Graco DURON Performance Max 395, DURON Performance Max 495, DURON Performance Max 595 Repair Manual

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Page 1

Repair

Performance Max 395/495/595 Airless Sprayers

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

Sprayer

395 233980

495 233981 233982

595 234589 234590

All models not available in all countries.

Important Safety Instructions

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

Related manuals

233980

309714 Rev. C

ti2399

309709. . . . . . .

309665. . . . . . .

Table of Contents

Component Function and Identification 4. . . . .

Grounding 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . .

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

Spin Test 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Brush Replacement 13. . . . . . . . . . . . . .

On/Off Switch Replacement 15. . . . . . . . . . . . .

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

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

309250. . . . . . .

309055. . . . . . .

Pressure Control Repair 16. . . . . . . . . . . . . . . .

Drive Housing Replacement 19. . . . . . . . . . . . .

Motor Replacement 20. . . . . . . . . . . . . . . . . . . . .

Displacement Pump Replacement 21. . . . . . . .

Technical Data 22. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number 22. . . . . . . . . . . . . . . . . . .

309639. . . . . . .

309705. . . . . . .

Page 2

The following Warnings are for the safe 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. Refer back to these Warnings. Additional, product–specific warnings may be found throughout the body of this manual where applicable.

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:

 Use equipment only in well ventilated area.

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

drop clothes (potential static arc).

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

 Sprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or

cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.

 Do not clean with materials having flash points lower than 70F (21C). Use water–based materi-

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

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

 Ground equipment and conductive objects in work area. Read Grounding instructions.

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

until you identify and correct the problem.

 Keep a fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

 Turn off and disconnect power cord before servicing equipment.

 Use only grounded electrical outlets

 Use only 3–wire extension cords.

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

 Do not expose to rain. Store indoors.

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. Seek immediate surgical treat-

ment.

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

 Do not put your hand over the spray tip.

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

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

 Engage trigger lock when not spraying.

 Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

2 309714

checking or servicing equipment.

Page 3

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

 Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

 Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in

all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

 Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco

replacement parts only.

 Do not alter or modify equipment.

 Use equipment only for its intended purpose. Call your Graco distributor for information.

 Route hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces.

 Do not kink or overbend hoses or use hoses to pull equipment.

 Keep children and animals away from work area.

 Comply with all applicable safety regulations.

 Do not operate equipment when fatigued or under the influence of drugs or alcohol.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious injury and/or substantial property damage.

MOVING PARTS HAZARD

Moving parts can pinch 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 equip-

ment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

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:

 Protective eye wear.

 Clothing and respirator as recommended by the fluid and solvent manufacturer.

 Gloves.

 Hearing protection.

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Component Identification and Function

Fig. 1

ti2377a

ti2399

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 Spray gun 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 Adjusting 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 HandTite 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 Power Cord Rack Holds wrapped power cord for storage

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

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

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Page 5

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:

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

1. Lock gun safety latch.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4. Unlock gun safety latch. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open pressure drain valve. Leave pressure drain 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.

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

WARNING

ELECTRIC SHOCK HAZARD MOVING PARTS 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, 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 Guide, pages 7 – 11, for other possible solutions.

WARNING

HOT SURFACES HAZARD EXPLOSION HAZARD

Motor housing may be very hot during operation and could burn skin if touched. Flammable materials spilled on hot, bare motor could cause fire or explosion. Have motor shroud in place during operation to reduce risk of burns, fire or explosion or cut fingers.

CAUTION

To reduce risk of pressure control malfunction:

 Use needle nose pliers to disconnect wire. Never

pull on wire, pull on connector.

 Mate wire connectors properly. Center flat blade of

insulated male connector in female connector.

 Route wires carefully to avoid interference with

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

CAUTION

Do not run sprayer dry for more than 30 seconds to avoid damaging pump packings.

4. Install motor shroud before operation of sprayer and replace if damaged. Motor shroud directs cooling air around motor to prevent overheating. It can reduce risk of burns, fire or explosion, or cut fingers; see preceding WARNING.

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Grounding

WARNING

Your system must be grounded. Read Warnings, page 2.

