Graco 309941J User Manual

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Page 1

Repair

Ultrar Max II 695/795/1095/1595t TexSprayt Mark V Airless Sprayers

– For Portable Airless Spraying of Architectural Coatings and Paints –

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

Models: See page 2

309941J

ti4281a

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Page 2

Table of Contents

Component Function and Identification 4. . . . .

General Repair Information 5. . . . . . . . . . . . . . .

Grounding 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical/Fluid Flow 6. . . . . . . . . . . . . . . .

Electrical 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Repair 10. . . . . . . . . . . . . . . .

Models

Vac Model Type Lo-Boy Hi-Boy

695 Standard 248037 248036

Premium 248031 248030

120 795 Standard 248308 248038

North America Premium 248033 248032

1095 Standard 248039

Premium 248034

1595

Mark V 249029**

240 695 248042 248041

Europe 795 248043

1095 248044

Mark V 249031

240 695 248046 248045

Europe Multi-cord 795 248047

1095 248048

Mark V* 249178

110 695 248049

UK 795 248050

1095 248051

Mark V 249072

240 695 248058 248057

Asia 795 248059

1095 248060

240 695 248593 248592

Australia 795 249431 248594

1095 248595

100 695 248053 248052

Japan & Taiwan 795 248055 248054

1095 248056

Standard 248747

248040**

Premium 248746

248035**

249030

Drive and Bearing Housing Replacement 16. .

Motor Replacement 18. . . . . . . . . . . . . . . . . . . . .

Displacement Pump Replacement 20. . . . . . . .

Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 22. . . . . . . . . . . . . . .

ti4281a

Hi-Boy

ti4278a

Lo-Boy

Also for Asia and Australia;

Not ETL Approved

All models not available in all countries.

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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:

D Use equipment only in well ventilated area.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static arc).

D Keep work area free of debris, including solvent, rags and gasoline.

D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

D Ground equipment and conductive objects in work area. See Grounding instructions.

D Use only conductive hoses.

D Hold gun firmly to side of grounded pail when triggering into pail.

D If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

INJECTION HAZARD

High–pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate medical attention.

D Do not point the gun at anyone or at any part of the body.

D Do not put your hand over the spray tip.

D Do not stop or deflect leaks with your hand, body, glove or rag.

D Do not spray without tip guard and trigger guard installed.

D Engage trigger lock when not spraying.

D Follow the Pressure Relief Procedure on page 5 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

ELECTRIC SHOCK HAZARD

Improper grounding, setup or usage of the system can cause electric shock.

D Turn off and disconnect power cord before servicing equipment. Wait 5 minutes after disconnecting

from power source before servicing motor control.

D Use only grounded electrical outlets.

D Use only 3-wire extension cords.

D Ensure ground prongs are intact on sprayer and extension cords.

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:

D Protective eyewear

D Clothing and respirator as recommended by the fluid and solvent manufacturer

D Gloves

D Hearing protection

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.

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Component Identification and Function

Fig. 1

ti2377a

ti4281a

A Motor DC motor, permanent magnet, totally enclosed, fan cooled

B Drive Assembly Transfers power from DC motor to displacement pump

D Displacement Pump Transfers fluid to be sprayed from source through spray gun

E Fluid Outlet Fluid hose is connected here

F Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open

G Fluid Filter Final filter of fluid to spray gun

H Pressure Control Knob Controls fluid outlet pressure

J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump

outlet. Works with pressure adjusting knob.

K ON/OFF Switch Power switch that controls main power to sprayer

M 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends

N Spray Gun High pressure spray gun with gun safety latch

P Spray Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun

R HandTitet Tip Guard Tip guard reduces risk of injection injury

S Gun Safety Latch Gun safety latch inhibits accidental triggering of spray gun. Contractor II gun

shown. Refer to your gun manual to properly set your gun safety latch.

