Graco Inc 1095 Premium Hi-Boy, 3A0157A, 795 Premium Hi-Boy, 695 Premium Hi-Boy, 1595 Premium Hi-Boy User Manual

Repair

Electric Airless Sprayers

- For Portable Airless Spraying of Architectural Coatings and Paints -

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

IMPORTANT SAFETY INSTRUCTIONS

Read all warnings and instructions in this manual. Save these instructions.

ti14838a

695/795

695/795 Premium Hi-Boy

ti15034a

3A0157A

ENG

ti15036a

MARK V

ti15035a

1095/1595 Premium Hi-Boy

Related Manuals: Operation 3A0156

Parts 3A0158 Gun 311861

Models:

695 ULTRA MAX lIl

Model QuikReel Hi-Boy Lo-Boy 258719 ✓✓ 258720 ✓ 258722 ✓ 258872 ✓ 258873 ✓ 258874 ✓ 258876 ✓ 258877 ✓✓ 826124 ✓✓ 826125 ✓ 826127 ✓

795 ULTRA MAX III

Model QuikReel Hi-Boy Lo-Boy 258723 ✓✓ 258724 ✓ 258878 ✓✓ 258879 ✓ 258881 ✓ 258882 ✓✓ 826128 ✓✓ 826129 ✓

1095 ULTRA MAX III

Model QuikReel Hi-Boy Lo-Boy 258727 ✓✓ 258728 ✓ 258883 ✓✓ 258884 ✓ 258886 ✓✓ 826130 ✓✓ 826131 ✓

1595 ULTRA MAX III

Model QuikReel Hi-Boy Lo-Boy 258763 ✓✓ 258764 ✓ 258765 ✓✓ 258766 ✓ 826132 ✓✓ 826133 ✓ 826134 ✓✓ 826135 ✓

MARK IV

Model QuikReel Hi-Boy Lo-Boy 258729 ✓✓

MARK V

Model QuikReel Hi-Boy Lo-Boy 258730 ✓✓ 258887 ✓✓

2 3A0157A

Table of Contents

Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Extension Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . .10

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

240 VAC and 110 VAC Motor Control Board . . . . . . . . 21

240 VAC Filter Board . . . . . . . . . . . . . . . . . . . . . . . . .23

Pressure Adjust Potentiometer . . . . . . . . . . . . . . . . . . 24

Pressure Control Transducer . . . . . . . . . . . . . . . . . . .25

Drive and Bearing Housing Replacement . . . . . . . . . . . 27

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Displacement Pump Replacement 695/795/Mark V . . . 31

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Displacement Pump Replacement 1095/1595/Mark V . 33

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Reed Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . 38

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

120V Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

120V Models (with 15/20 Amp Switch): . . . . . . . . . . . 40

240V Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 44

3A0157A 3

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 applicable.

Grounding Instructions

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.

WARNING

GROUNDING

• 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 ground-

ing 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 circuit and has a grounding plug similar to the plug illustrated

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 mm

• An undersized cord results in a drop in line voltage and loss of power and overheating.

) minimum to carry the current that the product draws.

4 3A0157A

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 cig-

arettes, motors, and electrical equipment.

• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity cre-

ates 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.

• Do not clean with materials having flash points lower than 70° F (21° C). Use water-based material or

mineral spirits-type material only. For complete information about your fluid, request the MSDS from the fluid distributor or retailer.

• 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 clean-

ing, 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 spray-

ing, 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.

3A0157A 5

Warnings

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.

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 at main switch before disconnecting any cables and before servicing

equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regula-

tions.

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, fol-

low the Pressure Relief Procedure and disconnect all power sources.

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, hearing loss, inhalation of toxic fumes, and burns. This 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.

6 3A0157A

Component Identification

13.

12.

11.

1 Premium Digital Display 2 ON/OFF switch 3

WatchDog

™

Switch (not available on Mark V) 4 Pressure Control 5 Prime / Spray Valve 6 Filter 7 Siphon Tube 8Pump 9

Bearing Housing / ProConnect 10 Drain Tube 11 Trigger Lock 12 Model/serial tag 13 Hose Reel

6. 7.

™

10.

ti14839a

3A0157A 7

Pressure Relief Procedure

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

dissipate.

ti4265a

2. Lock gun trigger safety. Remove guard and SwitchTip.

ti10166a

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

ti2769a

ti14841a

4. Put drain tube in pail. Turn prime valve down to DRAIN position.

ti2595a

ti14842a

8 3A0157A

Grounding

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 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.

ti2810a

Do not modify plug! Tampering with the plug will result in a voided warranty. If plug will not fit in outlet, have grounded outlet installed by a qualified electrician. Do not use an adapter.

ti4297a

Pails

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.

ti5850a

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.

Power Requirements

• 100-120V units require 100-120 VAC, 50/60 Hz, 15A, 1 phase.

• 230V units require 230 VAC, 50/60 HZ, 10A, 1 phase.

Extension Cord

Use an extension cord with an undamaged ground contact. If an extension cord is necessary, use a 3-wire, 12

AWG (2.5 mm

Ground

120 volt plug

) minimum.