The sprayer requires:

Grounded Outlets

Grounding Plug

120 VAC

Fig. 2

 100–120 VAC, 50/60 Hz, 15A circuit with a ground-

ing receptacle.

 Do not alter ground prong or use adapter.

 Do not use sprayer if the electrical cord has a

damaged ground prong. Only use an extension cord with an undamaged, 3–prong plug.

Recommended extension cord lengths:

 120 Vac: 300 ft (90 m) 12 AWG (1.0 mm) , 3 wire

with grounding prong

ti3001b

Fluid supply container: follow local codes.

Solvent pails used when flushing: follow local

code. Only use conductive metal pails, placed on grounded surface such as concrete. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

Grounding the metal pail: connect a ground wire to the pail by clamping one end to pail and other end to ground such as a water pipe.

Maintaining grounding continuity when flushing or relieving pressure: hold metal part of spray gun

firmly to the side of a grounded metal pail, then trigger gun.

Long lengths reduce sprayer performance.

Spray gun: ground through connection to a properly grounded fluid hose and pump.

ti6762a

Fig. 3

6 309714

Page 7

Relieve pressure; page 5.

MOTOR WON’T OPERATE

Troubleshooting

TYPE OF PROBLEM

Basic Fluid Pressure Problems

Basic Mechanical Problems

Basic Electrical Problems

WHAT TO CHECK

If check is OK, go to next check

1. Pressure control knob setting. Motor will not run if at minimum setting (fully counterclockwise).

2. Spray tip or fluid filter may be clogged. 2. Relieve pressure and clear clog or clean fil-

1. Pump (41) for frozen or hardened paint. 1. Thaw sprayer if water or water-based paint

2. Displacement pump connecting rod pin (9a). Pin must be completely pushed into connecting rod (9) and retaining spring (9b) must be firmly in groove of pump pin. See Fig. 11.

3. Motor (54). Remove drive housing assembly (42). See page 19. Try to rotate fan by hand.

1. Motor control board. Board shuts down and displays error code.

2. Electrical supply: Meter must read 85–130 Vac.

WHAT TO DO

When check is not OK refer to this column

1. Slowly increase pressure setting to see if motor starts.

ter; refer to separate gun or tip instruction manual.

has frozen in sprayer. Place sprayer in warm area to thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer, replace pump packings. See page 21 (Displacement Pump Replace- ment).

2. Push pin into place and secure with spring retainer.

3. Replace motor (54) if fan won’t turn. See page 20.

1. See Motor Control Board Diagnostics, page 16.

2. Reset building circuit breaker; replace building fuse. Try another outlet.

3. Extension cord. Check extension cord continuity with volt meter.

4. Sprayer power supply cord (56). Inspect for damage such as broken insulation or wires.

3. Replace extension cord.

4. Replace power supply cord.

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Troubleshooting

MOTOR WON’T OPERATE (Continued)

TYPE OF PROBLEM

Basic Electrical Problems (continued)

WHAT TO CHECK

If check is OK, go to next check

1. That motor leads are securely fastened and properly mated.

2. For loose motor brush lead connections and terminals. See page 13.

3. Brush length which must be 1/2 in. minimum. See page 13.

NOTE: Brushes do not wear at the same rate on both sides of motor. Check both brushes.

4. For broken or misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush. See page 13.

5. Motor brushes may be binding in brush holders. See page 13.

6. Motor armature commutator for burn spots, gouges and extreme roughness. See page 13.

7. Motor armature for shorts using armature tester (growler) or perform spin test. See page 12.

WHAT TO DO

When check is not OK refer to this column

1. Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.

Clean circuit board terminals. Securely reconnect leads.

2. Tighten terminal screws. Replace brushes if leads are damaged. See page 13.

3. Replace brushes. See page 13.

4. Replace spring if broken. Realign spring with brush. See page 13.

5. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.

6. Remove motor and have motor shop resurface commutator if possible. See page 20.

7. Replace motor. See page 20.

Refer to wiring diagram, Fig. 8, to identify test points (TP).