T Hose Rack Holds wrapped hose for storage

U Suction Tube Transfers fluid to be sprayed from source to pump

V Drain Tube Fluid outlet used to drain and prime the sprayer

W AutoClean Reverse flush system

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General Repair Information

Pressure Relief Procedure

WARNING

INJECTION HAZARD

System pressure must be manually relieved to prevent system from starting

or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres- sure Relief Procedure whenever you:

D are instructed to relieve pressure, D stop spraying, D check or service any system equipment, D or install or clean spray tip.

CAUTION

To reduce risk of pressure control malfunction:

D Use needle nose pliers to disconnect wire. Never

pull on wire, pull on connector.

D Mate wire connectors properly. Center flat blade of

insulated male connector in female connector.

D Route wires carefully to avoid interference with

other connections of pressure control. Do not pinch wires between cover and control box.

1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

WARNING

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.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above, VERY SLOWLY loosen tip

guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

Grounding

WARNING

ELECTRIC SHOCK HAZARD MOVING PARTS HAZARD HOT SURFACE HAZARD

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 unplug sprayer when inspection is complete. Install all covers, guards, gaskets, screws, washers and shroud before operating sprayer.

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, pages 6 – 9, for other possible solutions.

Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.

1. Fig. 2. Ultra Max II 695, 795 and 1095 100–120 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. Ultra Max II 1595 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.

Grounding Plug

Fig. 2

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.

Grounded Outlets

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Relieve pressure; page 5.

Mechanical/Fluid Flow

Troubleshooting

TYPE OF PROBLEM

Low or No Fluid/Pressure Output

WHAT TO CHECK

If check is OK, go to next check

1. Spray tip worn 1. Follow Pressure Relief Procedure Warn-

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

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

6. Suction hose connections 6. Tighten any loose connections. Check for

7. Filter clogged 7. Relieve pressure. Check and clean filter.

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

9. Verify pump does not continue to stroke when gun trigger is released. (Prime valve not leaking.)

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

20.

WHAT TO DO

When check is not OK refer to this column

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

tip.

5. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 20. Strain paint before using to remove particles that could clog pump.

missing or damaged seals.

9. Service pump. See page 20.

10.Replace packings, page 20. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

Motor runs but pump does not stroke

11. Pump rod damage 11.Repair pump, page 20

12.Low stall pressure 12. Do either or both: a. Turn pressure control knob fully

clockwise. Make sure pressure control knob is properly installed to allow full clockwise position.

b. Try a new pressure transducer.

1. Displacement pump pin (32) damaged or miss-

ing, page 20

2. Connecting rod assembly (43) damaged,

page 16

3. Gears or drive housing damaged, page 16 3. Inspect drive housing assembly and gears

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod, page 20.

2. Replace connecting rod assembly, page 16

for damage and replace if necessary, page 16

6 309941

Page 7

Troubleshooting

Electrical

Symptom: Sprayer does not run or stops running

D Plug sprayer into correct voltage, grounded outlet

D Set power switch OFF for 30 seconds and then ON

again. This ensures sprayer is in normal run mode.

D Turn pressure control knob clockwise 1/2 turn.

D View digital display

Relieve pressure; page 5.

WARNING

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.

D 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.

DIGITAL DISPLAY

Blank Never lights

–––– psi Blinks once and

CONTROL BOARD STATUS LIGHT

LED 100

stops

INDICATION

No power to control board

No RUN command to control board.

WHAT TO DO

1. Verify required voltage is present

2. Check wiring connections to control board

3. Perform continuity check on power cord and switch. Replace power cord or switch as needed.

4. If steps 1 – 3 are ok, replace control board

1. Make sure prime valve is open and there is no pressure in the system

2. Turn pressure control knob clockwise

3. Check potentiometer connection to control board

4. Check pressure control knob alignment to potentiometer shaft. Turn shaft fully clockwise and attach knob in full ON position.

5. Unplug potentiometer. Short out center pin of control board potentiometer connector to each outer pin (one at a time). If sprayer runs, replace potentiometer, page 15.

