309251E Ultra Max 695/795/1095 Airless Paint Sprayers

REPAIR
309251
Rev. E
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
Ultra Max695/795/1095
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
220–240 VAC
120 VAC (North America)
Sprayer
Series Lo–boy Hi–boy Parts
Sprayer
Series Lo–boy Hi–boy Parts
695
B
245005
245004 309253
245009
695
B
245002
245000 309252
A
795
A
245025
245024 309261
245027
1095
A
245003
245011
245051
246309
245001
245010
245050
246308
795
A
245022
245023
245020 309260
245021
245028
1095
A
245034 309261
245038
100–120 VAC (U.K., Japan, Taiwan)
Sprayer
Series Lo–boy Hi–boy Parts
695
B
795
A
1095
A
245008
245006 309253
245007
245026 309261
245037
254035 309261
245036
North
America Global
. . . . . . . 309252 309253 (695)
. . . . . . . 309260 309261 (795/1095)
Related manuals
. . . . . . . 309250 (695)
. . . . . . . 309257
Operation
. . . . . . . 309277 (795/1095)
Pump
Parts
. . . . . . . 309640
. . . . . . . 309639
Spray Gun
245030 309260
245031
245032
245039
Spray Tip
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Function and Identification . . . . . . . . . . . . 3
General Repair Information . . . . . . . . . . . . . . . . . . . . . . 4
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . 9
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 13
GRACO INC.
P.O. BOX 1441
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 20
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Displacement Pump Replacement . . . . . . . . . . . . . . . 23
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MINNEAPOLIS, MN
COPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
WARNING
ADVERTÊNCIA
Fire and explosion hazard: Solvent and paint fumes can ignite or
explode.
To help prevent a fire and explosion:
Use only in an extremely well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes and
plastic drop cloths (static arc hazard). Do not plug or unplug power
cords or turn lights on or off in spray area.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of grounded pail when triggering into pail.
Use only conductive airless paint hose.
Do not use 1,1,1-trichloroethane, methylene chloride, other
halogenated hydrocarbon solvents or fluids containing such
solvents in pressurized aluminum equipment. Such use could
result in a chemical reaction, with the possibility of explosion.
To reduce risk of electric shock, use grounded outlet only. Shut
OFF and unplug when repairing.
Perigo de incêndio e explosão: os solventes e os vapores da pintura
poderão explodir ou incendiar.
Para ajudar a evitar incêndio e explosão:
Utilize unicamente em áreas extremamente bem ventiladas.
Elimine todas as fontes de ignição, tais como luzes piloto, cigarros e
arcos de estática resultantes dos plásticos de proteção. Não ligue nem
desligue os cabos de alimentação ou as luzes numa área de
pulverização.
Ponha em contato com a terra o pulverizador, o objeto a ser
pulverizado, e os baldes de tinta e de solventes.
Segure a pistola firmemente de encontro ao lado do balde em contato com
a terra, quando estiver descarregando para dentro do mesmo.
Utilize somente tubos flexíveis condutores para pintura a alta pressão.
Não utilize 1,1,1-tricloroetano, cloreto de metileno, outros solventes de
hidrocarbonetos halogenados ou líquidos contendo tais solventes em
equipamento de alumínio pressurizado. Tal utilização poderá
resultar numa reação química, com possibilidade de explosão.
Para reduzir o risco de choque elétrico, use a tomada aterrada
somente. Feche FORA e desconecte ao reparar.
Fluid injection and high pressure hazard: High pressure spray or
leaks can inject fluid into the body.
Perigo de injeção de líquidos à alta pressão: a pulverização ou vazamentos à alta pressão podem injetar líquido no corpo.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Keep clear of nozzle and leaks.
Never spray without a tip guard.
Do PRESSURE RELIEF if you stop spraying or begin servicing
sprayer.
Do not use components rated less than sprayer Maximum
Working Pressure.
Never allow children to use this unit.
Para ajudar a evitar injeção de líquido, faça sempre o seguinte:
Engate o trinco de segurança do gatilho quando não estiver pulverizando.
Mantenha-se afastado dos bocais e locais onde há vazamentos.
Nunca pulverize sem que haja uma proteção na extremidade.
ALIVIE A PRESSÃO quando parar de pulverizar e antes de iniciar a
manutenção do pulverizador.
Não utilize componentes com uma classificação inferior à do pulverizador
Pressão Máxima de Trabalho.
Nunca permita que crianças utilizem esta unidade.
If high pressure fluid pierces your skin, the injury might look like
“just a cut”. But it is a serious wound! Get immediate medical attention.
Se o líquido a alta pressão penetrar na sua pele, o ferimento poderá
parecer “simplesmente um corte”. Mas é um ferimento grave! Procure o
médico imediatamente.
MISE EN GARDE
ADVERTENCIA
Danger d’incendie et d’explosion : les gaz de solvant et de peinture
peuvent s’enflammer ou exploser.
