Graco 334119B - Express 690/ Express Mark IV Electric Airless Sprayers Owner's Manual

Operation

Express 690 / Express Mark IV

Electric Airless Sprayers

For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

For portable airless spraying of architectural paints and coatings.

3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual and related manuals.

Be familiar with the controls and the proper usage of the equipment.

Save these instructions.

Related Manuals:

344120

312830

311254

334123

334119B

EN

Express 690 Express Mark IV ti24783a

2

Models

Table of Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Requirements . . . . . . . . . . . . . . . . . . . . . 7

Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SwitchTip Installation . . . . . . . . . . . . . . . . . . . . . . 12

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Clear Tip Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . 15

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Models

Part #

17A001

Model

Express 690

17A002 Express 690

17A003

17A004

17C118

17C119

17A005

17A006

Express 690

Express Mark IV

Express 690

Express Mark IV

Express Mark IV

Express Mark IV

Voltage

120

230

Region

North America

South America

Europe

230

120

230

230

230

230

Asia

North America

South America

South America

South America

Europe

Asia

Spray Gun

SG3

(Manual 312830)

SG3

(Manual 312830)

SG3

(Manual 312830)

Flex Plus

(Manual 311254)

SG3

(Manual 312830)

Flex Plus

(Manual 311254)

Flex Plus

(Manual 311254)

Flex Plus

(Manual 311254)

Hose

1/4 in x 50 ft (0.63cm x 15m)

1/4 in x 50 ft (0.63cm x 15m)

1/4 in x 50 ft (0.63cm x 15m)

3/8 in x 50 ft (0.95cm x 15m)

1/4 in x 50 ft (0.63cm x 15m)

3/8 in x 50 ft (0.95cm x 15m)

3/8 in x 50 ft (0.95cm x 15m)

3/8 in x 50 ft (0.95cm x 15m)

334119B

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

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 qualified electrician.

• This product is for use on a nominal 120V or 230V circuit and has a grounding plug similar to the plugs illustrated in the figure below.

120V US 230V

• 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 grounding plug and a grounding 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 mm 2 ) 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.

334119B 3

4

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. All parts of the spray system, 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. Do not use pail liners unless they are are antistatic or conductive.

• 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

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.

• 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.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3000 psi (207 bar, 20.7 MPa). Use Graco replacement parts or accessories that are rated a minimum of 3000 psi (207 bar, 20.7 MPa).

• 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.

334119B

Warnings

334119B

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 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.

• 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.

• Do not spray with a hose shorter than 25 feet.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

ELECTRIC SHOCK HAZARD

This equipment must be grounded .

Improper grounding, 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 PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

CALIFORNIA PROPOSITION 65

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

5

Component Identification

Component Identification

A

B

OFF ON

C

D

E F G H

J

6

A ON/OFF Switch

B Pressure Control

C Filter

D Spray / Prime

E Pump

F Strainer

K L

G Drain Tube

H Model/Serial Tag

J Trigger Lock

K Trigger Lock

L Hose ti23877a

334119B

Grounding

Grounding

Pails

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock.

Grounding provides an escape wire for the electric current.

The sprayer cord includes a grounding wire with an appropriate grounding contact. Do not use the sprayer if the electrical cord has a damaged ground contact.

Solvent and oil/based fluids: follow local code. Use only conductive metal pails, placed on a grounded surface such as concrete.

Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity.

The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

ti7529b ti5850b

Grounding a metal pail: connect a ground wire to the pail by clamping one end to pail and other end to a true earth ground.

Do not modify plug! If it will not fit in outlet, have grounded outlet installed by a qualified electrician. Do not use an adapter.

Power Requirements

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

15A, 1 phase

• 230V units require 220-240 VAC, 50/60 Hz,

10A-16A

Extension Cords

Use an extension cord with an undamaged ground contact.

If an extension cord is necessary, use a 3-wire, 12 AWG

(2.5 mm 2 ) minimum. Longer cords and higher gauge cords reduce sprayer performance.

ti14840a

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.

334119B 7

Operation

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4. Turn pressure to lowest setting. Trigger gun to relieve pressure.

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 Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Turn power OFF. Wait 7 seconds for power to dissipate.

5. Put drain tube in pail. Turn prime valve down to

DRAIN position. Leave prime valve in DRAIN position until you are ready to spray again.