6. Check transducer connection

7. Disconnect and reconnect transducer plug to ensure good connection with control board socket. Check that transducer contacts are clean.

8. Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON. Replace transducer If sprayer runs. Replace control board If sprayer does not run.

7309941

Page 8

Electrical

Troubleshooting

DIGITAL DISPLAY

Displays high pressure when prime valve is open and there is no pressure in sprayer.

E=02

E=03

CONTROL BOARD STATUS LIGHT

–

Blinks 2 x repeatedly

Blinks 3 x repeatedly

INDICATION

Improper pressure signal to control

Control board is receiving excessive pressure signal from transducer. Transducer may be damaged or fluid flow path may be clogged.

Transducer or transducer connection error

WHAT TO DO

Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON. Replace transducer If sprayer runs. Replace control board If sprayer does not run.

1. Check fluid path for clogs, such as a clogged filter.

2. Open prime valve and gun if running AutoClean

3. 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.

4. Replace transducer if fluid path is not clogged and proper hose is used

1. Check transducer connection

2. Disconnect and reconnect transducer plug to ensure good connection with control board socket. Check that transducer contacts are ok.

3. Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON. Replace transducer If sprayer runs. Replace control board If sprayer does not run.

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Page 9

Electrical

Troubleshooting

DIGITAL DISPLAY

E=05 Blinks 5 x repeat-

E=06 Blinks 6 x repeat-

E=07 Blinks 7 x repeat-

E=09 Blinks 9 x repeat-

CONTROL BOARD STATUS LIGHT

edly

INDICATION

Possible locked pump or drive. May be motor connection or wiring error.

Motor is too hot or motor/thermal device connection may be bad.

Exceeded 2000 psi during timed flush cycle

Motor sensor failure Make sure motor sensor (resolver) is connected to

WHAT TO DO

1. Check motor wiring connections

2. Check for locked or frozen pump or drive train

3. If all motor wiring connections are OK and pump/ drive train are not locked up, replace motor

1. Check all wire connections from motor to control board

2. If connections are all ok, 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.

This error only occurs in flush timer mode

1. Make sure prime valve and gun are open

2. Make sure no flow obstructions or clogged filter

the control board and check wiring for damage

E=10 Blinks 10 x repeat-

edly

E=11 Blinks 11 x repeat-

edly

E=12 Blinks 12 x repeat-

edly

E=13 Blinks 13 x repeat-

edly

EMPTY

–

High control board temperature

Excessive motor speed

High Current 1. Check for locked or frozen pump or drive train

Model not selected Control board identity resistors must be properly

EMPTY on digital display indicates a loss of paint to the pump or a severe loss in pressure

1. Make sure the motor air intake is not blocked

2. Make sure control board is properly connected to the back plate and that conductive thermal paste is used on the power components, Fig. 3

Check for damaged gears or disconnected pump

2. Check for possible short circuits in wiring

3. Check pressure output and replace transducer if pressure is excessive

clipped to identify model type, manual 310657

1. Check for empty paint condition, clogged inlet strainer, failed pump or severe leak. Turn pressure control knob to zero to restart sprayer.

2. WatchDog (W-DOG) feature can be deactivated. See Operation Manual 309935.

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Page 10

Pressure Control Repair

100 – 120 Vac North American and Japan/Taiwan Motor Control Board

Removal

2. Fig. 3. Remove four screws (38) and cover (96).

3. Disconnect display connector (A) from motor control board (95).

4. Remove bottom two screws (39) and allow control panel (68) to hang down freely.

5. Disconnect control board power lead(s) (D) from ON/OFF switch (33) and motor control board (95).

6. Disconnect potentiometer connector (C) from motor control board.

7. Disconnect 15/20A switch (178) (1595).

8. Disconnect transducer connector (E) from motor control board.

9. Disconnect motor connectors (F, G and H) from motor control board.

10. Remove top two screws (39) and control box (61).

11. Remove five screws (27), three screws (102) and motor control board.

Relieve pressure; page 5. Wait 5 minutes before servicing.