Pour éviter les risques d’incendie et d’explosion :
N’utiliser l’appareil que dans une zone extrêmement bien aérée.
Éliminer toute source d’inflammation ; telle que veilleuses, cigarettes et
arcs d’électricité statique créés par les toiles de peintre en plastique. Ne
pas brancher et débrancher de cordons électriques, ou allumer et
éteindre des lumières dans la zone de pulvérisation.
Mettre à la terre le pulvérisateur, l’objet à pulvériser ainsi que les seaux
de peinture et de solvants.
Tenir le pistolet fermement contre la paroi d’un seau mis à la terre lorsqu’on
pulvérise dans le seau.
N’utiliser qu’un flexible pour peinture pulvérisée sans air.
Ne jamais utiliser de trichloroéthane 1,1,1, de chlorure de méthylène,
d’autres solvants à base d’hydrocarbures halogénés, ni de produits
contenant de tels solvants dans un équipement sous pression en aluminium. Cela pourrait provoquer une réaction chimique avec risque d’explosion.
Pour réduire le risque de décharge électrique, employez la sortie au
sol seulement. Coupez et débranchez quand la réparation.
Peligro de incendio o explosión: Los gases de los disolventes y de la
pintura pueden inflamarse o provocar una explosión.
Para prevenir incendios y explosiones:
Use únicamente en un área muy bien ventilada.
Suprima todas las fuentes de ignición; como luces piloto, cigarrillos y
arcos estáticos de carpetas plásticas para protección contra pintura. No
enchufe ni desenchufe cables de alimentación ni apague ni encienda las
luces en un área de pulverización.
Ponga a tierra el pulverizador, el objeto que recibe el chorro pulverizado,
las cubetas de pintura y disolvente.
Sostenga firmemente la pistola a un lado de la cubeta puesta a tierra
cuando dispare dentro de ella.
Use solamente mangueras para pintura conductora sin aire.
No utilice nunca tricloretano-1,1,1, cloruro de metileno ni otros
disolventes a base de hidrocarburos halógenos o fluidos que contengan
dichos disolventes en un equipo a presión de aluminio. El uso de estas
sustancias puede provocar una intensa reacción química, con riesgos
de explosión.
Para reducir el riesgo de la descarga eléctrica, utilice el enchufe
puesto a tierra solamente. Apague y desenchufe al reparar.
Danger d’injection de fluide et haute pression : la pulvérisation sous
haute pression ou les fuites peuvent injecter des fluides dans le corps.
Pour éviter les risques d’injection, toujours :
Bloquer le loquet de sécurité de la gâchette à la fin de la pulvérisation.
Se tenir loin de la buse et des fuites.
Ne jamais pulvériser sans anti-gouttes.
DÉCHARGER LA PRESSION à la fin de la pulvérisation ou avant de
réparer le pulvérisateur.
Ne pas utiliser de composants dont la pression nominale est inférieure à
la pression maximale de service du système.
Ne jamais permettre aux enfants d’utiliser cet appareil.
Si un fluide haute pression perce la peau, la blessure peut paraître
une “simple coupure” Mais il s’agit bien d’une lésion grave! Consulter
immédiatement un médecin.
Peligro de inyección de fluido y alta presión: por la pulverización o las
filtraciones a alta presión se pueden inyectar fluidos en el organismo.
2
309251
Para prevenir la inyección en la piel, siempre:
Enganche el seguro del gatillo cuando no use el pulverizador.
No se acerque a la boquilla ni a las filtraciones.
Nunca aplique fluido pulverizado sin un guardaboquilla.
Realice el ALIVIO DE PRESIÓN si deja de pulverizar fluido o repara el
pulverizador.
No use componentes de capacidad nominal inferior a la presión máxima
de operación del pulverizador.
No permita que niños usen esta unidad.
Si fluido de alta presión le penetra la piel, la lesión podría parecer “sólo
un corte”. ¡Es una lesión seria! Consulte de inmediato al médico.
Component Identification and Function
T
A
B
R
P
S
ti2377a
G
J*
K
L
H
F
D
V
E
W*
U
M
N
Fig. 1
ti0866A
ti2377a
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, drain and flush sprayer when open
G
Fluid Filter
Final filter of fluid to spray gun
H
Pressure Adjusting Knob
Controls fluid outlet pressure
J*
Pressure Control/Display
Controls motor speed to maintain fluid outlet pressure. Works with pressure adjusting knob. Displays pressure, gallons/liters, flush time and error codes.
K
ON/OFF Switch
Power switch that controls main power to sprayer
L
15/20A or 10/12A Switch
Set to lower Amperage if circuit breaker trips when spraying (not all models)
M
Airless Paint Spray Hose
Grounded, conductive, nylon hose with spring guards on both ends
N
Spray Gun
High pressure spray gun with gun safety latch
P
RAC X SwitchTip
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
T
Power Cord & Hose Rack
Holds wrapped power cord and paint 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 valve
Spray gun connection for timed back–flush of sprayer with automatic shut off
*
Not available on all sprayers
309251
3
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 Pressure 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 and pressure control
knob to zero.