1. Power supply cord (56). Connect volt meter between TP1 (neutral) and L2. Plug in sprayer. Meter must read 85–130 Vac. Unplug sprayer.

2. ON/OFF switch (58). Connect volt meter between L1 and L2 terminal on ON/OFF switch. Plug in sprayer and turn ON. Meter must read 85–130 Vac

3. All terminals for damage or loose fit. 3. Replace damaged terminals and reconnect

1. Replace power supply cord.

2. Replace ON/OFF switch. See page 15.

securely.

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Page 9

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM

Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn-

WHAT TO CHECK

If check is OK, go to next check

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

3. Filter clogged. 3. Relieve pressure. Check and clean filter.

4. Prime valve leaking. 4. Relieve pressure. Repair prime valve.

5. Suction hose connections. 5. Tighten any loose connections.

6. Electrical supply with volt meter. Meter must read 85–130 Vac. Low voltages reduce sprayer performance.

7. Extension cord size and length; must be at least 12 gauge wire and no longer than 300 ft. Longer cord lengths reduce sprayer performance.

8. Leads from motor to pressure control circuit board (49) for damaged or loose wires or connectors. Inspect wiring insulation and terminals for signs of overheating.

9. For loose motor brush leads and terminals. See page 13.

WHAT TO DO

When check is not OK refer to this column

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

2. Service pump. See page 21.

6. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.

7. Replace with a correct, grounded extension cord.

8. Be sure male terminal blades are centered and firmly connected to female terminals. Replace any loose terminal or damaged wiring. Securely reconnect terminals.

9. Tighten terminal screws. Replace brushes if leads are damaged. See page 13.

10.For worn motor brushes which must be 1/2 in. minimum. See page 13.

11. For broken and misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.

12.Motor brushes for binding in brush holders. See page 13.

13.Low stall pressure. 13. Do either or both:

14.Motor armature for shorts by using an armature tester (growler) or perform spin test. See page 12.

10. Replace brushes. See page 13.

11. Replace spring if broken. Realign spring with brush. See page 13.

12.Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.

a. Turn pressure control knob fully

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

b. Try a new transducer.

14.Replace motor. See page 20.

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Page 10

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM

Motor runs and pump strokes 1. Paint supply. 1. Refill and reprime pump.

Motor runs but pump does not stroke

WHAT TO CHECK

If check is OK, go to next check

2. Intake strainer clogged. 2. Remove and clean, then reinstall.

3. Suction tube or fittings loose. 3. Tighten; use thread sealant or sealing tape

4. To see if intake valve ball and piston ball are seating properly. See page 21.

5. Leaking around throat packing nut which may indicate worn or damaged packings. See page 21.

6. Pump rod damage. 6. Repair pump, page 21.

1. Displacement pump pin (32) (damaged or missing), page 21.

2. Connecting rod assembly (43) for damage, page 19.

3. Gears or drive housing, page 19. 3. Inspect drive housing assembly and gears

WHAT TO DO

When check is not OK refer to this column

on threads if necessary.

4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 21. Strain paint before using to remove particles that could clog pump.

5. Replace packings, page 21. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod, page 21.

2. Replace connecting rod assembly, page 19.

for damage and replace if necessary, page 19.

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Page 11

Troubleshooting

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF PROBLEM

Motor is hot and runs intermittently.

ELECTRICAL SHORT

TYPE OF PROBLEM

Building circuit breaker opens as soon as sprayer switch is turned on.

CAUTION

Any short in any part of the motor power circuit will cause the control circuit to inhibit sprayer operation. Correctly diagnose and repair all shorts before checking and replacing control board.

WHAT TO CHECK

If check is OK, go to next check

1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up.

2. Be sure ambient temperature where sprayer is located is no more than 90 is not located in direct sun.

WHAT TO CHECK

If check is OK, go to next check

1. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page

20.

2. For missing inspection plate gasket (see page

20), bent terminal forks or other metal to metal contact points which could cause a short.

3. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page

12. Inspect windings for burns.

4. Motor control board (49) by performing motor control board diagnostics on page 16. If diagnostics indicate, substitute with a good board.