8

2. Engage trigger lock.

3. Remove guard and SwitchTip.

ti2769a ti23849a ti23853a

6. If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved: a. VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually.

b. Loosen nut or coupling completely.

c. Clear hose or tip obstruction.

Trigger Lock

Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

334119B

Setup

4. Remove tip guard.

1. Connect Graco airless hose to sprayer. Tighten securely.

ti2769a

5. Check inlet strainer for clogs and debris.

Setup ti24990a

2. Connect whip hose (if applicable) and gun to other end of hose. Tighten securely.

ti17608b

6. Fill throat packing nut with Graco TSL to prevent premature packing wear. Do this each time you spray.

3. Engage trigger lock.

334119B ti23854a

7. Turn power OFF.

ti23855a ti23849a ti22950a

9

Startup

8. Plug power supply cord into a properly grounded electrical outlet.

9. Turn prime valve down to DRAIN position.

Startup

1. Perform

Pressure Relief Procedure , page 8.

2. Turn pressure control to lowest pressure. ti23856a

10. Place pump in grounded metal pail partially filled with flushing fluid. Attach ground wire to pail and to true earth ground. Perform steps 1 - 5 of Startup to flush out storage oil shipped in sprayer. Use water to flush water-base paint and mineral spirits to flush oil-base paint and storage oil.

3. Turn power ON .

ti13670b ti4266b

4. Increase pressure 1/2 turn to start motor and allow fluid to circulate through drain tube for 15 seconds; turn pressure down.

15sec .

ti23857a

1/2

-

5. Turn prime valve forward to SPRAY position. Disengage trigger lock.

ti23850a

10 334119B

6. Hold gun against grounded metal flushing pail. Trigger gun and increase fluid pressure 1/2 turn. Flush

1 minute.

8. Place pump in paint pail.

Startup ti23851a

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. Do not stop leaks with hand or rag.

7. Inspect for leaks. If leaks occur, perform Pressure

Relief Procedure , page 8. Tighten fittings. Perform

Startup , steps 1 - 5. If no leaks, proceed to step 7.

ti23858a

9. Trigger gun again into flushing pail until paint appears. Move gun to paint pail and trigger for 20 seconds. ti18248a

10. Engage trigger lock. Assemble tip and guard, see instructions on next page.

ti23852a

334119B 11

SwitchTip Installation

SwitchTip Installation Spray

1. Spray test pattern. Increase pressure to eliminate heavy edges. Use smaller tip size if pressure adjustment can not eliminate heavy edges.

1. Perform

Pressure Relief Procedure , page 8.

2. Use spray tip (A) to insert OneSeal ™ (B) into guard (C).

C

B

A ti18243a

2. Hold gun perpendicular, 10-12 in. (25-30 cm) from surface. Spray back and forth. Overlap by 50%. Trigger gun after moving and release before stopping.

ti13023a

3. Insert SwitchTip.

ti18242a

Clear Tip Clog

ti13024a

4. Screw assembly onto gun and tighten.

SKIN INJECTION HAZARD

Never point gun at your hand or into a rag!

1. Release trigger, engage trigger lock. Rotate

SwitchTip. Disengage trigger lock. Trigger gun to clear clog. ti2710a ti13033a

2. Engage trigger lock. Return SwitchTip to original position. Disengage trigger lock and continue spraying.

ti13034a

12 334119B

Cleanup

Cleanup

4. Move gun to waste pail, hold gun against pail, trigger gun to thoroughly flush system. Release trigger and engage trigger lock.

1. Perform Pressure Relief Procedure , page 8,

steps

1 - 4. Remove tip guard from gun.

NOTE : Use water for water-base material, mineral spirits for oil-base material, or other solvents recommended by manufacturer.

2. Turn power ON . Turn prime valve forward to

SPRAY position.

ti18248a

5. Turn prime valve down to DRAIN position and allow flushing fluid to circulate until flushing fluid appears clear.

ti23859a

3. Increase pressure to 1/2. Hold gun against pail. Disengage trigger lock. Trigger gun until flushing fluid appears.

ti23856a

6. Turn prime valve forward to SPRAY position. Trigger gun into flushing pail to purge fluid from hose.

ti22944a ti18249a ti23859a ti18248a

334119B 13

Cleanup

7. Raise pump above flushing fluid and run sprayer for

15 to 30 seconds to drain fluid. Turn power OFF.

