Graco 309941B Ultra Max II 695/795/1095 Airless Sprayers Repair Owner's Manual

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Graco 309941B Ultra Max II 695/795/1095 Airless Sprayers Repair Owner's Manual | Manualzz

Repair

Ultra

r

Max II 695/795/1095

t

Airless Sprayers

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

Vac Model

Standard/

Premium

695 Standard 248037 248036

Premium 248031 248030

120

North America

795

1095

240

Europe

695

795

240

1095

695

Europe Multi-cord 795

110

UK

1095

695

795

1095

695 240

Asia 795

1095

695 240

Australia 795

1095

695 100

Japan & Taiwan 795

1095

All models not available in all countries.

Standard 248308 248038

Premium 248033 248032

Standard

Premium

248039

248034

248042 248041

248043

248044

248046 248045

248047

248058

248593

248053

248055

248048

248049

248050

248051

248057

248059

248060

248592

248594

248595

248052

248054

248056

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

Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001 ti4281a

248036

309941

Rev. B

Table of Contents

Component Function and Identification

General Repair Information

. . . . .

. . . . . . . . . . . . . . .

4

5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .

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

5

6

6

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7

10

Drive and Bearing Housing Replacement . . 14

Motor Replacement . . . . . . . . . . . . . . . . . . . . . 16

Displacement Pump Replacement . . . . . . . . 18

Technical Data

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

20

Graco Phone Number . . . . . . . . . . . . . . . . . . . 20

2 309941

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

D

Use equipment only in well ventilated area.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

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

D

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

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

D

Use only conductive hoses.

D

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

D If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

INJECTION HAZARD

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

D

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

D Do not put your hand over the spray tip.

D

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

D

Do not spray without tip guard and trigger guard installed.

D Engage trigger lock when not spraying.

D

Follow the Pressure Relief Procedure on page 5 if the spray tip clogs and before cleaning, checking or servicing the equipment.

ELECTRIC SHOCK HAZARD

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

D Turn off and disconnect power cord before servicing equipment.

D

Use only grounded electrical outlets.

D

Use only 3-wire extension cords.

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

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

D

Protective eyewear

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

D Gloves

D

Hearing protection

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

309941 3

Component Identification and Function

A G

B

R P S ti2377a V

J

K

H

T

N ti4281a

F

E

W

M

U D

Fig. 1

4

A Motor

B Drive Assembly

D Displacement Pump

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

E Fluid Outlet

F Prime Valve

G Fluid Filter Final filter of fluid to spray gun

H Pressure Adjusting Knob Controls fluid outlet pressure

J Pressure Control

Spray gun is connected here

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

K ON/OFF Switch

Controls motor speed to maintain fluid outlet pressure at displacement pump outlet. Works with pressure adjusting knob.

Power switch that controls main power to sprayer

M 50 ft (15 m) Main Hose

N Spray Gun

P Spray Tip

R HandTite t Tip Guard

S Gun Safety Latch

T

U

V

W

Hose Rack

Suction Tube

Drain Tube

AutoClean

1/4 in. ID, grounded, nylon hose with spring guards on both ends

High pressure spray gun with gun safety latch

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

Tip guard reduces risk of injection injury

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.

Holds wrapped hose for storage

Transfers fluid to be sprayed from source to pump

Fluid outlet used to drain and prime the sprayer

Reverse flush system

309941

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:

D are instructed to relieve pressure,

D stop spraying,

D check or service any system equipment,

D or install or clean spray tip.

CAUTION

To reduce risk of pressure control malfunction:

D Use needle nose pliers to disconnect wire. Never pull on wire, pull on connector.

D Mate wire connectors properly. Center flat blade of insulated male connector in female connector.

D

Route wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.

1.

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

1. Turn pressure to zero.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4.

Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open prime valve. Leave prime valve open until ready to spray again.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above , VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

WARNING

ELECTRIC SHOCK HAZARD

MOVING PARTS HAZARD

HOT SURFACE HAZARD

To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, guards, gaskets, screws, washers and shroud before operating sprayer.