Installation

1. Fig. 3. Apply small amount of thermal compound 110009 (5) to shaded component areas on rear of motor control board (95).

CAUTION

To reduce risk of motor control board failure, do not overtighten screws (102) which can damage the electric components.

2. Install motor control board (95) with five screws (27). Torque to 9–11 in-lb (1.02 – 1.24 N·m). Install and torque three screws (102) to values in Fig 3.

3. Connect motor connectors (F, G and H) to motor control board.

4. Install control box (61) with top two screws (39).

5. Connect transducer connector (E) to motor control board.

6. Connect 15/20A switch (178) (1595).

7. Connect motor control board power lead(s) (D) to ON/OFF switch (33).

8. Connect potentiometer connector (C) to motor control board.

9. Install control panel (68) with two screws (39) .

10. Connect display connector (A) to motor control board.

11. Install cover (96) with four screws (38).

100 – 120 Vac North American and Japan/Taiwan

Fig. 3

178

115

Tighten 1 screw to 14–17 in–lb

102

1595

Tighten 2 screws to 7–10 in–lb

ti4289b

10 309941

Page 11

Removal

240 Vac Motor Control Board

Relieve pressure; page 5. Wait 5 minutes before servicing.

Installation

1. Fig. 4. Apply small amount of thermal compound 110009 (5) to shaded areas on rear of motor control board (95).

2. Fig. 4. Remove four screws (38) and cover (96).

3. Disconnect display connector (A) from motor control board (95).

4. Remove bottom two screws (39). Disconnect potentiometer connector (C) from motor control board (95). Disconnect power cord connectors (D) and filter board connectors (J) from ON/OFF switch (33) and remove control panel (68).

5. Disconnect motor control board power connectors (K) from filter board (146).

6. Remove top two screws (39) and control box (61).

7. Disconnect transducer connector (E) from motor control board.

8. Disconnect motor connectors (F, G and H) from motor control board.

9. Remove five screws (27), three screws (102) and motor control board.

240 Vac Filter Board

Removal

2. Fig. 4. Remove four screws (38) and cover (96).

3. Disconnect display connector (A) from motor control board (95).

Relieve pressure; page 5. Wait 5 minutes before servicing.

CAUTION

To reduce risk of motor control board failure, do not overtighten screws (102) which can damage the electric components.

2. Install motor control board (95) with five screws (27). Torque to 9–11 in-lb (1.02 – 1.24 N·m). Install and torque three screws (102) to values shown in Fig 5.

3. Connect motor connectors (F, G and H) to motor control board.

4. Connect transducer connector (E) to motor control board.

5. Connect motor control board power connectors (K) to filter board (146).

6. Install control box (61) with top two screws (39).

7. Connect filter board power connectors (J) and power cord connectors (D) to ON/OFF switch (33).

8. Connect potentiometer connector (C) to motor control board.

9. Install control panel (68) with two screws (39) .

10. Connect display connector (A) to motor control board (95).

11. Install cover (96) with four screws (38).

Installation

1. Fig. 4. Install filter board (146) with four screws (163).

2. Connect motor control board power connectors (K) to filter board (146).

3. Connect filter board power connectors (J) to top two terminals of ON/OFF switch (33) and power cord connectors (D) to bottom two terminals of ON/OFF switch.

4. Connect potentiometer connector (C) to motor control board (95).

5. Install control panel (68) with two screws (39).

5. Disconnect motor control board power connectors (K) from filter board (146).

6. Remove four screws (163) from filter board (146).

6. Connect display connector (A) to motor control board (95).

7. Install cover (96) with four screws (38).

11309941

Page 12

240 Vac

Tighten 1 screw

to 14–17 in-lb (1.58–1.92 NSm)

Fig. 4

146

163

102

Tighten 2 screws

7–10 in–lb (.79–1.13 NSm)

ti4345a

115

12 309941

Page 13

Removal

110 Vac U.K. Motor Control Board

Relieve pressure; page 5. Wait 5 minutes before servicing.