F and sprayer

WHAT TO DO

When check is not OK refer to this column

1. Decrease pressure setting or increase tip size.

2. Move sprayer to shaded, cooler area if possible.

WHAT TO DO

When check is not OK refer to this column

1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.

2. Correct faulty conditions.

3. Replace motor. See page 20.

4. Replace with a new pressure control board (35). See page 16.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

Sprayer quits after sprayer operates for 5 to 10 minutes.

CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature can burn out a good board.

1. Basic Electrical Problems on page 7. 1. Perform necessary procedures.

2. ON/OFF switch (58) See page 15. Be sure sprayer is unplugged! Disconnect wires from switch. Check switch with ohmmeter. Reading must be infinity with ON/OFF switch OFF, and zero with switch ON.

3. For damaged or pinched wires in pressure control. See page 16.

1. Basic Electrical Problems on page 7. 1. Perform necessary procedures.

2. Electrical supply with volt meter. Meter must read 85–130 Vac.

3. Tightness of pump packing nut. Over tightening tightens packings on rod, restricts pump action, and damages packings.

2. Replace ON/OFF switch. See page 15.

3. Replace damaged parts. See page 16.

2. If voltage is too high, do not operate sprayer until corrected.

3. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary. See page 21.

11309714

Page 12

Spin Test

Setup

Electric Shock Hazard; page 5.

To check armature, motor winding and brush electrical continuity:

2. Remove drive housing; page 19.

3. Fig. 4. Remove pressure control cover (50). Disconnect connector (F).

4. Fig. 5. Remove motor shroud (23) and inspection covers (A).

Relieve pressure; page 5.

Armature Short Circuit Test

Quickly turn motor fan by hand. If no electrical shorts, motor coasts two or three revolutions before complete stop. If motor does not spin freely, armature is shorted. Replace motor; page 20.

Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity)

1. Connect red and black motor leads with test lead. Turn motor fan by hand at about two revolutions per second.

2. If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair as needed; page 13.

3. If still uneven or no resistance, replace motor; page 20.

Fig. 4

ti2572a

12 309714

Page 13

Motor Brush Replacement

The 395/495/595 sprayer’s motors are supplied by two different motor manufacturers. Style A motor has brush caps held on with screws. Style B has brush caps that snap onto the motor. Determine which style motor you are servicing and refer to the appropriate illustration in the following instructions.

Motor Brush Removal

Replace brushes worn to less than 1/2 in. Brushes wear differently on each side of motor, check both sides. Brush Repair Kit 287735 is available.

1. Read General Repair Information; page 5.

Style A

Fig. 5

ti2571a

2. Relieve pressure; page 5.

3. Fig. 5. Remove motor shroud and two inspection

covers (A).

Style B

4. Fig. 6 . Push in spring clip (A) to release hook (B) from brush holder (C). Pull out spring clip (A).

Included in Brush Repair Kit

Minimum 0.5” (12.5 mm)

ti4194a

BED

ti2542

Style A

Fig. 6

5. Fig. 6. Pull brush lead (D) off of terminal (E). Remove brush (F).

Motor lead; do not disconnect

Minimum 0.5” (12.5 mm)

Included in Brush Repair Kit

Style B

ti4195a

6. Inspect commutator for excessive pitting, burning or gouging. A black color on commutator is normal. Have commutator resurfaced by a motor repair shop if brushes wear too fast.

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Page 14

Motor Brush Replacement

Motor Brush Installation

CAUTION

When installing brushes, follow all steps carefully to avoid damaging parts.

Style A

Fig. 7

1. Fig. 7. Install new brush (F) with lead into brush holder (C).

2. Fig. 7. Slide brush lead (D) onto terminal (E).

3. Fig. 7. Install spring clip (A). Push down to set hook (B) into brush holder (C).

4. Repeat for other side.

5. Test brushes.

a. Remove pump (41); Displacement Pump

Replacement, page 21.

ti4194a

c. Turn sprayer ON. Slowly increase pressure

until motor is at full speed.

Style B

ti4195a

CAUTION

Do not run sprayer dry for more than 30 seconds while checking brushes to avoid damaging displacement pump packings.