10. If flushing with water, flush again with mineral spirits, or Pump Armor, to leave a protective coating to prevent freezing or corrosion.

ti22947a

8. Turn prime valve down DRAIN position. Unplug sprayer.

Pump Armor ti2895a

11. Wipe sprayer, hose and gun with a rag soaked in water or mineral spirits.

ti22945a ti23856a

9. Remove filters from gun and sprayer, if installed.

Clean and inspect. Install filters.

ti2776a ti15018a ti23861a

14 334119B

Troubleshooting

Troubleshooting

Mechanical/Fluid Flow

Perform Pressure Relief Procedure

; page 8.

TYPE OF PROBLEM

Pump output is low

Pump output is low

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK, refer to this column

Spray tip worn

Spray tip clogged

Paint supply

Intake strainer clogged

Intake valve ball and piston ball are not seating properly

Follow Pressure Relief Procedure

on page 8,

then replace tip. See your separate gun or tip manual.

Relieve pressure. Check and clean spray tip.

Refill and reprime pump.

Remove and clean, then reinstall

Remove intake valve and clean. Check balls and seats for nicks; replace if necessary; see pump manual. Strain paint before using to remove particles that could clog pump.

Clean filter; see operation manual.

Fluid filter, tip filter, or tip is clogged or dirty.

Prime valve leaking

Verify pump does not continue to stroke when gun trigger is released.

(Prime valve not leaking.)

Leaking around throat packing nut which may indicate worn or damaged packings.

Relieve pressure. Repair prime valve.

Service pump; see pump manual.

Pump rod damage

Low stall pressure

Replace packings; see pump manual. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

Repair pump. See pump manual.

Turn pressure knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position. If problem persists, replace pressure transducer.

Replace packings; see pump manual.

Piston packings are worn or damaged

O-ring in pump is worn or damaged Replace o-ring; see pump manual.

Intake valve ball is packed with material

Clean intake valve; see pump manual.

Pressure setting is too low

Large pressure drop in hose with heavy materials

Increase pressure; see pump manual.

Use larger diameter hose and/or reduce overall length of hose.

334119B 15

Troubleshooting

TYPE OF PROBLEM

Motor runs but pump does not stroke

Excessive paint leakage into throat packing nut

Fluid is spitting from gun

Pump is difficult to prime

WHAT TO CHECK

If check is OK, go to next check

Displacement pump pin damaged or missing; see pump manual.

Connecting rod assembly damaged; see pump manual.

Gears or drive housing damaged.

Throat packing nut is loose

WHAT TO DO

When check is not OK, refer to this column

Replace pump pin if missing. Be sure retainer spring is fully in groove all around connecting rod; see pump manual.

Replace connecting rod assembly; see pump manual.

Inspect drive housing assembly and gears for damage and replace if necessary; see pump manual.

Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.

Replace packings; see pump manual.

Throat packings are worn or damaged

Displacement rod is worn or damaged

Air in pump or hose

Replace rod; see pump manual.

Tip is partially clogged

Fluid supply is low or empty

Air in pump or hose

Intake valve is leaking

Pump packings are worn

Paint is too thick

Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.

Clear tip; see Operation manual.

Refill fluid supply. Prime pump; see pump manual. Check fluid supply often to prevent running pump dry.

Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.

Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.

Replace pump packings; see pump manual.

Thin the paint according to supplier recommendations.

16 334119B

Troubleshooting

Electrical

Symptom: Sprayer does not run, stops running, or will not shut off.

Control Board Status Light

Perform

Pressure Relief Procedure , page 8.

1. Plug sprayer into correct voltage, grounded outlet.

2. Set power switch OFF for 30 seconds and then ON again (this ensures sprayer is in normal run mode).

3. Turn pressure control knob clockwise 1/2 turn.

4. View digital display.

For units without a display, use control board status lights to troubleshoot problems. Turn the ON/OFF switch OFF, remove the control cover then turn power back ON.

Observe the status light. Blinking LED total count equals the error code (for example: two blinks equals CODE 02).

Keep clear of electrical and moving parts during troubleshooting procedures. To avoid electrical shock hazards when covers are removed for troubleshooting, wait

5 minutes after unplugging power cord for stored electricity to dissipate.

TYPE OF PROBLEM WHAT TO CHECK

Sprayer does not run at all

Control board status light never lights

Sprayer does not run at all

Control board status light blinks

2 times repeatedly

See flow chart, page 22.

Check transducer or transducer connections

HOW TO CHECK

1.