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.
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 repairing. Install all covers,
gaskets, screws and washers before
operating sprayer.
4
309251
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect wires. 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.
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
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 5 – 8, for other possible solutions.
WARNING
HOT SURFACES HAZARD
EXPLOSION HAZARD
Motor 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.
4. Install motor shroud before operation of sprayer and replace if damaged. Motor shroud directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Grounding
WARNING
Grounded
Outlets
Improper installation or alteration of grounding plug
results in risk of electric shock, fire or explosion
that could cause serious injury or death.
1. All models require a grounded outlet for power
connection. Circuit must be 50/60 Hz with an
Ampere rating equal to or greater than the sprayer.
See Fig. 2.
2. Do not alter ground prong or use adapter.
Grounding Plug
120 Vac model shown
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.
Troubleshooting
Relieve pressure; page 4.
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor won’t operate
1. Check digital display for error codes on spray- 1. If an error code (E=0X) is displayed or LED is
ers with digital displays or motor control board
blinking, go to page 18 for error code diaginside SmartControl for blinking LED on spraynostics. If not continue.
ers without digital displays
2. Make sure digital display is connected. If noth- 2. Tighten any loose power connections. Reing is displayed, check power cord, power
place power switch, power cord or extension
switch and all power connections for continuity.
cords if damaged. Reset circuit breaker if
Check building circuit power.
tripped.
3. Check pressure control knob setting. Motor will 3. Increase pressure setting
not run if pressure control knob is at minimum
setting.
4. With drain valve open and pressure control 4. Based on results of this test, investigate for
knob set to maximum, check if there is a light
possible wiring, motor, control, transducer or
blinking next to either psi, bar, or MPa
potentiometer problems in the following
steps
a. If light is blinking, control board is
commanding motor to run and problem is most likely motor or motor
wiring.
b. If light is not blinking, control board,
control board wiring, potentiometer
or transducer is most likely cause.
309251
5
Troubleshooting
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Motor
1. Connections at control board and brushes
1. Repair any loose connections
2. Brushes worn. Length must be 1/2 in. minimum. 2. Replace brushes. Page 9.
Check both sides.
3. Broken or misaligned brush springs
3. Realign or replace springs
4. Brushes or springs binding in brush holder
4. Clean brush holder and align brush leads for
free movement
5. Check for armature short using an armature 5. Replace motor
tester (growler) or perform spin test. Page 9.
6. Check motor armature commutator for burn 6. Remove motor and have motor shop resurspots or other damage
face commutator if possible. Page 22.
Control board or wiring
Control/sensor
6
309251
1. Loose control board wiring
1. Repair any loose connections
2. Damaged control board
2. Replace control board
1. Potentiometer damaged
1. Replace potentiometer
2. Pressure transducer damaged
2. Replace pressure transducer
Troubleshooting
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low or fluctuating output
1. For worn spray tip.
1. Follow Pressure Relief Procedure Warning, then replace tip. See your separate
gun or tip manual.
2. Verify pump does not continue to stroke when 2. Service pump. See page 23.
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.
6. Reset building circuit breaker; replace
Meter must read:
building fuse. Repair electrical outlet or try
210–255 Vac for 220–240 Vac models.
another outlet.
85–130 Vac for 100–120 Vac models. Low voltages reduce sprayer performance.
7. Extension cord size and length; must be at least 7. Replace with a correct, grounded exten12 gauge wire and no longer than 300 ft. Longer
sion cord.
cord lengths reduce sprayer performance.
8. Low stall pressure.
8. Do either or both:
c.
Turn pressure control knob fully
clockwise. Make sure pressure
control knob is properly installed
to allow full clockwise position.
d. Try a new transducer.
9. Motor armature for shorts by using an armature 9. Replace motor. See page 22.
tester (growler) or perform spin test. See page
9.
10.
Paint supply.
10.Refill and reprime pump.
11.
Intake strainer clogged.
11. Remove and clean, then reinstall.
12.
Suction tube or fittings loose.
12.Tighten; use thread sealant or sealing tape
on threads if necessary.
13.
To see if intake valve ball and piston ball are 13.Remove intake valve and clean. Check
seating properly. See page 23.
balls and seats for nicks; replace if necessary, page 23. Strain paint before using to
remove particles that could clog pump.
14. Leaking around throat packing nut which may 14.Replace packings, page 23. Also check
indicate worn or damaged packings. See page
piston valve seat for hardened paint or
23.
nicks and replace if necessary. Tighten
packing nut/wet-cup.
15. Pump rod damage
15.Repair pump, page 23.
