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REPAIR
KEEP FOR REFERENCE.
Read this and all related manuals for important warnings and instructions.
INSTRUCTIONS
First choice when quality counts.
309251
Rev. B
Ultra Max 695/795/1095
Airless Paint Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
220–240 VAC
Sprayer
695
795
1095
Series Lo–boy Hi–boy Parts
A 245005 245004
245009
309253
A 309261
A
245025 245024
245027
245034
245038
309261
100–120 VAC (U.K., Japan, Taiwan)
Sprayer
695
795
1095
Series Lo–boy Hi–boy Parts
A 245008 245006
245007
309253
A 245026 309261
A 245037 254035
245036
309261
Related manuals
. . . . . . . 309257
. . . . . . . 309250 (695)
. . . . . . . 309277 (795/1095)
Operation Pump
120 VAC (North America)
Sprayer
695
795
1095
Series Lo–boy Hi–boy Parts
A
A
A
245002
245003
245011
245051
245022
245023
245000
245001
245010
245050
245020
245021
245028
245030
245031
245032
245039
309252
309260
309260
Parts
North
America Global
. . . . . . . 309252 309253
. . . . . . . 309260 309261
(695)
(795/1095)
. . . . . . . 309091 . . . . . . . 309055
Spray Gun
Spray Tip
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification . . . . . . . . . . . .
2
3
General Repair Information . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
5
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . .
9
9
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 13
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 20
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Displacement Pump Replacement
Technical Data
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
24
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
WARNING
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.
Fluid injection and high pressure hazard: High pressure spray or leaks can inject fluid into the body.
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.
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.
MISE EN GARDE
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.
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.
2 309251
ADVERTÊNCIA
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.
Perigo de injeção de líquidos à alta pressão: a pulverização ou vazamentos à alta pressão podem injetar líquido no corpo.
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.
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.
ADVERTENCIA
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.
Peligro de inyección de fluido y alta presión: por la pulverización o las filtraciones a alta presión se pueden inyectar fluidos en el organismo.
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
9643A
G
J
K
L
H
F D
V
E
W
U
M
Fig. 1
N ti0866A
A Motor
B
E
F Prime Valve
G
Drive Assembly
D Displacement Pump
Fluid Outlet
Fluid Filter
DC motor, permanent magnet, totally enclosed, fan cooled
Transfers power from DC motor to displacement pump
Transfers fluid to be sprayed from source through spray gun
Spray gun is connected here
Used to prime, drain and flush sprayer when open
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
P RAC 5 Switch Tip
High pressure spray gun with gun safety latch
Uses high pressure fluid to clear tip clogs without removing tip from spray gun
R HandTite Tip Guard
S Gun Safety Latch
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
W AutoClean valve
Tip guard reduces risk of injection injury
Gun safety latch inhibits accidental triggering of spray gun
Fluid outlet used to drain and prime the sprayer
Spray gun connection for timed back–flush of sprayer with automatic shut off
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 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.
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.
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.
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.
4 309251
Grounding
WARNING
Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.
Grounded
Outlets
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.
Grounding Plug
120 Vac model shown
2. Do not alter ground prong or use adapter.
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
PROBLEM
Motor won’t operate
Relieve pressure ; page 4.
WHAT TO CHECK
If check is OK, go to next check
1. Check digital display for error codes
2. Make sure digital display is connected. If nothing is displayed, check power cord, power switch and all power connections for continuity.
Check building circuit power.
3. Check pressure control knob setting. Motor will not run if pressure control knob is at minimum setting.
4. With drain valve open and pressure control knob set to maximum, check if there is a light blinking next to either psi, bar, or MPa a. If light is blinking, control board is commanding motor to run and problem is most likely motor or motor wiring.
WHAT TO DO
When check is not OK refer to this column
1. If an error code (E=0X) is displayed, go to page 18 for error code diagnostics. If not continue.
2. Tighten any loose power connections. Replace power switch, power cord or extension cords if damaged. Reset circuit breaker if tripped.
3. Increase pressure setting
4. Based on results of this test, investigate for possible wiring, motor, control, transducer or potentiometer problems in the following steps b. If light is not blinking, control board, control board wiring, potentiometer or transducer is most likely cause.
309251 5
PROBLEM
Motor
Control board or wiring
Control/sensor
Troubleshooting
WHAT TO CHECK
If check is OK, go to next check
1. Connections at control board and brushes
2. Brushes worn. Length must be 1/2 in. minimum.
Check both sides.