Make sure there is no pressure in the system (see

Pressure Relief Procedure

, page 8

). Check fluid path for clogs, such as clogged filter.

2.

Use airless paint spray hose with no metal braid

1/4 in. x 50 ft minimum. Smaller hose or metal braid hose may result in high-pressure spikes.

3.

Set sprayer to OFF and disconnect power to sprayer.

4.

Check transducer and connections to control board.

5.

Disconnect transducer from control board socket.

Check that transducer and control board contacts are clean and secure.

6.

Reconnect transducer to control board socket.

Connect power, set sprayer ON and control knob

1/2 turn clockwise. If sprayer does not run properly, set sprayer to OFF and go to next step.

7.

Install new transducer. Connect power, set sprayer

ON and control knob 1/2 turn clockwise. Replace control board if sprayer does not run properly.

334119B 17

Troubleshooting

TYPE OF PROBLEM WHAT TO CHECK

Sprayer does not run at all

Control board status light blinks

3 times repeatedly

Check transducer or transducer connections (control board is not detecting a pressure signal).

Sprayer does not run at all

Control board status light blinks four times repeatedly

Check voltage supply to the sprayer (control board is detecting a multiple voltage surges).

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.

4.

Reconnect transducer to control 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 (less than 9k ohm between red and black wires and 3-6k ohm between green and yellow wires).

1.

Set sprayer to OFF and disconnect power to sprayer.

2.

Locate a good voltage supply to prevent damage to electronics.

18 334119B

Troubleshooting

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all

Control board status light blinks

5 times repeatedly

Control is commanding motor to run 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 motor amp draw is excessive.

1.

Remove pump and try to run sprayer. If motor runs, check for locked or frozen pump or drive train.

If sprayer does not run, continue to step 2.

2.

Set sprayer to OFF and disconnect power to sprayer.

3.

Disconnect motor connector(s) from control board socket(s). Check that motor connector and control board contacts are clean and secure. If contacts are 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 to motion should be felt at the fan.

The motor should be replaced if no resistance is felt.

Repeat for pin combinations 1 & 3 and 2 & 3. Pin 4

(the green wire) is not used in this test. If all spin test is positive, continue to step 6.

Green Blue Red Black

STEP 1:

STEP 2:

Green Blue Red Black

STEP 3:

Green Blue Red Black

334119B 19

Troubleshooting

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all

Control board status light blinks

5 times repeatedly

Control is commanding motor to run 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 motor amp draw is excessive.

6.

Perform Field 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 zero

Ohms.

ti13140a

Sprayer does not run at all

Control board status light blinks

6 times repeatedly

Allow sprayer to cool. If sprayer runs when cool, correct cause of overheating. Keep sprayer in cooler location with good ventilation. Make sure motor air intake is not blocked.

If sprayer still does not run, follow

Step 1.

NOTE: Motor must be cooled down for the test.

1.

Check thermal device connector (yellow wires) at control board.

2.

Disconnect thermal device connector from control board socket. Make sure contacts are clean and secure. Measure resistance of the thermal device. If reading is not correct, replace motor.

Check Motor Thermal Switch: Unplug thermal wires. Set meter to ohms. Meter should read zero

Ohms.

20

ti13140a

3.

Reconnect thermal device connector to control board socket. Connect power, turn sprayer ON and control knob 1/2 turn clockwise. If sprayer does not run, replace control board.

334119B

Troubleshooting

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all

Control board status light blinks eight times repeatedly

Sprayer does not run at all

Control board status light blinks

10 times repeatedly

Check voltage supply to the sprayer

(incoming voltage too low for sprayer operation)

1.

Set sprayer to OFF and disconnect power to sprayer.

Check to see if control board is over heating.

2.

Remove other equipment that uses the same circuit.

3.

Locate a good voltage supply to avoid damage to electronics.

1.

Make sure motor air intake is not blocked.

2.

Make sure fan has not failed.

3.

Make sure control board is properly connected to back plate and that conductive thermal paste is used on power components.

4.

Replace control board.

Excessive current protection enabled

5.

Replace motor.

1.

Cycle power on and off. Sprayer does not run at all

Control board status light blinks

12 times repeatedly

Sprayer does not run at all

Control board status light blinks

15 times repeatedly

Check the connections above the motor

Sprayer does not run at all

Control board status light blinks

16 times repeatedly

Check the connections. Control is not receiving a motor position sensor signal

1.

Set sprayer to OFF and disconnect power to sprayer.

