Graco 309714A Duron Performance Max 395/495 Airless Sprayers-Repair Owner's Manual
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Repair
Performance Max 395/495
Airless Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Sprayer
395
495
233980
233981
All models not available in all countries.
233982
309714
Rev. A
233980
ti2399
Related manuals
. . . . . . . 309709
. . . . . . . 309665
. . . . . . . 309250
. . . . . . . 309055
. . . . . . . 309639
. . . . . . . 309705
Table of Contents
Component Function and Identification
Grounding
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information . . . . . . . . . . . . . . .
5
4
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement . . . . . . . . . . . . . .
10
10
On/Off Switch Replacement . . . . . . . . . . . . . 12
Pressure Control Repair . . . . . . . . . . . . . . . .
Drive Housing Replacement . . . . . . . . . . . . .
13
16
Motor Replacement . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Replacement . . . . . . . .
17
18
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number . . . . . . . . . . . . . . . . . . .
20
20
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2003, 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 static arcs from plastic drop cloths. 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.
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
Risque d’incendie et d’explosion imminent pendant la pulvérisation ou le rinçage à pression de fluides inflammables dans une zone à mauvaise circulation d’air et en présence de gaz inflammables pouvant s’allumer par une flamme nue ou des étincelles.
Pour éviter les risques d’incendie et d’explosion:
Manipuler les fluides à l’air libre ou dans une zone extrêmement bien aérée.
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.
Retirer, éteindre ou déboucher toute source d’inflammation, recouvrir tout interrupteur mural avec du ruban adhésif. Ne pas fumer dans la zone de pulvérisation.
Ne jamais remplir le réservoir d’essence lorsque le moteur est chaud ou en marche.
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 mettre en marche un moteur dans une zone fermée.
L’injection de fluide constitue une lésion grave! Si un fluide haute pression perce la peau, la blessure peut paraître comme une
«simple coupure». Mais il s’agit bien d’une lésion grave! Consulter immédiatement un médecin.
Pour éviter les risques d’injection, toujours:
Bloquer le loquet de sécurité de la gâchette à la fin de la pulvérisation.
Pointer le pistolet loin de soi-même et toute autre personne à proximité
Décharger la pression avant de vérifier ou réparer une fuite.
Décharger la pression après la mise hors tension du pulvérisateur ou
à la fin de la pulvérisation.
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. En cas de blessure pour avoir utilisé cet appareil, consulter immédiatement un médecin.
2 309714
ADVERTÊNCIA
Poderá ocorrer incêndio e explosão quando for pulverizado ou injetado líquido inflamável numa área onde houver má circulação de ar; vapores inflamáveis poderão incendiar-se a partir de uma chama ou fagulhas a descoberto.
Para ajudar a evitar incêndio e explosão:
Utilize no exterior ou numa área muito bem ventilada.
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.
Retire, elimine ou desligue todas as fontes de ignição; coloque fita adesiva na tomada da parede. Não fume na área de pulverização.
Nunca abasteça o depósito de combustível com o motor em funcionamento ou quente.
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 de um balde em contato com a terra, quando estiver descarregando para dentro do mesmo.
Utilize somente tubos flexíveis condutores para pintura a alta pressão.
Nunca faça funcionar o motor numa área fechada.
A injeção de líquido é um ferimento grave! 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.
Para ajudar a evitar injeção de líquido, faça sempre o seguinte:
Engate o trinco de segurança do gatilho quando não estiver pulverizando.
Sempre aponte a pistola para longe de você mesmo(a) ou de outras pessoas.
Alivie a pressão antes de verificar ou reparar qualquer vazamento.
Alivie a pressão quando desligar o pulverizador ou parar de pulverizar.
Não utilize componentes classificados para uma pressão nominal inferior à pressão máxima de trabalho dos sistemas.
Nunca permita que crianças utilizem esta unidade. Se sofrer algum ferimento durante a utilização deste equipamento, procure o médico imediatamente.
ADVERTENCIA
Pueden ocurrir incendios y explosiones cuando se pulveriza fluido inflamable o cuando se lava con este tipo de fluido en un área donde la circulación de aire es deficiente y los vapores inflamables se pueden encender al contacto con el fuego o chispas.
Para prevenir incendios y explosiones:
Use en espacios abiertos o en un área muy bien ventilada.
No utilice nunca tricloretano–1,1,1, cloruro de metileno, u otros disolventes a base de hidrocarburos halógenos o fluidos que contengan tales disolventes en un equipo a presión de aluminio. El uso de estas sustancias puede provocar una intensa reacción química, con riesgos de explosión.
Retire, apague o desconecte todas las fuentes de ignición; asegure el interruptor de la pared con cinta. No fume en el área de pulverización.
Nunca llene el estanque de combustible mientras el motor esté en marcha o caliente.
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.
Nunca haga andar el motor dentro de un área cerrada.
¡ La inyección de fluido en la piel es una lesión seria! 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.
Para prevenir la inyección en la piel, siempre:
Enganche el seguro del gatillo cuando no use el pulverizador.
No apunte la pistola ni a sí mismo ni a los demás.
Alivie la presión antes de inspeccionar o reparar cualquier filtración.
Alivie la presión cuando apague el pulverizador o deje de usarlo.
No use componentes cuya capacidad nominal sea inferior a la presión máxima de operación del sistema.
No permita que niños usen esta unidad. Si se lesiona usando este equipo, sométase de inmediato a tratamiento médico.