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.

ti13243a

3A0157A 9

Troubleshooting

Mechanical/Fluid Flow

Perform Pressure Relief Procedure; page 8.

TYPE OF PROBLEM

E=XX is displayed

False tripping of WatchDog

system. EMPTY is displayed. Pump does not run.

WHAT TO CHECK

If check is OK, go to next check

1. Fault condition exists 1. Determine fault correction from table,

1. Operating conditions out of WatchDog parameters. Pump output is low, see below.

When check is not OK, refer to this column

page 13.

1. Turn pressure down. Refer to operation manual for adjusting. Operate without WatchDog active; see operation manual.

WHAT TO DO

10 3A0157A

Troubleshooting

TYPE OF PROBLEM

Pump output is low

WHAT TO CHECK

If check is OK, go to next check

When check is not OK, refer to this column

WHAT TO DO

1. Spray tip worn 1. Follow Pressure Relief Procedure on

page 8, then replace tip. See your separate gun or tip manual.

2. Spray tip clogged 2. Relieve pressure. Check and clean spray tip.

3. Paint supply 3. Refill and reprime pump.

4. Intake strainer clogged 4. Remove and clean, then reinstall

5. Intake valve ball and piston ball

are not seating properly

5. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary; see pump manual 310643 or

310894. Strain paint before using to remove particles that could clog pump.

6. Suction hose connections 6. Tighten any loose connections. Check for missing or damaged seals.

7. Fluid filter, tip filter, or tip is

7. Clean filter; see operation manual.

clogged or dirty.

8. Prime valve leaking 8. Relieve pressure. Repair prime valve.

9. Verify pump does not continue to

stroke when gun trigger is

9. Service pump; see pump manual 310643 or 310894.

released. (Prime valve not leaking.)

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

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

11. Pump rod damage 11. Repair pump. See pump manual 310643 or 310894.

12. Low stall pressure 12. Turn pressure knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position. If problem persists, replace pressure transducer.

13. Piston packings are worn or

damaged

14. O-ring in pump is worn or dam-

aged

15. Intake valve ball is packed with

material

13. Replace packings; see pump manual 310643 or 310894.

14. Replace o-ring; see pump manual 310643 or 310894.

15. Clean intake valve; see pump manual 310643 or 310894.

16. Pressure setting is too low 16. Increase pressure; see pump manual 310643 or 310894.

17. Large pressure drop in hose with

heavy materials

17. Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft of 1/4 in. hose significantly reduces performance of sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum).

3A0157A 11

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

No display, sprayer operates

WHAT TO CHECK

If check is OK, go to next check

1. Displacement pump pin (32) damaged or missing; see pump manual 310643 or 310894.

When check is not OK, refer to this column

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod; see pump manual

WHAT TO DO

310643 or 310894.

2. Connecting rod assembly (43) damaged; see pump manual

2. Replace connecting rod assembly; see pump manual 310643 or 310894.

310643 or 310894.

3. Gears or drive housing damaged, page 28.

3. Inspect drive housing assembly and gears for damage and replace if necessary; see pump manual 310643 or 310894.

1. Throat packing nut is loose 1. Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.

2. Throat packings are worn or

damaged

3. Displacement rod is worn or

damaged

2. Replace packings; see pump manual 310643 or 310894.

3. Replace rod; see pump manual 310643 or

310894.

1. Air in pump or hose 1. Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.

2. Tip is partially clogged 2. Clear tip; see tip guard manual 309640.

3. Fluid supply is low or empty 3. Refill fluid supply. Prime pump; see pump manual 310643 or 310894. Check fluid supply often to prevent running pump dry.

1. Air in pump or hose 1. Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.

2. Intake valve is leaking 2. Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.

3. Pump packings are worn 3. Replace pump packings; see pump manual 310643 or 310894.

4. Paint is too thick 4. Thin the paint according to supplier recommendations.

1. Display is damaged or has bad

1. Check connections. Replace display.

connection

12 3A0157A

Electrical

Symptom: Sprayer does not run or stops running.

Perform Pressure Relief Procedure; page 8.

• Plug sprayer into correct voltage, grounded outlet

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

• Turn pressure control knob clockwise 1/2 turn

• View digital display

Troubleshooting

To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting, wait 30 seconds after unplugging power cord for stored electricity to dissipate. Keep clear of electrical and moving parts during troubleshooting procedures.

WARNING

If no digital display is available, use control board status light to troubleshoot problems: Turn ON/OFF switch OFF, remove control cover and then turn power back ON. Observe status light. Blinking LED total count equals digital error code i.e., two blinks equals E=02.

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all See flow chart, page 19. Digital display is blank Control board status light never

lights Sprayer does not run at all Check transducer or transducer Digital display shows E=02

Control board status light blinks 2 times repeatedly

connections

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.

3A0157A 13

Troubleshooting

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all Check transducer or transducer Digital display shows E=03

Control board status light blinks 3 times repeatedly

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

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).

14 3A0157A

+ 30 hidden pages