Motor runs but pump does not 1. Displacement pump pin (114) (damaged or 1. Replace pump pin if missing. Be sure remissing), page 23.
tainer spring (27) is fully in groove all
stroke
around connecting rod, page 23.
2. Connecting rod assembly (9) for damage, page 2. Replace connecting rod assembly,
21.
page 21.
3. Gears or drive housing, page 21.
3. Inspect drive housing assembly and gears
for damage and replace if necessary,
page 21.
309251
7
Troubleshooting
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Building circuit breaker opens
1. Current limit exceeded
1. Switch to another circuit with less load. If
sprayer has a 15/20A or 10/12A switch,
change to lower value.
2. All electrical wiring for damaged insulation, and 2. Repair or replace any damaged wiring or
all terminals for loose fit or damage. Also wires
terminals. Securely reconnect all wires.
between pressure control and motor. See page
22.
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.
3. For missing inspection plate gasket (see page 3. Correct faulty conditions.
22), bent terminals or other metal to metal contact points which could cause a short.
4. Motor armature for shorts. Use an armature 4. Replace motor. See page 22.
tester (growler) or perform spin test. See page
9. Inspect windings for burns.
5. Motor control board (35) by performing motor 5. Replace with a new pressure control board
control board diagnostics on page 16. If diag(35). See page 16.
nostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
Display reads all 8’s
Switches on back of display are set
incorrectly.
AutoClean problem
Manual 309278
8
309251
Set the four switches psi, bar, MPa and
liters/gallons to proper settings for your
sprayer. Fig. 13, page 16.
Spin Test
Setup
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Electric Shock Hazard; page 4.
To check armature, motor winding and brush electrical
continuity:
1.
Relieve pressure; page 4.
1. Fig. 3. Connect red and black motor leads together
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 9.
3. If still uneven or no resistance, replace motor;
page 22.
2. Remove drive housing; page 21.
3. Fig. 10. Remove four screws (60), pressure control
cover (49), two screws (108), control panel (67).
Fig. 3. Disconnect motor connector (F).
4. Fig. 4. Remove motor shroud (90) and inspection
covers (A).
F
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 22.
ti0941
Fig. 3
Motor Brush Replacement
695 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 243214 is available. Spring
clip, 112766, may be purchased separately.
90
1. Read General Repair Information; page 4.
2.
Relieve pressure; page 4.
7703B
3. Fig. 4. Remove motor shroud (90) and two inspection covers (A).
(Continued on page 10)
A
Fig. 4
309251
9
Motor Brush Replacement
4. Fig. 5. Push in spring clip (A) to release hook (B)
from brush holder (C). Pull out spring clip (A).
CAUTION
5. Fig. 5. Pull brush lead (D) out of terminal (E).
Remove brush (F).
When installing brushes, follow all steps carefully to
avoid damaging parts.
1
Motor lead; do not disconnect
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair Kit
1. Fig. 6. Install new brush (F) with lead into brush
holder (C).
3
2. Fig. 5. Slide brush lead (D) into terminal (E).
3. Fig. 6. Install spring clip (A). Push down to set
hook (B) into brush holder (C).
2
B
695 Motor Brush Installation
1
F
A
1
F
C
B
E
C
D
Fig. 5
03881
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.
E
Fig. 6
03881
4. Repeat for other side.
5. Test brushes.
a. Remove pump (79); Displacement Pump
Replacement, page 23.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c.
Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
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. Install pump (79); Displacement Pump Replacement, page 23.
10
309251
Motor Brush Replacement
795/1095 Motor Brush Removal
NOTE: Replace brushes worn to less than 1/2 in.
Brushes wear differently on each side of motor,
check both sides. Brush Repair Kit 220853 is
available. Spring clip, 110816,
may be
purchased separately.
1. Read General Repair Information; page 4.
2.
4. Fig. 8. Push in 110816 spring clip (A) to release
hooks (B) from brush holder (C). Pull out spring
clip.
5. Fig. 8. Loosen terminal screw (D). Pull brush lead
(E) away, leaving motor lead (F) in place. Remove
brush (G) and spring (H).
Relieve pressure; page 4.
H
A
C B
3. Fig. 4. Remove motor shield (90). Remove inspection covers (B) and gaskets on each side of
motor.
G
54
E
D
F
01227
Fig. 8
6. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes wear too fast.
A
Fig. 7
B
7703B
(Continued on page 12)
309251
11
Motor Brush Replacement
795/1095 Motor Brush Installation
11. Repeat for other side.
CAUTION
12. Test brushes.
When installing brushes, follow all steps carefully to
avoid damaging parts.
7. Fig. 9. Install new brush (G) with lead in long slot
(J) of brush holder (C).
8. Fig. 8. Slide brush lead (E) under washer of terminal screw (D) and tighten screw. Be sure motor
lead (F) is connected at terminal screw.
a. Remove pump connecting rod pin.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c.
Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
9. Fig. 9.Place spring (H) on brush (G).
10. Fig. 9. Install spring clip (A). Push down to hook
short slots (K) in brush holder (C).
C
K
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displacement pump packings.
13. Install brush inspection covers and gaskets.
J
G
14. Break in brushes.
A
a. Operate sprayer 1 hour with no load.
E
b. Install connecting rod pin.
15. Fig. 4. Install gaskets and inspection covers (B)
on each side of motor. Install motor shield (90).
H
NOTE SPRING COIL DIRECTION
Fig. 9
12
309251
01227
On/Off Switch Replacement
695/795 120 Vac (245000 – 245003, 245010, 245011, 245020 – 245023, 245028, 245050, 245051, 246308, 246309)
Installation
Removal
1.
Relieve pressure; page 4.
1. Push ON/OFF switch (86) into control panel (67)
until inside tabs snap in place.
2. Fig. 10. Remove four screws (60) and pressure
control cover (49). Disconnect display connector
(B) (not available on all sprayers).
3. Remove two screws (108) and control panel (67).
4. Disconnect two wires (A) from ON/OFF
switch (86).
5. Squeeze inside tabs on ON/OFF switch (86) and
remove from control panel (67).
2. Connect two wires (A) to ON/OFF switch (86).
3. Install control panel (67) with two screws (108).
4. Connect display connector (B) (not available on all
sprayers). Install pressure control cover (49) with
four screws (60).
North America
695/795 120 VAC
58
112
49
108
41
72
43
60
42
67
86
A
108
On/Off
Switch
Ref 86
Black
D B E C
Wiring Diagram
70
Black
White
Green
Ref
38
LED
Power Cord
Ref 66
Red (+)
Black (–)
Yellow
Motor
Display
Not available
on all sprayers
Pressure
Transducer
Ref 68
Potentiometer
Ref 64
ti0848A
Fig. 10
309251
13
On/Off and 15/20A Switch Replacement
1095 120 Vac (245030 – 245032, 245039)
Removal
1.
Installation
1. Push 15/20A switch (60) into control panel (67) until
inside tabs snap in place.
Relieve pressure; page 4.
2. Connect two wires (A2) to 15/20A switch (86).
2. Fig. 11. Remove four screws (60) and pressure
control cover (49). Disconnect display connector (B).
3. Push ON/OFF switch (86) into control panel (67) until
inside tabs snap in place.
3. Remove two screws (108) and control panel (67).
4. Disconnect two wires (A1) from ON/OFF switch (86).
4. Connect two wires (A1) to ON/OFF switch (86).
5. Squeeze inside tabs on ON/OFF switch (86) and
remove from control panel (67).
5. Install control panel (67) with two screws (108).
6. Disconnect two wires (A2) from 15/20A switch (86).
6. Install display connector (B). Install pressure control
7. Squeeze inside tabs on 15/20A switch (60) and
remove from control panel (67).
cover (49) with four screws (60).
North America
1095 120 VAC
43
58
108
112
49
41
72
42
60
67
A1
86
60
Wiring Diagram
D B E C
On/Off
70
A2
108
Switch
Ref 86
Black
15/20A
Switch 60
Black
White
Green
Ref
38
LED
Power Cord
Ref 66
Display
Violet
Not available
on all sprayers
Red (+)
Black (–)
Yellow
Motor
Fig. 11
14
309251
Pressure
Transducer
Ref 68
Potentiometer
Ref 64
ti0902A
On/Off Switch Replacement
695/795/1095 240 Vac (245004, 245005, 245009)
Removal
Installation
1.
1. Push ON/OFF switch (86) into control panel (67)
until inside tabs snap in place.
Relieve pressure; page 4.
2. Fig. 12. Remove four screws (60) and pressure
2. Connect four wires (A) to ON/OFF switch.
control cover (49). Disconnect display connector (B).
3. Remove two screws (108) and control panel (67).
3. Install control panel (67) with two screws (108).
4. Disconnect four wires (A) at ON/OFF switch (86).
4. Install display connector (B). Install pressure control
5. Squeeze inside tabs on ON/OFF switch (86) and
remove from control panel (67).
cover (49) with four screws (60).
695/795/1095 240 VAC
43
58
108
112
49
41
72
42
60
67
86
A
108
CAUTION
Heat from inductor coil of filter board may destroy
wire insulation that comes in contact with it. Exposed wires could cause shorts and component
damage. Bundle and tie all loose wires so none lay
in contact with inductor coil of filter board.
B
D E C
Wiring Diagram
On/Off
Switch
Ref 86
Brown
Blue
Blue
Brown
LED
Display
Not available
on all sprayers
Red (+)
Black (–)
Yellow
Power
Cord
Ref 66
Pressure
Transducer
Ref 68
Potentiometer
Ref 64
Motor
ti0897A
Fig. 12
309251
15
Pressure Control Repair
Motor Control Board
Removal
Refer to Fig. 10, 11 or 12 depending on sprayer and
voltage.