2.

Remove motor shroud.

3.

Disconnect motor control and inspect for damage at connectors.

4.

Reconnect motor control.

5.

Turn power on. If code continues, replace motor.

1.

Turn power OFF.

2.

Disconnect motor position sensor and inspect for damage at connectors.

Sprayer does not run at all

Control board status light blinks

17 times repeatedly

Check voltage supply to the sprayer, (sprayer plugged into wrong voltage) ti18685a

3.

Reconnect sensor.

4.

Turn power ON. If code continues, replace motor.

1.

Set sprayer to OFF and disconnect power to sprayer.

2.

Locate a good voltage supply to avoid damage to electronics.

334119B 21

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 17).

No light

Once

Light on

Continuously

Normal operation

Control board commanding motor to run

Flashing See Code section for further troubleshooting

See Step 1. Do you have over

100 VAC

(220 VAC for

230V units)?

YES

NO

See Step 2. Do you have over

100 VAC

(220 VAC for

230V units)?

YES

NO

Repair or replace power cord.

Replace the

ON/OFF switch.

22

See Step 3. Is the proper reading present through the thermal switch wires?

NO

YES

If motor is hot, let cool and retest. If Step 3 still shows incorrect resistance, replace motor. The motor has a defective thermal device.

See step 4. Does the motor run?

NO

Connect a test transducer to the board. Does the motor run?

YES

YES

Replace potentiometer.

Replace the transducer

NO

Replace the control board.

334119B

200-240V

-

V

STEP 1:

Plug power cord in and turn switch ON.

Connect probes to on/off switch. Turn meter to AC Volts.

-

STEP 3:

Check motor thermal switch.

Unplug yellow wires. Meter should read zero Ohms.

NOTE: Motor should be cool during reading.

STEP 4:

Disconnect potentiometer.

Plug power cord in and turn switch ON.

-

200-240V

STEP 2:

Plug power cord in and turn switch ON.

Connect probes to on/off switch. Turn meter to AC Volts.

Troubleshooting

334119B 23

Troubleshooting

Sprayer Will Not Shut Off

1. Perform Pressure Relief Procedure

; page 8.

Leave prime valve open and power switch OFF.

Troubleshooting Procedure

2. Remove control box cover so the control board status light can be viewed if available.

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.

YES

Unplug the transducer from control board. Does motor stop running?

YES

Bad transducer. Replace and test with a new one.

NO Replace the control board.

24 334119B

Wiring Diagrams

120V Models

Wiring Diagrams

Potentiometer

Blue

Pressure

Tr a nsducer

Bl a ck

On/Off

Switch

Blue

Motor Senser Le a ds

Bl a ck

Green

Ground

Therm a l Switch

Motor

Green

Ground

Power Plug

White

Motor Le a ds ti23870a

334119B 25

Wiring Diagrams

230V Models

Bl a ck

Blue

Potentiometer

Pressure

Tr a nsducer

Brown

On/Off

Switch

Blue

Green

Ground

Motor Senser Le a ds

Blue

Brown

Therm a l Switch

Motor

Power Plug

Motor Le a ds ti23869a

26 334119B

Technical Data

Technical Data

Express Sprayers

Sprayer

Maximum Delivery

Maximum Tip Size

Fluid Outlet npsm

690

Mark IV

Cycles

Generator Minimum

120V, A, Hz

230V, A, Hz

Dimensions

Weight:

Height:

Width:

Wetted parts

Noise Level:

Sound Power

Sound Pressure

U.S.

0.95 gpm

0.031

1/4 in.

3/8 in.

226 per gallon

5000 W

14.8, 50/60

9, 50/60

94 lb

28.5 in. (Handle down)

38.75 in. (Handle up)

Metric

3.6 lpm

0.031

1/4 in.

3/8 in.

60 per liter

5000 W

14.8, 8, 50/60

9, 50/60

43 kg

72.4 cm (Handle down)

98.4 cm (Handle up)

22.5 in.

57.2 cm zinc- and nickel-plated carbon steel, nylon, stainless steel, PTFE, Acetal, leather, UHMWPE, aluminum, tungsten carbide, PEEK, brass

91 dBa*

82 dBa*

91 dBa*

82 dBa*

*per ISO 3744; measured at 3.1 ft *per ISO 3744; measured at 1 m

334119B 27

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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the 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 buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees 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

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 334119

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision B - November 2014