2.

Test repair after problem is corrected.

3.

If sprayer does not operate properly , review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting, pages

6 – 9, for other possible solutions.

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.

1.

100–120 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. 220–240 Vac models require a 50 Hz, 10A circuit with a grounding receptacle. See Fig. 2.

2.

Do not alter ground prong or use adapter.

Grounding Plug

Grounded

Outlets

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.

309941 5

Troubleshooting

Relieve pressure ; page 5.

Mechanical/Fluid Flow

TYPE OF PROBLEM

Low Output or Pressure

WHAT TO CHECK

If check is OK, go to next check

1. For worn spray tip.

2. Spray tip clogged.

3. Paint supply.

4. Intake strainer clogged.

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure Warning, then replace tip. See your separate gun or tip manual.

2. Relieve pressure. Check and clean spray tip.

3. Refill and reprime pump.

4. Remove and clean, then reinstall.

5. To see if intake valve ball and piston ball are seating properly.

5. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 18. Strain paint before using to remove particles that could clog pump.

6. Suction hose connections.

7. Filter clogged.

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

7. Relieve pressure. Check and clean filter.

8. Prime valve leaking.

8. Relieve pressure. Repair prime valve.

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

9. Service pump. See page 18.

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

18.

10.Replace packings, page 18. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

11. Pump rod damage.

11. Repair pump, page 18.

12.Low stall pressure.

Motor runs but pump does not stroke

1. Displacement pump pin (32) (damaged or missing), page 18.

12. Do either or both: a.

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

b.

Try a new pressure transducer.

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod, page 18.

2. Connecting rod assembly (43) for damage, page 14.

2. Replace connecting rod assembly, page 14.

3. Gears or drive housing, page 14.

3. Inspect drive housing assembly and gears for damage and replace if necessary, page 14.

6 309941

D

Troubleshooting

Electrical

Symptom: Sprayer does not run or stops running

Relieve pressure ; page 5.

D

Plug sprayer into correct voltage, grounded outlet

D

Set power switch OFF for 30 seconds and then ON again. This ensures sprayer is in normal run mode.

WARNING

To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting, wait

30 seconds after unplugging power cord for stored electricity to dissipate. Keep clear of electrical and moving parts during troubleshooting procedures.

D Turn pressure control knob up 1/2

D

View digital display

D

If no digital display is available, use control board status light to troubleshoot problems: Turn ON/OFF switch OFF, remove control cover and then turn power back ON. Observe status light.

DIGITAL

DISPLAY

Blank

CONTROL BOARD

STATUS LIGHT

Never lights

INDICATION WHAT TO DO

No power to control board

1.

Verify required voltage is present

2.

Check wiring connections to control board

3.

Perform continuity check on power cord and switch.

Replace power cord or switch as needed.

4.

If steps 1 – 3 are ok, replace control board

–––– psi Blinks once and stops

No RUN command to control board.

Potentiometer or transducer problem

1.

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

2.

Turn pressure control knob clockwise

3.

Check potentiometer connection to control board

4.

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

5.

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

6.

Check transducer connection

7.

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

8.

Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON.

Replace transducer If sprayer runs. Replace control board If sprayer does not run.

309941 7

Troubleshooting

Electrical

DIGITAL

DISPLAY

CONTROL BOARD

STATUS LIGHT

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

E=02

Blinks 2 x repeatedly

INDICATION

Improper pressure signal to contro l

WHAT TO DO

Open prime valve. Connect a known good transducer in place of the sprayer transducer. Set sprayer ON. Replace transducer If sprayer runs.

Replace control board If sprayer does not run.

Control board is receiving excessive pressure signal from transducer.

Transducer may be damaged or fluid flow path may be clogged.

1.

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

2.

Open prime valve and gun if running AutoClean.