6. Install brush inspection covers and gaskets.

7. Break in brushes.

a. Operate sprayer 1 hour with no load.

b. With sprayer OFF, turn pressure control knob

fully counterclockwise to minimum pressure. Plug in sprayer.

14 309714

b. Install pump (41); Displacement Pump Re-

placement, page 21.

Page 15

On/Off Switch Replacement

Removal

2. Fig. 8. Remove four screws (12) and pressure control cover (50).

3. Disconnect two wires (A) from ON/OFF switch (58).

4. Remove toggle boot (30) and locking ring. Remove ON/OFF switch (58).

Relieve pressure; page 5.

37a

Installation

1. Install new ON/OFF switch (58). Install locking ring and toggle boot (30).

2. Connect two wires (A) to ON/OFF switch.

3. Install pressure control cover (50) with four screws (12).

Power Plug Ref 56

ON/OFF Switch Ref 58

TP1

Black

Green

Red (+)

49 6

Potentiometer Ref 37

White

Black

ti2509b

L2 L1

Black

Pressure Transducer Ref 38

Fig. 8

from Motor

Black (–)

2 x White

ti2471a

15309714

Page 16

Removal

Refer to Fig. 8.

Pressure Control Repair

Motor Control Board

Installation

1. Clean pad on rear of motor control board. Apply small amount of thermal compound 073019 to pad.

1. Relieve pressure; page 5.

2. Remove four screws (12) and cover (50).

3. Disconnect all leads to motor control board (49).

4. Remove six screws (6) and circuit board (49).

Motor Control Board Diagnostics

Note: Keep a new transducer on hand to use for test.

CAUTION

Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if test transducer is used.

1. For sprayers with digital display, see Digital Dis-

play Messages, page 17.

LED BLINKS

SPRAYER OPERATION INDICATES

2. Fig. 8. Install motor control board (49) with six screws (6).

3. Connect all leads to motor control board (49). See Fig. 8.

4. Bundle and tie all loose wires so none lay in contact with inductor coil (not 120 Vac sprayers).

5. Install cover (50) with four screws (12).

2. Remove four screws (12) and cover (50). See Fig. 8.

3. Turn ON/OFF switch ON.

4. Observe LED operation and reference following table:

Relieve pressure and un-

plug sprayer before servicing control board; page 5.

WHAT TO DO

Once Sprayer runs Normal operation Do nothing

Two times repeatedly

Three times repeatedly

Four times repeatedly

Five times repeatedly

Six times repeatedly

Sprayer shuts down and LED continues to blink two times repeatedly

Sprayer shuts down and LED continues to blink three times repeatedly

Sprayer shuts down and LED continues to blink four times repeatedly

Sprayer does not start or shuts down and LED continues to blink five times repeatedly

Sprayer shuts down and LED blinks six times repeatedly

Run away pressure. Pressure greater than 4500 psi (310 bar, 31 MPa) or damaged pressure transducer.

Pressure transducer is faulty or missing

Line voltage is too high Check for voltage supply prob-

Motor fault Check for locked rotor, shorted

Motor is too hot or there is a fault in the motor thermal device

Replace motor control board or pressure transducer.

Check transducer connection. Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.

lems

wiring or disconnected motor. Repair or replace failed parts.

Allow sprayer to cool. If sprayer runs correctly when cool, check motor fan function and air fow. Keep sprayer in cool location. If sprayer does not run when cool and continues to blink 6 times, replace motor.

16 309714

Page 17

Pressure Control Repair

Digital Display Messages

No display does not mean that sprayer is not pressurized. Relieve pressure before repair; page 5.

DISPLAY

No Display

psi bar MPa

SPRAYER OPERATION

Sprayer stops. Power is not applied. Sprayer may be pressurized.

Sprayer is pressurized. Power is applied. (Pressure varies with tip size and pressure control setting.)

Sprayer may continue to run. Power is applied.

Sprayer stops. Power is applied.

Sprayer does not start or stops. Power is applied.

Sprayer stops. Power is applied.

INDICATION ACTION

Loss of power Check power source. Relieve pres-

sure before repair or disassembly.