3. Broken or misaligned brush springs
4. Brushes or springs binding in brush holder
WHAT TO DO
When check is not OK refer to this column
1. Repair any loose connections
2. Replace brushes. Page 9.
3. Realign or replace springs
4. Clean brush holder and align brush leads for free movement
5. Replace motor 5. Check for armature short using an armature tester (growler) or perform spin test. Page 9.
6. Check motor armature commutator for burn spots or other damage
1. Loose control board wiring
2. Damaged control board
1. Potentiometer damaged
2. Pressure transducer damaged
6. Remove motor and have motor shop resurface commutator if possible. Page 22.
1. Repair any loose connections
2. Replace control board
1. Replace potentiometer
2. Replace pressure transducer
6 309251
Troubleshooting
PROBLEM
Low or fluctuating output
WHAT TO CHECK
If check is OK, go to next check
1. For worn spray tip.
WHAT TO DO
When check is not OK refer to this column
1. Follow Pressure Relief Procedure Warn-
ing, then replace tip. See your separate gun or tip manual.
2. Service pump. See page 23.
2. Verify pump does not continue to stroke when gun trigger is released.
3. Filter clogged.
4. Prime valve leaking.
5. Suction hose connections.
3. Relieve pressure. Check and clean filter.
4. Relieve pressure. Repair prime valve.
5. Tighten any loose connections.
6. Electrical supply with volt meter.
Meter must read:
210–255 Vac for 220–240 Vac models.
85–130 Vac for 100–120 Vac models. 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. Low stall pressure.
6. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.
7. Replace with a correct, grounded extension cord.
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.
Motor runs but pump does not stroke
9. Motor armature for shorts by using an armature tester (growler) or perform spin test. See page
9.
10. Paint supply.
11.
Intake strainer clogged.
12.
Suction tube or fittings loose.
13.
To see if intake valve ball and piston ball are seating properly. See page 23.
14. Leaking around throat packing nut which may indicate worn or damaged packings. See page
23.
15. Pump rod damage
1. Displacement pump pin (1 14) (damaged or missing), page 23.
2. Connecting rod assembly (9) for damage, page
21.
3. Gears or drive housing, page 21.
d. Try a new transducer.
9. Replace motor. See page 22.
10.Refill and reprime pump.
11. Remove and clean, then reinstall.
12.Tighten; use thread sealant or sealing tape on threads if necessary.
13.Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 23. Strain paint before using to remove particles that could clog pump.
14.Replace packings, page 23. Also check piston valve seat for hardened paint or nicks and replace if necessary. T ighten packing nut/wet-cup.
15.Repair pump, page 23.
1. Replace pump pin if missing. Be sure retainer spring (27) is fully in groove all around connecting rod, page 23.
2. Replace connecting rod assembly, page 21.
3. Inspect drive housing assembly and gears for damage and replace if necessary, page 21.
309251 7
Troubleshooting
TYPE OF PROBLEM
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.
Display reads all 8’s
WHAT TO CHECK
If check is OK, go to next check
Building circuit breaker opens 1. Current limit exceeded
2. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page
22.
3. For missing inspection plate gasket (see page
22), bent terminals or other metal to metal contact points which could cause a short.
4. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page
9. Inspect windings for burns.
5. Motor control board (35) by performing motor control board diagnostics on page 16. If diagnostics 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.
Switches on back of display are set incorrectly.
WHAT TO DO
When check is not OK refer to this column
1. Switch to another circuit with less load. If sprayer has a 15/20A or 10/12A switch, change to lower value.
2. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.
3. Correct faulty conditions.
4. Replace motor. See page 22.
5. Replace with a new pressure control board
(35). See page 16.
Set the four switches psi, bar, MPa and liters/gallons to proper settings for your sprayer. Fig. 13, page 16.
AutoClean problem Manual 309278
8 309251
1.
Setup
Electric Shock Hazard; page 4.
Spin Test
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Fig. 3. Connect red and black motor leads together with test lead. Turn motor fan by hand at about two revolutions per second.
To check armature, motor winding and brush electrical continuity:
Relieve pressure ; page 4.
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.
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.
ti0941
2.
Relieve pressure ; page 4.
3. Fig. 4. Remove motor shroud (90) and two inspection covers (A).
(Continued on page 10)
Fig. 4
A
7703B
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).
695 Motor Brush Installation
5. Fig. 5. Pull brush lead (D) out of terminal (E).
Remove brush (F).
2
1 Motor lead; do not disconnect
2 Minimum 0.5” (12.5 mm)
3
Included in Brush Repair Kit
CAUTION
When installing brushes, follow all steps carefully to avoid damaging parts.
1. Fig. 6. Install new brush (F) with lead into brush holder (C).
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).