3.

Use airless paint spray hose with no metal braid, 1/4 in. x 50 ft minimum. Smaller hose or metal braid hose may result in high–pressure spikes.

E=03 Blinks 3 x repeatedly

4.

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

1.

Check transducer connection Transducer or transducer connection error 2.

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

3.

Open prime valve. Connect a known good transducer in place of the sprayer transducer.

Set sprayer ON. Replace transducer If sprayer runs. Replace control board If sprayer does not run.

8 309941

Troubleshooting

Electrical

DIGITAL

DISPLAY

E=05

E=06

E=07

E=09

E=10

E=11

E=12

CONTROL BOARD

STATUS LIGHT

Blinks 5 x repeatedly

Blinks 6 x repeatedly

Blinks 7 x repeatedly

INDICATION WHAT TO DO

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

1.

Check motor wiring connections

2.

Check for locked or frozen pump or drive train

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

3.

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

1.

Check all wire connections from motor to control board

2.

If connections are all ok, allow sprayer to cool. If sprayer runs when cool, correct cause of overheating. Keep sprayer in cooler location with good ventilation. Make sure motor air intake is not blocked.

This error only occurs in flush timer mode Exceeded 2000 psi during timed flush cycle 1.

Make sure prime valve and gun are open

Blinks 9 x repeatedly

Blinks 10 x repeatedly

Blinks 11 x repeatedly

Blinks 12 x repeatedly

Motor sensor failure

High control board temperature

2.

Make sure no flow obstructions or clogged filter

Make sure motor sensor (resolver) is connected to the control board and check wiring for damage

1.

Make sure the motor air intake is not blocked

2.

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

Check for damaged gears or disconnected pump Excessive motor speed

High Current 1.

Check for locked or frozen pump or drive train

E=13

EMPTY

Blinks 13 x repeatedly

Model not selected

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

2.

Check for possible short circuits in wiring

3.

Check pressure output and replace transducer if pressure is excessive

Control board identity resistors must be properly clipped to identify model type, manual 309709

1.

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

2.

WatchDog feature can be deactivated. See Operation Manual.

309941 9

96

38

39

Removal

1.

Pressure Control Repair

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

Installation

1.

Fig. 3. Apply small amount of thermal compound

110009 (5) to shaded component areas on rear of motor control board (95).

Relieve pressure ; page 5.

2.

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

3.

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

4.

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

5.

Disconnect control board power lead(s) (D) from

ON/OFF switch (33) and motor control board (95).

6.

Disconnect potentiometer connector (C)

from motor control board.

7.

Disconnect transducer connector (E) from motor control board.

8.

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

9.

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

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

100 – 120 Vac

North American and Japan/Taiwan

95

CAUTION

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

2.

Install motor control board (95) with five screws

(27). Torque to 9–11 in-lb (1.02 – 1.24 N·m). Install and torque three screws (102) to values shown in

Fig 3.

3.

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

4.

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

5.

Connect transducer connector (E) to motor control board.

6.

Connect motor control board power lead(s) (D) to

ON/OFF switch (33).

7.

Connect potentiometer connector (C) to motor control board.

8.

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

9.

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

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

5

Tighten 1 screw to 14–17 in–lb

26

A

61

68

33 D

D

F

C

G

A

H

E

102

40

27

95

Tighten 2 screws to 7–10 in–lb

80

20

67 ti4289a

82

Fig. 3

10 309941

39 34 115

Removal

1.

240 Vac and 110 Vac U.K. Motor Control Board

Relieve pressure ; page 5.

Installation

1.

Fig. 4. Apply small amount of thermal compound

110009 (5) to shaded areas on rear of motor control board (95).

2.

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

CAUTION

3.

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

4.

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

5.

Disconnect motor control board power connectors

(K) from filter board (146).

6.

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

7.

Disconnect transducer connector (E) from motor control board.

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

2.