Lead (D) to potentiometer.
1.
Wires to power cord and switch
Relieve pressure; page 4.
2. Remove four screws (60) and pressure control
cover (49). Disconnect display connector (B).
3. Remove two screws (108) and control panel (67).
4. Disconnect at motor control board (112):
Motor connector: two yellow, black (+) and
red (–).
Lead (D) from potentiometer.
Lead (E) from transducer.
Wires from power cord and switch
5. Remove six screws (41) and motor control
board (112).
Motor connector: two yellow, black (+) and
red (–).
4. Route loose wires so none lay in contact with
inductor coil on filter board (not 120 Vac sprayers).
See Wiring Diagram CAUTION, Fig. 11.
5. Install control panel (67) with two screws (108).
6. Install display connector (B). Install pressure
control cover (49) with four screws (60).
Digital Display Settings (Not available on
all sprayers)
The units on the digital display may be set to psi, bar,
MPa and gallons or liters.
1. Fig. 10. Remove four screws (60) and cover (49).
Disconnect display cable (B).
2. Set switches as desired, Fig. 13.
Installation
1. Clean pad on rear of motor control board. Apply
small amount of thermal compound 073019 to pad.
2. Fig. 10. Install motor control board (112) with six
screws (41).
gallons
Shown set for
gallons and psi
3. Connect to motor control board (112):
Lead (E) to transducer.
16
309251
SET
liters
Fig. 13
MPa bar psi
Pressure Control Repair
Stored Data (Not available on all sprayers)
The SmartControl contains stored data to assist with troubleshooting and maintenance. To view this stored data on
the digital display, proceed as follows:
1.
Relieve pressure; page 4.
4. Release display button about 1 second after
turning on sprayer.
Sprayer model number displays (U695, U795, etc.) for
a few seconds and then data point 1 is displayed.
2. Plug in sprayer.
5. Push display button and next data point displays.
3. Hold down display button and turn sprayer ON.
6. Turn sprayer OFF and then ON to leave stored
data mode.
Data Point
Definition
1
Number of hours power switch has been ON with power applied
2
Number or hours motor has been running
3
Number of hours sprayer has been above 500 psi with power applied
4
Not used
5
Last recorded Error Code E=XX. See Error Code messages on page 18.
6
Control board software revision number
Note: Gallon/liter counter resets to zero at 65,000 gallons (245 700 liters)
309251
17
Pressure Control Repair
Digital Display Messages (Not available on all sprayers)
No display does not mean that sprayer is not pressurized. Relieve pressure before repair; page 4.
DISPLAY*
No Display
psi
bar
MPa
SPRAYER
OPERATION
INDICATION
ACTION
Sprayer may be pressurized.
Loss of power or display not
connected
Check power source. Relieve
pressure before repair or disassembly. Verify display is connected.
Sprayer is pressurized. Power is applied.
(Pressure varies with tip size and pressure
control setting.)
Normal operation
Spray
1. Sprayer stops. Power is applied.
1. Remove any filter clogs or flow
obstructions. Lock gun trigger
open if using AutoClean valve.
2. Sprayer stops. Power is applied.
1. Exceeded pressure limit of
4500 psi. Sprayer is pressurized.
2. Sprayer is not pressurized
3. Sprayer continues to run
3. Pressure rise nears 4500 psi
3. Replace control board
Sprayer stops. Power is applied.
Pressure transducer faulty,
bad connection or broken
wire.
Check transducer connections
and wire. Replace transducer or
control board, if necessary.
Sprayer stops. Power is applied.
Line voltage too high
Check for voltage supply problem
Sprayer stops. Power is applied.
Too much motor current
Check for locked rotor, pump obstruction, damaged drive train,
shorted wiring or motor. Repair or
replace failed parts.
Sprayer stops. Power is applied.
No operation, motor over
heated or unplugged
Allow sprayer to cool. Correct
cause of overheating. Verify motor is plugged into motor control
board
Sprayer stops. Power is applied.
Pressure greater than
2000 psi (138 bar, 14 MPa)
while in Flush Timer Mode
Make sure spray gun is triggered
and prime valve is open when using AutoClean
Sprayer stops. Power is applied.
Low line voltage
Check for voltage supply problem
Power is applied.
Digital display switches are
not set
Set switches on back of digital
display to appropriate settings.
Fig. 13, page 16.
Sprayer may be pressurized.
Pressure less than
200 psi (14 bar, 1.4 MPa)
Increase pressure as needed
*Error codes also appear on control board as a blinking red LED. LED is an alternate to display.
Electric shock hazard; page 4.
1. Remove four screws (60) and cover (49).
2. Turn sprayer ON. Count LED blinks. Blink count is
the same as error code (E=0X) in preceding
Digital Display Messages table.