1
B
F
3 A
1
F
C B
E
Fig. 5
D
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.
C
Fig. 6
E
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 Re-
placement, page 23.
10 309251
2.
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, 1 10816, may be purchased separately.
4. Fig. 8. Push in 110816 spring clip (A) to release hooks (B) from brush holder (C). Pull out spring clip.
1. Read General Repair Information; page 4.
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.
Fig. 7
54
B
A
7703B
G
F
E
D
Fig. 8 01227
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.
(Continued on page 12)
309251 11
Motor Brush Replacement
795/1095 Motor Brush Installation
11. Repeat for other side.
CAUTION
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.
12. Test brushes.
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).
CAUTION
Do not run sprayer dry for more than 30 seconds while checking brushes to avoid damaging displacement pump packings.
C
K
J
G
A
E
13. Install brush inspection covers and gaskets.
14. Break in brushes.
a. Operate sprayer 1 hour with no load.
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 01227
12 309251
1.
On/Off Switch Replacement
695/795 120 Vac (245000 – 245003, 245010, 245011, 245020 – 245023, 245028, 245050, 245051)
Removal Installation
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).
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).
North America
695/795 120 VAC
2. Connect two wires (A) to ON/OFF switch (86).
3. Install control panel (67) with two screws (108).
4. Install display connector (B). Install pressure control cover (49) with four screws (60).
49
112
41
108
58
72
43 42
60
67
86
A
On/Off
Switch
Ref 86
Black
108
D
70
B E C
Black
White
Green
Ref
38
Power Cord
Ref 66
Red (+)
Black (–)
Yellow
Wiring Diagram
Display
Motor
Pressure
Transducer
Ref 68
Potentiometer
Ref 64
Fig. 10 ti0848A
309251 13
1.
On/Off and 15/20A Switch Replacement
1095 120 Vac (245030 – 245032, 245039)
Removal Installation
1.
Push 15/20A switch (60) into control panel (67) until inside tabs snap in place .
Relieve pressure ; page 4.
2.
Fig. 11. Remove four screws (60) and pressure control cover (49). Disconnect display connector (B).
3.
Remove two screws (108) and control panel (67).
4.
Disconnect two wires (A1) from ON/OFF switch (86).
5.
Squeeze inside tabs on ON/OFF switch (86) and remove from control panel (67).
6.
Disconnect two wires (A2) from 15/20A switch (86).
7.
Squeeze inside tabs on 15/20A switch (60) and remove from control panel (67).
2.
Connect two wires (A2) to 15/20A switch (86).
3.
Push ON/OFF switch (86) into control panel (67) until inside tabs snap in place .
4.
Connect two wires (A1) to ON/OFF switch (86).
5. Install control panel (67) with two screws (108).
6.
Install display connector (B). Install pressure control cover (49) with four screws (60).
North America
1095 120 VAC
49
112
41
108
58 43
72
42
60
67
A1
86
60
A2
108
D
On/Off
Switch
Ref 86
Black
B E C
70
Black
White
Green
Ref
38
Power Cord
Ref 66
15/20A
Switch 60
Wiring Diagram
Display
Motor
Violet
Red (+)
Black (–)
Yellow
Pressure
Transducer
Ref 68
Potentiometer
Ref 64 ti0902A
Fig. 11
14 309251
On/Off Switch Replacement
695/795/1095 240 Vac (245004, 245005, 245009)
Removal Installation
1.
Relieve pressure ; page 4.
1. Push ON/OFF switch (86) into control panel (67) until inside tabs snap in place.
2. Fig. 12. Remove four screws (60) and pressure control cover (49). Disconnect display connector (B).
3.
Remove two screws (108) and control panel (67).
4. Disconnect four wires (A) at ON/OFF switch (86).
5. Squeeze inside tabs on ON/OFF switch (86) and remove from control panel (67).
2. Connect four wires (A) to ON/OFF switch.
3. Install control panel (67) with two screws (108).
4.
Install display connector (B). Install pressure control cover (49) with four screws (60).
695/795/1095 240 VAC
49
112
41
108
58 43
72
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
On/Off
Switch
Ref 86
Brown
Blue
Blue
Brown
Fig. 12
Power
Cord
Ref 66
42
Wiring Diagram
Motor
Red (+)
Black (–)
Yellow
Display
Pressure
Transducer
Ref 68
Potentiometer
Ref 64 ti0897A
309251 15
1.
Pressure Control Repair
Motor Control Board
Removal
Refer to Fig. 10, 11 or 12 depending on sprayer and voltage.
Lead (D) to potentiometer.
Motor connector: two yellow, black (+) and red (–).