Install motor control board (95) with five screws

(27). Torque to 9–11 in-lb (1.02 – 1.24 N·m). Install and torque three screws (102) to values shown in

Fig 4.

3.

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

4.

Connect transducer connector (E) to motor control board.

5.

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

8.

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

9.

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

6.

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

7.

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

8.

Connect potentiometer connector (C) to motor control board.

9.

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

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

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

240 Vac and 110 Vac U.K. Filter Board

Removal Installation

1.

Fig. 4. Connect motor control board power connectors (K) to filter board (146).

1.

Relieve pressure ; page 5.

2.

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

2.

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

3.

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

3.

Fig. 4. Connect filter board power connectors (J) to top two terminals of ON/OFF switch (33) and power cord connectors (D) to bottom two terminals of ON/OFF switch.

4.

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

4.

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

5.

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

5.

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

6.

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

6.

Disconnect motor control board power connectors

(K) from filter board (146).

7.

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

309941 11

240 Vac and 110 Vac U.K.

95

5

Tighten 1 screw to 14–17 in-lb (1.58–1.92 N S m)

26

K

A

163

146

61

96

F

C

G

A

H

E

102

B

33

J

A A

27

95

38

39

Tighten 2 screws

7–10 in–lb (.79–1.13 N S m)

D

C

E

80

20 ti4345a

68

39 67

82

34

115

Fig. 4

Removal

1.

Pressure Adjust Potentiometer

Installation

Relieve pressure ; page 5.

1.

Install gasket (115), nut and potentiometer (82) on control panel (68). Torque nut to 30–35 in-lb

(3.38–3.95 N·m).

2.

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

3.

Disconnect potentiometer connector (C)

from motor control board (95).

2.

Install knob (34) with a hex wrench.

4.

Remove knob (34) with a hex wrench.

3.

Connect potentiometer connector (C) to motor control board.

5.

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

4.

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

12 309941

Removal

1.

Pressure Control Transducer

7.

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

Relieve pressure ; page 5.

2.

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

Installation

1.

Install o-ring (20) and transducer (86) in filter base

(67). Torque to 35–45 ft-lb (47–61 N·m).

2.

Install grommet (40) onto transducer (86).

3.

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

3.

Connect transducer connector (E) to motor control board.

4.

Disconnect potentiometer connector (C) from motor control board.

4.

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

5.

Remove four screws (39) and control box (61).

Allow control panel to hang down freely.

5.

Connect potentiometer connector (C) to motor control board.

6.

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

6.

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

309941 13

Drive and Bearing Housing Replacement

CAUTION

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

Disassembly

1.

Relieve pressure ; page 5.

2.

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

3.

Remove pump (91); Displacement Pump Replacement , page 18.

4.

Fig. 5. Remove two screws (158) and shroud (72).

5.

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

6.

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

7.

Remove five screws (6) and pull drive housing (90) off motor (84).

Assembly

Fig. 6. Make sure gear (89) and thrust washers (28,

30, 90a, 36) are in place. Brush grease onto gear teeth.

1.

Fig. 5. Push drive housing (90) onto motor (84) and install with five screws (6). Torque to 190–210 in-lb (21–23 N·m).

2.

Install bearing housing (83) with four screws (14) and washers (12). Torque to 25–30 ft-lb (34–40

N·m).

3.

Install front cover (51) with four screws (31).

4.

Install shroud (72) with two screws (31).

5.

Install pump (41); Displacement Pump Replacement , page 18.

6.

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

14 309941

Fig. 5

158

157

72

84 ti4253a

90

51

6

24

56

108

44

43

12

14

31

55

158

157

85

309941 15

Removal

1.

Motor Replacement

Installation

Relieve pressure ; page 5.

1.

Slide new motor (84) under two screws (23) in cart frame (62) near control.

2.

Remove pump (91); Displacement Pump Replacement , page 18.

2.

Install two screws (23) and nuts (19) on motor side opposite control.