Installation

1. Fig. 5. Apply small amount of thermal compound 110009 (5) to shaded areas on rear of motor control board (95).

2. Fig. 5. Remove four screws (38) and cover (96).

3. Disconnect display connector (A) from motor control board (95).

4. Remove bottom two screws (39). Disconnect potentiometer connector (C) from motor control board (95). Disconnect filter board connector (J) and power cord connector (D) from ON/OFF switch (33). Remove control panel (68).

5. Disconnect motor control board power connectors (K) from filter board (146). Disconnect filter connector (L) from power cord connector (L).

6. Remove top two screws (39) and control box (61).

7. Disconnect transducer connector (E) from motor control board.

8. Disconnect motor connectors (F, G and H) from motor control board.

9. Remove five screws (27), three screws (102) and motor control board.

110 Vac U.K. Filter Board

Removal

Relieve pressure; page 5. Wait 5 minutes before servicing.

CAUTION

To reduce risk of motor control board failure, do not overtighten screws (102) which can damage the electric components.

2. Install motor control board (95) with five screws (27). Torque to 9–11 in-lb (1.02 – 1.24 N·m). Install and torque three screws (102) to values shown in Fig 5.

3. Connect motor connectors (F, G and H) to motor control board.

4. Connect transducer connector (E) to motor control board.

5. Connect motor control board power connectors (K) to filter board (146). Connect filter connector (L) to power cord connector (L).

6. Install control box (61) with top two screws (39).

7. Fig. 5. Connect filter board power connector (J) and power cord connector (D) to ON/OFF switch (33).

8. Connect potentiometer connector (C) to motor control board.

9. Install control panel (68) with two screws (39) .

10. Connect display connector (A) to motor control board (95).

11. Install cover (96) with four screws (38).

Installation

1. Fig. 5. Connect motor control board power connectors (K) to filter board (146). Connect filter connector (L) to power cord connector (L).

2. Fig. 5. Remove four screws (38) and cover (96).

3. Disconnect display connector (A) from motor control board (95).

5. Disconnect motor control board power connectors (K) from filter board (146). Disconnect filter connector (L) from power cord connector (L).

6. Remove four screws (163) from filter board (146).

2. Install filter board (146) with four screws (163).

3. Fig. 5. Connect filter board power connector (J) and power cord connector (D) to ON/OFF switch (33).

4. Connect potentiometer connector (C) to motor control board (95).

5. Install control panel (68) with two screws (39).

6. Connect display connector (A) to motor control board (95).

7. Install cover (96) with four screws (38).

13309941

Page 14

110 Vac U.K.

Tighten 1 screw

to 14–17 in lb (1.58–1.92 NSm)

Fig. 5

146

163

102

Tighten 2 screws

7–10 in–lb (.79–1.13 NSm)

ti5015a

115

14 309941

Page 15

Pressure Adjust Potentiometer

Removal

2. Fig. 3, 4 or 5. Remove four screws (38) and cover (96).

3. Disconnect potentiometer connector (C) from motor control board (95).

Relieve pressure; page 5. Wait 5 minutes before servicing.

Installation

1. Install gasket (115), nut and potentiometer (82) on control panel (68). Torque nut to 30–35 in-lb (3.38–3.95 N·m).

2. Install pressure control knob (34): Check pressure control knob alignment to potentiometer shaft. Turn shaft fully clockwise and attach knob in full ON position with a hex wrench.

4. Remove pressure control knob (34) with a hex wrench.

5. Remove gasket (115), nut and potentiometer (82) from control panel (68).

Pressure Control Transducer

Removal

2. Fig. 3 or 5. Remove four screws (38) and cover (96).

3. Disconnect transducer connector (E) from motor control board (95).

4. Disconnect potentiometer connector (C) from motor control board.

5. Remove four screws (39) and control box (61). Allow control panel to hang down freely.

6. Remove transducer (86) and o-ring (20) from filter base (67).

Relieve pressure; page 5. Wait 5 minutes before servicing.