Wires to power cord and switch
Relieve pressure ; page 4.
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).
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).
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).
3. Connect to motor control board (112):
Lead (E) to transducer.
6. Install display connector (B). Install pressure control cover (49) with four screws (60).
Digital Display Settings
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.
Fig. 13 liters gallons
SET
MPa bar psi
Shown set for gallons and psi
16 309251
1.
Pressure Control Repair
Stored Data
The SmartControl contains stored data to assist with troubleshooting and maintenance. To view this stored data on the digital display, proceed as follows:
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.
3. Hold down display button and turn sprayer ON.
5. Push display button and next data point displays.
6. Turn sprayer OFF and then ON to leave stored data mode.
5
6
3
4
Data Point
1
2
Definition
Number of hours power switch has been ON with power applied
Number or hours motor has been running
Number of hours sprayer has been above 500 psi with power applied
Not used
Last recorded Error Code E=XX. See Error Code messages on page 18.
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
No display does not mean that sprayer is not pressurized. Relieve pressure before repair ; page 4.
DISPLAY SPRAYER
OPERATION
No Display Sprayer may be pressurized.
psi bar
MPa
INDICATION ACTION
Loss of power or display not connected
Check power source. Relieve pressure before repair or disassembly. Verify display is connected.
Spray Sprayer is pressurized. Power is applied. (Pressure varies with tip size and pressure control setting.)
Sprayer stops. Power is applied.
Normal operation
Sprayer stops. Power is applied.
Sprayer stops. Power is applied.
Sprayer stops. Power is applied.
Sprayer stops. Power is applied.
Sprayer stops. Power is applied.
Sprayer stops. Power is applied.
Power is applied.
Sprayer may be pressurized.
Exceeded pressure limit
Pressure transducer faulty, bad connection or broken wire.
Line voltage too high
Too much motor current
No operation, motor over heated or unplugged
Pressure greater than
2000 psi (138 bar, 14 MPa) while in Flush Timer Mode
Low line voltage
Digital display switches are not set
Pressure less than
200 psi (14 bar, 1.4 MPa)
Remove any filter clogs or flow obstructions. Make sure gun trigger is locked open if using AutoClean valve.
Check transducer connections and wire. Replace transducer or control board, if necessary.
Check for voltage supply problem
Check for locked rotor, pump obstruction, damaged drive train, shorted wiring or motor.
Repair or replace failed parts.
Allow sprayer to cool. Correct cause of overheating. Verify motor is plugged into motor control board
Make sure spray gun is triggered and prime valve is open when using AutoClean
Check for voltage supply problem
Set switches on back of digital display to appropriate settings. Fig. 13, page 16.
Increase pressure as needed
After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
18 309251
1.
Pressure Control Repair
Pressure Control Transducer
Removal
Refer to Fig. 10, 11 or 12 depending on sprayer voltage.
Pressure Adjust Potentiometer
Removal
Refer to Fig. 10, 11or 12 depending on sprayer voltage.
Relieve pressure ; page 4.
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).
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
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.
695 Removal
1.
Relieve pressure ; page 4.
2. Remove pump (79); Displacement Pump Re-
placement, page 23.
3. Fig. 15. Remove four screws (39) and remove shroud (90).
4. Remove four screws (104) and washers (17).
5. Remove four screws (40) and front cover (100).
6. Remove two nuts (33), pail hanger (54) and spring clip (95).
7. Remove two screws (105) and washers (17).
8. Pull drive housing (78) off of motor (75).
9. Slide connecting rod (76) out of drive housing.
695 Installation
1. Slide connecting rod (76) into drive housing.
2. Push drive housing (78) onto motor (75).
3. Install washers (17) and two screws (105).
4. Install spring clip (95), pail hanger (54) and two nuts (33).
5. Install front cover (100) and four screws (40).
6. Install washers (17) and four screws (104).
7. Fig. 15. Install shroud (90) with four screws (39).
8. Install pump (79); Displacement Pump Replace-
ment, page 23.
90
39
75
104
17
19
115 78
95
17
105 100
40
695
33
76
54
Fig. 14 ti0767A
20 309251
Drive Housing Replacement
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.
795/1095 Removal
1.
Relieve pressure ; page 4.
2. Remove pump (79); Displacement Pump Re-
placement, page 23.
3. Fig. 15. Remove four screws (123) and remove shroud (90).
4. Remove four screws (10) and washers (15).
5. Remove four screws (101) and front cover (104).
6. Remove two nuts (33), pail hanger (54) and spring clip (129).
7. Remove four screws (19) and washers (17) and bearing housing (126) from drive housing (78).
8. Remove two screws (20) and washers (15) and pull drive housing (78) off of motor (75).
9. Slide connecting rod (76) out of bearing housing.
795/1095 Installation
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).
