ref 20 Ref 20 Ref Pressure Control Box Bottom View 38 49 19 232917 page 22 232914 232915 232918 232919 1 1 9668A 125 126 43 20 309067 Complete Sprayer Parts ...

Page 21: ...IPPLE 1 4 npt x 1 4 npsm 1 47 241937 HOSE suction swivel 1 48 240711 FILTER fluid manual 308249 1 49 195186 CLIP spring 1 50 241936 HOSE drain assy 1 51 235014 ASSEMBLY drain valve 1 includes 55 and 56 52 224807 VALVE base 1 53 111600 PIN grooved 1 54 187625 HANDLE drain valve 1 55 111699 GASKET seat valve 1 56 187615 SEAT valve lapped 1 57 LABEL DANGER English 2 187791 232915 2 189702 232917 2 60...

Page 22: ...75 85 3 4 9 23 24 20 68 67 69 66 100 39 Pressure Control Box Bottom View 76 77 28 78 82 81 80 19 45 98 47 84 71 72 74 73 56 17 32 27 55 51 21 22a 57 60 103 105 99 64 95 112 111 232916 232917 232918 232919 and 232914 page 20 1 114 20 Ref 118 117 30 116 120 232914 A 232916 A 232918 A 232919 A 121 9669 A 67 Ref 77 Ref 116 Ref 22a 107 108 78 80 119 96 1 ...

Page 23: ... 193718 NIPPLE 1 4 npt x 1 4 npsm 2 47 190321 HANGER pail 1 48 240711 FILTER fluid Manual 308249 49 192648 CLIP spring 1 51 235014 ASSY drain valve includes 55 and 56 1 52 224807 VALVE base 1 53 111600 PIN grooved 1 54 187625 HANDLE drain valve 1 55 111699 GASKET seat valve 1 56 187615 SEAT valve lapped 1 57 LABEL DANGER English 187791 232918 232919 and 232914 2 189702 232916 2 60 LABEL WARNING el...

Page 24: ... 25 39 38 40 70 37 31 32 57 42 26 22 35 16 65 8 9 75 85 3 4 9 60 23 24 20 21 68 67 69 66 100 74 71 72 19 73 Model 232912 and 232913 Series A Pressure Control Box Bottom View 76 77 27 78 82 81 80 17 55 56 28 22a 33 103 64 99 95 97 67 Ref 30 Ref 78 22a 96 107 108 77 Ref 80 Ref 71 9670A 110 47 Ref 50 Ref 109 43 ...

Page 25: ...ALL thrust 1 42 107310 PLUG tube 2 43 157191 FITTING adapter 1 44 235004 STRAINER 1 2 npsm 1 46 193718 NIPPLE 1 4 npt x 1 4 npt 1 47 241937 HOSE suction swivel 1 48 240038 FILTER fluid 1 see manual 308249 49 195186 CLIP spring 1 50 241936 HOSE drain assy 1 51 235014 ASSEMBLY drain valve 1 includes 55 and 56 52 224807 VALVE base 1 53 111600 PIN grooved 1 54 187625 HANDLE drain valve 1 55 111699 GAS...

Page 26: ... 15 25 40 38 70 37 31 79 33 42 26 22 35 16 65 8 9 75 85 3 4 9 23 24 20 68 67 69 66 100 39 Model 232910 and 232911 Series A Pressure Control Box Bottom View 76 77 28 78 82 81 80 19 45 98 47 71 72 74 73 56 17 32 27 55 51 21 22a 57 30 Ref 82 Ref 60 103 105 99 64 95 67 Ref 78 22a 96 107 108 77 Ref 9671A ...

Page 27: ...e 2 43 192809 TUBE suction 1 44 187190 STRAINER 1 2 npsm 1 45 112777 SCREW 8 32 x 38 2 46 193718 NIPPLE 1 4 npt x 1 4 npsm 2 47 190321 HANGER pail 1 48 240038 FILTER fluid 1 Manual 308249 49 192648 CLIP spring 1 51 235014 ASSEMBLY drain valve 1 includes 55 and 56 52 224807 VALVE base 1 53 111600 PIN grooved 1 54 187625 HANDLE drain valve 1 55 111699 GASKET seat valve 1 56 187615 SEAT valve lapped ...

Page 28: ...rees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A ...

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