3. Follow instructions in table.
18
309251
2. Replace transducer
After a fault, do following steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
Pressure Control Repair
Pressure Control Transducer
Pressure Adjust Potentiometer
Removal
Refer to Fig. 10, 11 or 12 depending on sprayer
voltage.
Removal
Refer to Fig. 10, 11or 12 depending on sprayer
voltage.
1.
1.
Relieve pressure; page 4.
2. Remove four screws (60) and pressure control
cover (49). Disconnect display connector (B).
3. Remove two screws (108) and control panel (67).
4. Remove upper two screws (108) and control
housing (58).
5. Disconnect lead (E) from motor control
board (112).
6. Unscrew nut holding transducer (68) in power bar
plate (56).
7. Remove transducer and o–ring (26).
8. Remove grommet (42) holding transducer lead in
cart frame (72).
9. Thread transducer lead plastic connector down
through hole in cart frame.
10. Remove grommet from transducer lead.
Installation
1. Install grommet (42) on transducer lead.
2. Thread transducer lead plastic connector up
through hole in cart frame (72) .
3. Install grommet holding transducer lead in cart
frame.
4. Install o–ring (26) and transducer (68).
5. Screw nut holding transducer in power bar plate
(56). Torque to 30–35 ft-lb.
6. Connect lead (E) to motor control board (112).
7. Install control housing (58) with upper two screws
(108).
8. Install control panel (67) with two screws (108).
9. Install display connector (B). Install pressure
control cover (49) with four screws (60).
Relieve pressure; page 4.
2. Remove four screws (60) and pressure control
cover (49). Disconnect display connector (B).
3. Remove two screws (108) and control panel (67).
4. Disconnect lead (D) from motor control board
(112).
5. Remove potentiometer knob (36), sealing shaft nut
(32), shaft spacer (96) and pressure adjust potentiometer (64).
Installation
1. Install pressure adjust potentiometer (64), shaft
spacer (96), sealing shaft nut (32) and potentiometer knob (36).
a. Turn potentiometer fully clockwise.
b. Install knob at full clockwise position.
2. Connect lead (D) to motor control board (112).
3. Install control panel (67) with two screws (108).
4. Install display connector (B). Install pressure
control cover (49) with four screws (60).
309251
19
Drive Housing Replacement
7. Remove two screws (105) and washers (17).
CAUTION
8. Pull drive housing (78) off of motor (75).
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
9. Slide connecting rod (76) out of drive housing.
695 Installation
695 Removal
1.
1. Slide connecting rod (76) into drive housing.
2. Push drive housing (78) onto motor (75).
Relieve pressure; page 4.
3. Install washers (17) and two screws (105).
2. Remove pump (79); Displacement Pump Re4. Install spring clip (95), pail hanger (54) and two
nuts (33).
placement, page 23.
5. Install front cover (100) and four screws (40).
3. Fig. 15. Remove four screws (39) and remove
shroud (90).
6. Install washers (17) and four screws (104).
4. Remove four screws (104) and washers (17).
7. Fig. 15. Install shroud (90) with four screws (39).
5. Remove four screws (40) and front cover (100).
8. Install pump (79); Displacement Pump Replace-
6. Remove two nuts (33), pail hanger (54) and spring
clip (95).
ment, page 23.
90
39
75
17
104
19
115
78
95
17
105
100
40
695
54
33
76
Fig. 14
20
309251
ti0767A
Drive Housing Replacement
8. Remove two screws (20) and washers (15) and
pull drive housing (78) off of motor (75).
CAUTION
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
9. Slide connecting rod (76) out of bearing housing.
795/1095 Installation
795/1095 Removal
1.
1. Slide connecting rod (76) into bearing housing.
2. Push drive housing (78) onto motor (75) and install
with two washers (15) and screws (20).
Relieve pressure; page 4.
2. Remove pump (79); Displacement Pump Re-
3. Install bearing housing (126) on drive housing (78)
with four screws (19) and washers (17).
placement, page 23.
4. Install spring clip (129), pail hanger (54) and two
nuts (33).
3. Fig. 15. Remove four screws (123) and remove
shroud (90).
5. Install front cover (124) and four screws (101).
4. Remove four screws (10) and washers (15).
6. Install washers (10) and four screws (15).
5. Remove four screws (101) and front cover (104).
7. Fig. 15. Install shroud (90) with four screws (123).
6. Remove two nuts (33), pail hanger (54) and spring
clip (129).
8. Install pump (79); Displacement Pump Replace7. Remove four screws (19) and washers (17) and
bearing housing (126) from drive housing (78).
90
ment, page 23.
123
75
10
15
39
37
28
78
76
17
795/1095
124
101
K
15
19
20
54
Fig. 15
33
126
129
ti0767A
309251
21
Motor Replacement
Removal
10. Thread motor lead (J) out through slot in frame.
1.