3. Install bearing housing (126) on drive housing (78) with four screws (19) and washers (17).
4. Install spring clip (129), pail hanger (54) and two nuts (33).
5. Install front cover (124) and four screws (101).
6. Install washers (10) and four screws (15).
7. Fig. 15. Install shroud (90) with four screws (123).
8. Install pump (79); Displacement Pump Replace-
ment, page 23.
90
123
75
10
15
39
37 28
78
17
K
76
124
101
795/1095
15
20
19
54
33
126
129
Fig. 15 ti0767A
309251 21
1.
Removal
Motor Replacement
10. Thread motor lead (J) out through slot in frame.
Relieve pressure ; page 4.
2. Remove pump (79); Displacement Pump Re-
placement, page 23.
11. Remove four screws (31), nuts (127) and motor
(75) from frame (72).
Installation
1. Install new motor (75) on cart frame (72) with four screws (31) and nuts (127).
CAUTION
Do not drop gear cluster (A) when removing drive housing (78). Gear cluster may stay engaged in motor front end bell or drive housing.
2. Thread motor lead (J) in through slot in frame.
3. Install strain relief (43, page 12, 13, 14).
4. Connect all leads to board (112).
5. Install control housing (58) with two screws (108).
6. Install panel (67) with two screws (108).
3. Remove drive housing (78); Drive Housing Re-
placement, page 21.
4. Remove four screws (60) and cover (49).
5. Disconnect lead (B) from board (112).
6. Remove two screws (108) and panel (67).
7. Remove two top screws (108) and housing (58).
8. Disconnect all leads from board (112).
9. Remove strain relief (43, page 13, 14, 15).
7. Connect lead (B) to board (112).
8. Install cover (49) with four screws (60).
9. Install drive housing (78); Drive Housing Re-
placement, page 21.
10. Install pump (79); Displacement Pump Replace-
ment, page 23.
(A) 795,1095
75
31
J
49
58
108
112
127
72
(A) 695
60
Fig. 16
22 309251
67
108
B
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.
Removing pump
Installing pump
WARNING
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.
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
Fig. 17 ti0915
3. Fig. 18. Use screwdriver: push retaining spring up and push out pin.
114
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 N m).
1. Fig. 20. Pull piston rod out 1.5 in. Screw in pump until holes in bearing cross link and piston rod align.
1.5 in.
Fig. 18
4. Fig. 19. Loosen locknut by hitting firmly with a plastic hammer. Unscrew pump.
ti0916 ti0918
Fig. 20
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 N m).
Fig. 19 ti0917
Fig. 21 ti0917
Fig. 22. Fill packing nut with Graco TSL, through one of the slits, until fluid flows onto the top of seal.
Fig. 22 7677B
309251 23
795
1095
Technical Data
Model
695
795
1095
100–120V,
∅ , A, Hz
220–240V,
∅ , A, Hz
Generator
Minimum
W
Motor
HP (W)
Cycles per gallon (liter)
Maximum
Delivery gpm (lpm)
1, 15,
50/60
1, 15,
50/60
1, 15/20,
50/60
1, 10,
50/60
1, 10,
50/60
1, 10,
50/60
3000
4000
4000
0.9 (373) 566 (150)
1.0 (466) 244 (64.6)
1.2 (560) 200 (53)
Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc-plated carbon steel, polyurethane, polyethylene, stainless steel, PTFE steel, tungsten carbide
, Delrin , chrome plating, leather, V -Max UHMWPE, aluminum, stainless
NOTE: Delrin and PTFE
Dimensions
0.6 (2.3)
0.8 (3.0)
1.1 (3.8)
Maximum
Tip size
1 gun
0.026
0.028
0.032
2 guns
N/A
0.019
0.021
Fluid
Outlet npsm
1/4 in.
1/4 in
1/4 in
Model
695 Hi–Boy
Style
Lo–Boy
Hi–Boy
Lo–Boy
Hi–Boy
Weight lb (kg)
87 (39)
78 (35)
107 (48.5)
101 (46)
120 (54)
Height in. (cm)
30 (76)
22 (56)
30 (76)
22 (56)
30 (76)
Width in. (cm)
22.5 (57)
19.5 (49.5)
20.5 (52.1)
22.5 (57)
22.5 (57)
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.
Length in. (cm)
25.5 (65)
27 (69)
28 (71)
27 (69)
29 (74)
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
PRINTED IN USA 309251 01/2001, Revised 3/2001
24 309251
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