3. Connect potentiometer connector (C) to motor control board.

4. Install cover (96) with four screws (38).

7. Remove grommet (40) from transducer and save for reuse.

Installation

1. Install o-ring (20) and transducer (86) in filter base (67). Torque to 35–45 ft-lb (47–61 N·m).

2. Install grommet (40) onto transducer (86).

3. Connect transducer connector (E) to motor control board.

4. Install control box (61) and control panel (68) with four screws (39).

5. Connect potentiometer connector (C) to motor control board.

6. Install cover (96) with four screws (38).

15309941

Page 16

Drive and Bearing Housing Replacement

7. Remove five screws (6) and pull drive housing (90)

CAUTION

off motor (84).

Do not drop gear cluster (89) when removing drive housing (90). Gear cluster may stay engaged in motor front end bell or drive housing.

Disassembly

2. Remove screw (31), two nuts (24), pail hanger (55) and pump rod cover (108).

3. Remove pump (91); Displacement Pump Re-

placement, page 20.

4. Fig. 6. Remove two screws (158) and shroud (72).

5. Remove four screws (158) and front cover (51).

6. Remove four screws (14) and washers (12) to remove bearing housing (83) and connecting rod (85).

Relieve pressure; page 5.

Assembly

Fig. 7. Make sure gear (89) and thrust washers (28, 30, 90a, 36) are in place. Brush grease onto gear teeth.

1. Fig. 6. 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 screws (31).

5. Install pump (41); Displacement Pump Replace-

ment, page 20.

6. Install pump rod cover (108) and pail hanger (55) with screw (31) and two nuts (24).

16 309941

Page 17

158

157

Fig. 6

ti4253a

158

157

43 12

14 31

108

17309941

Page 18

Motor Replacement

Removal

2. Remove pump (91); Displacement Pump Re-

placement, page 20.

Relieve pressure; page 5. Wait 5 minutes before servicing.

CAUTION

Do not drop gear cluster (89) when removing drive housing (90). Gear cluster may stay engaged in motor front end bell or drive housing.

3. Remove drive housing (89); Drive Housing Re- placement, page 16.

4. Fig. 7. Remove four screws (38) and control cover (96).

5. Remove bottom two screws (39) and and allow control panel (68) to hang down freely.

Installation

1. Slide new motor (84) under two screws (23) in cart frame (62) 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 115–135 in-lb (13–15 N·m).

4. Install strain relief (29) onto motor wires and into power bar plate (69).

5. Install control housing (61) with top two screws (39).

6. Connect all three motor connectors to motor control board (95).

6. Disconnect all three motor connectors from motor control board (95).

7. Remove top two screws (39) and control housing (61).

8. Remove strain relief (29) from motor wires and power bar plate (69).

9. Remove two screws (23) and nuts (19) on side opposite control.

10. Loosen two nuts (19) on side near control and remove motor (84) from cart frame (62).

7. Install control panel (68) with two screws (39).

8. Install control cover (96) with four screws (38).

9. Install drive housing (42); Drive Housing Re- placement, page 16.

10. Install pump (13); Displacement Pump Replace-

ment, page 20.

18 309941

Page 19

158

157

90A

(A) 795

157

158

Fig. 7

LED Status Light

ti4254a

19309941

Page 20

Displacement Pump Replacement

See manual 310643 for pump repair instructions.

See manual 309943, 309944 or 309951 – 309954 for applicable sprayer part number references.

Removal

1. Flush pump (13).

3. Fig. 8. Remove screw (31) and slide pump rod shield (108) forward.

ti4258a

Fig. 8

Relieve pressure; page 5.

108

WARNING

If pump pin works loose, parts could break off due to force of pumping action. Parts could project through the air and result in serious injury or property damage.