11. Remove four screws (31), nuts (127) and motor
(75) from frame (72).
Relieve pressure; page 4.
Installation
2. Remove pump (79); Displacement Pump Re1. Install new motor (75) on cart frame (72) with four
screws (31) and nuts (127).
placement, page 23.
2. Thread motor lead (J) in through slot in frame.
CAUTION
3. Install strain relief (43, page 12, 13, 14).
Do not drop gear cluster (A) when removing drive
housing (78). Gear cluster may stay engaged in
motor front end bell or drive housing.
4. Connect all leads to board (112).
5. Install control housing (58) with two screws (108).
3. Remove drive housing (78); Drive Housing Replacement, page 21.
6. Install panel (67) with two screws (108).
4. Remove four screws (60) and cover (49).
7. Connect lead (B) to board (112).
5. Disconnect lead (B) from board (112).
8. Install cover (49) with four screws (60).
6. Remove two screws (108) and panel (67).
9. Install drive housing (78); Drive Housing Replacement, page 21.
7. Remove two top screws (108) and housing (58).
10. Install pump (79); Displacement Pump Replace-
8. Disconnect all leads from board (112).
9. Remove strain relief (43, page 13, 14, 15).
ment, page 23.
(A) 795,1095
75
31
J
58
49
112
108
127
72
60
B
67
Fig. 16
22
309251
108
(A) 695
J
1
Liberally apply grease
ti0767A
Displacement Pump Replacement
See manual 309250 or 309277 for pump repair instructions.
See parts manuals for sprayer part number references.
Installing pump
Removing pump
1. Flush pump. Relieve pressure. Fig. 17. Cycle
pump with piston rod (201) in its lowest position.
2. Fig. 17. Remove suction tube and hose.
WARNING
If 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. Make sure pin is properly installed.
201
CAUTION
If the pump jam nut loosens during operation, the
threads of the bearing housing and drive train will be
damaged. Make sure jam nut is tightened to
75 +/–5 ft–lb (102 Nm).
ti0915
Fig. 17
3. Fig. 18. Use screwdriver: push retaining spring up
and push out pin.
1. Fig. 20. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
114
1.5 in.
Fig. 18
ti0916
2. Fig. 18. Push pin (21) into hole. And push retaining
spring into groove all the way around connecting
rod.
Fig. 21. Screw jam nut down onto pump until stops.
Screw pump up into bearing housing until it is stopped
by jam nut. Back off pump and jam nut to align pump
outlet to back. Tighten jam nut by hand, then tap 1/8 to
1/4 turn with a plastic hammer to approximately
75 +/–5 ft–lb (102 Nm).
4. Fig. 19. Loosen locknut by hitting firmly with a
plastic hammer. Unscrew pump.
Fig. 19
ti0918
Fig. 20
ti0917
ti0917
Fig. 21
Fig. 22. Fill packing nut with Graco TSL, through one
of the slits, until fluid flows onto the top of seal.
7677B
Fig. 22
309251
23
Technical Data
Model
100–120V,
∅, A, Hz
220–240V,
∅, A, Hz
Generator
Minimum
W
Motor
HP (W)
Cycles per
gallon (liter)
Maximum
Delivery
gpm (lpm)
Maximum
Tip size
Fluid
Outlet
npsm
1 gun
2 guns
695
1, 15,
50/60
1, 10,
50/60
3000
0.9 (373)
566 (150)
0.6 (2.3)
0.026
N/A
1/4 in.
795
1, 15,
50/60
1, 10,
50/60
4000
1.0 (466)
244 (64.6)
0.8 (3.0)
0.028
0.019
1/4 in
1095
1, 15/20,
50/60
1, 10,
50/60
4000
1.2 (560)
200 (53)
1.1 (3.8)
0.032
0.021
1/4 in
Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . .
zinc-plated carbon steel, polyurethane, polyethylene,
stainless steel, PTFE, Delrin,
chrome plating,
leather, V-Max UHMWPE, aluminum, stainless
steel, tungsten carbide
NOTE: Delrin is a registered trademark of the
DuPont Co.
Dimensions
Model
695
795
1095
Style
Weight lb (kg)
Height in. (cm)
Width in. (cm)
Length in. (cm)
Hi–Boy
87 (39)
30 (76)
22.5 (57)
25.5 (65)
Lo–Boy
78 (35)
22 (56)
19.5 (49.5)
27 (69)
Hi–Boy
107 (48.5)
30 (76)
20.5 (52.1)
28 (71)
Lo–Boy
101 (46)
22 (56)
22.5 (57)
27 (69)
Hi–Boy
120 (54)
30 (76)
22.5 (57)
29 (74)
Graco Phone Number
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.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
www.graco.com
24
309251
PRINTED IN USA 309251 01/2001, Revised 3/2003
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