3.

Tighten all four screws (23) and nuts (19). Torque nuts to 115–135 in-lb (13–15 N·m).

CAUTION

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

3.

Remove drive housing (89); Drive Housing Replacement , page 14.

4.

Fig. 6. Remove four screws (38) and control cover

(96).

5.

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

6.

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

7.

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

8.

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

9.

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

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

Install drive housing (42); Drive Housing Replacement , page 14.

10. Install pump (13); Displacement Pump Replacement , page 18.

16 309941

96

38

39

29

27

68

61

69

158

157

58

(A) 795

23

84

19

36

90A

28

90

51

157

158

89

30 ti4254a

6

12

14

31

23

LED Status Light

19

95

Fig. 6

309941 17

Displacement Pump Replacement

See manual 310643 for pump repair instructions.

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

Removal

1.

Flush pump (13).

2.

Relieve pressure ; page 5.

3.

Fig. 7. Remove screw (31) and slide pump rod shield (108) forward.

4.

Fig. 9. Cycle pump in JOG mode until pump pin

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

5.

Fig. 8. Remove suction tube (76), hose (94) and any washers and o-rings.

6.

Loosen pump jam nut (56). Unscrew pump.

94 ti4258a 56

76

31

Fig. 7

108 ti4258a

Fig. 8

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.

Installation

4.

Screw in pump until threads are flush with drive housing opening. Align pump outlet to back.

5.

Fig. 8. Install washers, o-rings and suction tube

(76) and hose (94).

6.

Fig. 10. Screw jam nut (56) up onto pump until nut 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).

CAUTION

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

1.

Fig. 9. Extend pump piston rod 1.5 in. Apply grease to top of pump rod at (A) or inside connecting rod.

44

A

1.5 in.

Fig. 10

7.

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

(31).

8.

Fig. 11. Fill packing nut with Graco TSL until fluid flows onto top of seal.

43 ti4258a

Fig. 9

2.

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

3.

Push pump up until pump threads engage.

18 309941

Fig. 11 ti4258a

Notes

309941 19

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

695

795

14, 50/60

15, 50/60

9, 50/60

10, 50/60

5000

5000

1095 15, 50/60 10, 50/60 5000

1.75 (1300)

2.00 (1490)

2.20 (1640)

Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc- and nickel-plated carbon steel, nylon, stainless steel, PTFE, Acetel, leather, UHMWPE, aluminum, tungsten carbide, PEEK, brass

243 (64)

195 (52)

123 (33)

0.75 (2.8)

0.95 (3.6)

1.1 (4.1)

Noise Level

Sound power

1 Gun 2 Guns

0.027

0.031

0.033

N/A

0.021

0.023

1/4 in.

1/4 in

1/4 in

. . . . . . . . . . . . . . . . . . . . . . . . .

Sound pressure . . . . . . . . . . . . . . . . . . . . . . .

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

91 dBa*

82 dBa*

Dimensions

Model

695

Weight lb (kg)

Lo-Boy Hi-boy

94 (43) 94 (43)

795

1095

98 (45)

N/A

98 (45)

120 (55)

Height in. (cm)

Lo-Boy

26.5 (67.3) Handle down,

38.8 (98.6) Handle up

Hi-Boy

28.5 (72.4) Handle down,

38.75 (98.4) Handle up

26.5 (67.3) Handle down,

38.8 (98.6) Handle up

N/A

28.5 (72.4) Handle down,

38.75 (98.4) Handle up

29.5 (74.9) Handle down,

38.5 (97.8) Handle up

Length Width in (cm) in. (cm)

25.75

(65.4)

20.5

(52.1)

25

(63.5)

20.5

(52.1)

26 (66) 22.5

(57.2)

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 Office: Minneapolis

International Offices: Belgium, Korea, Hong Kong, Japan www.graco.com

PRINTED IN USA 309941 12/2003, Revised 3/2004

20 309941

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