Normal operation Spray

Pressure greater than 4500 psi (310 bar, 31 MPa) or pressure transducer faulty

Pressure transducer faulty, bad connection or broken wire.

Line voltage too high Check for voltage supply problem

Motor fault Check for locked rotor, shorted wir-

Motor it too hot. Allow sprayer to cool. If sprayer

Replace pressure control board or pressure transducer.

Check transducer connection. Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.

ing or disconnected motor. Repair or replace failed parts.

runs correctly when cool, check motor fan function and air fow. Keep sprayer in cool location. If sprayer does not run when cool and continues to blink 6 times, replace motor.

Power is applied.

Sprayer stops. Power is applied.

Pressure less than 200 psi (14 bar, 1.4 MPa)

Empty paint pail. Loss of pressure.

Increase pressure if desired. Drain valve may be open.

Refill paint pail. Check for leaks or clogged pump inlet. Repeat Start-

up procedure.

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Page 18

Pressure Control Repair

Pressure Control Transducer

Removal

Refer to Fig. 8.

2. Remove four screws (12) and cover (50).

3. Disconnect lead (E) from motor control board (49).

4. Remove two screws (47) and filter housing (15).

5. Thread transducer lead plastic connector down through transducer grommet (20).

6. Remove pressure control transducer (38) and packing o-ring (3) from filter housing.

Installation

1. Install packing o-ring (3) and pressure control transducer (38) in filter housing (15). Torque to 30–35 ft-lb.

2. Thread transducer lead plastic connector up through transducer grommet (20).

3. Install filter housing (15) with two screws (47).

4. Connect lead (E) to motor control board (49).

5. Install cover (50) with four screws (12).

Relieve pressure; page 5.

Stored Data (Not available on all sprayers)

Pressure Adjust Potentiometer

Removal

Refer to Fig. 8.

2. Remove four screws (12) and cover (50).

3. Disconnect all leads from motor control board (49).

4. Remove six screws (6) and board (49)

5. Remove potentiometer knob (11), nut (37a) and pressure adjust potentiometer (37).

Installation

1. Install pressure adjust potentiometer (37), nut (37a) and potentiometer knob (11).

a. Turn potentiometer fully clockwise.

b. Install knob at full clockwise position.

2. Install board (49) with six screws (6).

3. Connect all leads to motor control board (49). See Fig. 8.

4. Install cover (50) with four screws (12).

Relieve pressure; page 5.

The SmartControl contains stored data to assist with troubleshooting and maintenance. To view this stored data on the digital display, proceed as follows:

4. Release display button about 1 second after

2. Plug in sprayer.

3. Hold down display button and turn sprayer ON.

Data Point Definition

1 Number of hours power switch has been ON with power applied

2 Number or hours motor has been running

3 Last error code. Press and hold display button to clear error code to E=00

4 Software revision

Relieve pressure; page 5.

turning on sprayer.

Sprayer model number displays (U395, U495) for a few seconds and then data point 1 is displayed.

5. Push display button and next data point displays.

6. Turn sprayer OFF and then ON to leave stored data mode.

18 309714

Page 19

Drive Housing Replacement

CAUTION

Do not drop gear cluster (44) and (40) when removing drive housing (42). Gear cluster may stay engaged in motor front end bell or drive housing.

Disassembly

5. Remove two screws (12) and cover (22).

6. Remove four front screws (47).

7. Pull drive housing (42) off of motor (54).

Assembly

1. Fig. 9. Push drive housing (42) onto motor (54).

2. Remove two screws (12) and pump rod cover (70).

3. Remove pump (41); Displacement Pump Re-

placement, page 21.

4. Fig. 9. Remove two screws (12) and shroud (23).

Relieve pressure; page 5.

2. Install four front screws (47).

3. Install cover (22) with two screws (12).

4. Install shroud (23) with two screws (12).

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

ment, page 21.

6. Install pump rod cover (70) with two screws (12).

Fig. 9

ti2570b

19309714

Page 20

Motor Replacement

Disassembly

2. Remove pump (13); Displacement Pump Re-

placement, page 21.

Relieve pressure; page 5.