CAUTION

4. Fig. 10. Cycle pump in JOG mode until pump pin

5. Fig. 9. Remove suction tube (76), hose (94) and

6. Loosen pump jam nut (56). Unscrew pump.

Fig. 9

Installation

4. Screw in pump until threads are flush with drive

5. Fig. 9. Install washers, o-rings and suction tube

6. Fig. 11. Screw jam nut (56) up onto pump until nut

(44) is in position to be removed. Turn power switch OFF and unplug power cord. Push up retaining ring (43) and push pump pin out.

any washers and o-rings.

housing opening. Align pump outlet to back.

(76) and hose (94).

stops. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approxi-

mately 75" 5 ft–lb (102 Nm).

ti4258a

If the pump jam nut loosens during operation, the threads of the drive housing will be damaged.

1. Fig. 10. Extend pump piston rod 1.5 in. Apply grease to top of pump rod at (A) or inside connecting rod.

1.5 in.

Fig. 10

2. Install pump pin (44). Verify retaining spring (43) is in groove of connecting rod (85).

3. Push pump up until pump threads engage.

ti4258a

20 309941

Fig. 11

7. Fig. 8. Install pump rod shield (108) with screw (31).

8. Fig. 12. Fill packing nut with Graco TSL until fluid flows onto top of seal.

ti4258a

Fig. 12

Page 21

Technical Data

Model 100–120V,

A, Hz

695 14, 50/60 9, 50/60 5000 1.75 (1300) 243 (64) 0.75 (2.8) 0.027 N/A 1/4 in.

795 15, 50/60 10, 50/60 5000 2.00 (1490) 195 (52) 0.95 (3.6) 0.031 0.021 1/4 in

1095 15, 50/60 10, 50/60 5000 2.20 (1640) 123 (33) 1.1 (4.1) 0.033 0.023 1/4 in

Mark V N/A 10, 50/60 5000 2.20 (1640) 110 (29) 1.2 (4.3) 0.035 0.023 3/8 in

1595 20/15,

50/60

Mark V 20/15,

50/60

Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

220–240V, ∅, A, Hz

N/A 5000 2.5 (1860) 110 (29) 1.25 (4.7) 0.037 0.025 1/4 in

N/A 5000 2.5 (1860) 110 (29) 1.25 (4.7) 0.037 0.025 3/8 in

Generator Minimum W

Motor HP (W) Cycles per

gallon (liter)

Maximum Delivery gpm (lpm)

Maximum Tip size

1 Gun 2 Guns

Fluid Outlet npsm

Noise Level

Sound power 91 dBa*. . . . . . . . . . . . . . . . . . . . . . . . .

Sound pressure 82 dBa*. . . . . . . . . . . . . . . . . . . . . . .

* per ISO 3744; measured at 3.1 feet (1 m)

Dimensions

Model Weight lb (kg) Height in. (cm) Length

Lo-Boy Hi-boy Lo-Boy Hi-Boy

695 94 (43) 94 (43) 26.5 (67.3) Handle down,

38.8 (98.6) Handle up

795 98 (45) 98 (45) 26.5 (67.3) Handle down,

38.8 (98.6) Handle up

1095 N/A 120 (55) N/A 29.5 (74.9) Handle down,

1595 N/A 125 (57) N/A 29.5 (74.9) Handle down,

Mark V N/A 130 (59) N/A 29.5 (74.9) Handle down,

28.5 (72.4) Handle down,

38.75 (98.4) Handle up

28.5 (72.4) Handle down,

38.75 (98.4) Handle up

38.5 (97.8) Handle up

in. (cm) in. (cm)

25.75 (65.4)

25 (63.5)

26 (66) 22.5

Width

20.5 (52.1)

(57.2)

21309941

Page 22

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 by an authorized Graco distributor 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 procedures concernées.

TO PLACE AN ORDER OR FOR SERVICE, 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.

22 309941

This manual contains English GN 309941 MM 309941

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

www.graco.com

PRINTED IN USA 309941J

12/2003, Rev. 4/2005