CAUTION

Do not drop gear cluster (44) and (40) when removing drive housing (42). Gear cluster may stay engaged in motor front end bell or drive housing.

3. Remove drive housing (42); Drive Housing Re- placement, page 19.

4. Remove four screws (12) and cover (50).

5. Disconnect all leads from board (49). Remove six screws (6) and board.

7. Remove two screws (47) and control housing (48).

8. Remove two screws (47) and manifold (15).

9. Remove four screws (47) and motor (54) from frame (59).

Assembly

1. Install new motor (54) on frame (59) with four screws (47).

2. Install manifold (15) with two screws (47).

3. Install control housing (48) with two screws (47).

4. Install strain relief (19; Fig. 8).

5. Fig. 8. Install board (49) with six screws (6). Connect all leads to board.

6. Install drive housing (42); Drive Housing Re- placement, page 19.

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

6. Remove strain relief (19; Fig. 8).

ment, page 21.

Fig. 10

20 309714

Liberally apply grease

ti2569b

Page 21

Displacement Pump Replacement

See manual 309053 for pump repair instructions.

See manual 309057 or 309058 for sprayer part number references.

Removal

1. Flush pump (13).

3. Fig. 11. Loosen two screws (10b) and rotate cover (10a).

10a

Fig. 11

Relieve pressure; page 5.

10b

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. Cycle pump until pump pin (9a) is in position to be

5. Fig. 12. Remove suction tube (78) and hose (19).

6. Loosen pump jam nut (12). Unscrew pump.

ti2568a

Fig. 12

Installation

3. Push pump up until pump threads engage.

4. Screw in pump until threads are flush with drive

5. Fig. 12. Install suction tube (78) and hose (19).

6. Fig. 14. Screw jam nut (12) up onto pump until nut

removed. Remove pump pin (9a).

ti2568a

housing opening. Align pump outlet to back.

stops. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately 75" 5 ft–lb (102 Nm).

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

1. Fig. 13. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod.

Fig. 13

ti2615a

2. Fig. 11. Install pump pin (9a). Verify retainer spring (9b) is in groove of pump pin.

ti2568a

Fig. 14

7. Fig. 15. Fill packing nut with Graco TSL until fluid flows onto top of seal.

10b

10a

Fig. 15

8. Fig. 11. rotate cover (10a); tighten screws (10b).

ti2568a

21309714

Page 22

Technical Data

Model 100–120V,

∅, A, Hz

395 1, 15, 60 3000 5/8 (466) 680 (180) 0.45 (1.7) 0.021 1/4 in.

495 1, 15, 60 3750 3/4 (560) 680 (180) 0.54 (2.0) 0.023 1/4 in

595 1, 15, 60 4000 9/10 (671) 585 (155) 0.60 (2.3) 0.026 1/4 in

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

NOTE: Delrin and Teflon are registered trademarks of the

zinc-plated carbon steel, nylon, stainless steel, Teflon

, Delrin, chrome plating, leather, UHMWPE,

aluminum, tungsten carbide

DuPont Co.

Generator Minimum W

Motor HP (W)

Cycles per gallon (liter)

Noise Level

Sound power 100 dBa*. . . . . . . . . . . . . . . . . . . . . . . .

Sound pressure 90 dBa*. . . . . . . . . . . . . . . . . . . . . . .

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

Maximum Delivery gpm (lpm)

Maximum Tip size

Fluid Outlet npsm

Dimensions

Weight lb (kg)

Model

Stand 43 (20) 43 (20) N/A 21 (53.3) 15 (38.1) 14 (35.6)

Lo–Boy N/A N/A 69 (31) 21 (53.3) 26 (66.0) 20.5 (52.1)

Hi–Boy N/A 66 (30) 72 (33) 29.5 (74.9) Handle

395 495 595

Height in. (cm) Length in. (cm) Width in. (cm)

21 (53.3) 20.5 (52.1) down, 39.5 (100.3) Handle up

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.

International Offices: Belgium, Korea, China, Japan

Graco Headquarters: Minneapolis

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

www.graco.com

PRINTED IN USA 309714 1/2003, Revised 5/2005

22 309714