Component Identification and Function
H G
A
K
B
V
U
R P S ti2377a
J
T
N
F
M ti2399
E
D
Fig. 1
A Motor
B Drive Assembly
D Displacement Pump
E Fluid Outlet
F Prime Valve
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 and drain sprayer (also relieves fluid outlet pressure) when open
G Fluid Filter Final filter of fluid to spray gun
H Pressure Adjusting Knob Controls fluid outlet pressure
J Pressure Control
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 Tip Guard
S Gun Safety Latch
T Power Cord Rack
U Suction Hose
V Drain Tube
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. Contactor II gun shown. Refer to your gun manual to properly set your gun safety latch.
Holds wrapped power cord for storage
Transfers fluid to be sprayed from source to pump
Fluid outlet used to drain and prime the sprayer
309714 3
General Repair Information
Pressure Relief Procedure
1.
Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.
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.
WARNING
ELECTRIC SHOCK HAZARD
MOVING PARTS HAZARD
To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, gaskets, screws, washers and shroud before operating sprayer.
2.
Test repair after problem is corrected.
3.
If sprayer does not operate properly , review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, pages 5 – 9, for other possible solutions.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4.
Unlock gun safety latch. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain valve open until ready to spray again.
If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above , VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.
WARNING
HOT SURFACES HAZARD
EXPLOSION HAZARD
Motor housing may be very hot during operation and could burn skin if touched.
Flammable materials spilled on hot, bare motor could cause fire or explosion.
Have motor shroud in place during operation to reduce risk of burns, fire or explosion or cut fingers.
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect wire. Never pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of insulated male connector in female connector.
Route wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.
CAUTION
Do not run sprayer dry for more than 30 seconds to avoid damaging pump packings.
4.
Install motor shroud before operation of sprayer and replace if damaged. Motor shroud directs cooling air around motor to prevent overheating. It can reduce risk of burns, fire or explosion, or cut fingers; see preceding WARNING .
4 309714
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.
Fig. 2. Both models require a 50/60 Hz, 15A circuit with a grounding receptacle.
2.
Do not alter ground prong or use adapter.
3.
A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used.
Grounding Plug
Fig. 2
Troubleshooting
Grounded
Outlets
Relieve pressure ; page 4.
MOTOR WON’T OPERATE
TYPE OF PROBLEM
Basic Fluid Pressure
Problems
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
1. Pressure control knob setting. Motor will not run if at minimum setting (fully counterclockwise).
1. Slowly increase pressure setting to see if motor starts.
Basic Mechanical
Problems
2. Spray tip or fluid filter may be clogged.
1. Pump (41) for frozen or hardened paint.
2. Relieve pressure and clear clog or clean filter; refer to separate gun or tip instruction manual.
1. Thaw sprayer if water or water-based paint has frozen in sprayer. Place sprayer in warm area to thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer, replace pump packings. See page 18 ( Displacement Pump Replacement ).
2. Displacement pump connecting rod pin (9a).
Pin must be completely pushed into connecting rod (9) and retaining spring (9b) must be firmly in groove of pump pin. See Fig. 10.
2. Push pin into place and secure with spring retainer.
3. Motor (54). Remove drive housing assembly
(42). See page 16. Try to rotate fan by hand.
3. Replace motor (54) if fan won’t turn. See page 17.
Basic Electrical Problems 1. Motor control board. Board shuts down and displays error code.
1. See Motor Control Board Diagnostics , page 13.
2. Electrical supply:
Meter must read 85–130 Vac.
2. Reset building circuit breaker; replace building fuse. Try another outlet.
3. Extension cord. Check extension cord continuity with volt meter.
3. Replace extension cord.
4. Sprayer power supply cord (56). Inspect for damage such as broken insulation or wires.
4. Replace power supply cord.
309714 5
Troubleshooting
MOTOR WON’T OPERATE (Continued)
TYPE OF PROBLEM
Basic Electrical Problems
(continued)
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
1 .
That motor leads are securely fastened and properly mated.
1. Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
2. For loose motor brush lead connections and terminals. See page 10.
2. Tighten terminal screws. Replace brushes if leads are damaged. See page 10.
3. Brush length which must be 1/2 in. minimum.
See page 10.
3. Replace brushes. See page 10.
NOTE: Brushes do not wear at the same rate on both sides of motor. Check both brushes.
4. For broken or misaligned motor brush springs.
Rolled portion of spring must rest squarely on top of brush. See page 10.
4. Replace spring if broken. Realign spring with brush. See page 10.
5. Motor brushes may be binding in brush holders.
See page 10.
5. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.
6. Motor armature commutator for burn spots, gouges and extreme roughness.
See page 10.
6. Remove motor and have motor shop resurface commutator if possible. See page 17.
7. Motor armature for shorts using armature tester
(growler) or perform spin test. See page 10.
7. Replace motor. See page 17.
Refer to wiring diagram, Fig.
7, to identify test points (TP).
1. Power supply cord (56). Connect volt meter between TP1 (neutral) and L2.
Plug in sprayer. Meter must read 85–130 Vac.
Unplug sprayer.
1. Replace power supply cord.
2. ON/OFF switch (58). Connect volt meter between L1 and L2 terminal on ON/OFF switch.
Plug in sprayer and turn ON.
Meter must read 85–130 Vac
2. Replace ON/OFF switch. See page 12.
3. All terminals for damage or loose fit.
3. Replace damaged terminals and reconnect securely.
6 309714
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF PROBLEM
Low 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 Warning, then replace tip. See your separate gun or tip manual.
2. Verify pump does not continue to stroke when gun trigger is released.
2. Service pump. See page 18.
3. Filter clogged.
3. Relieve pressure. Check and clean filter.
4. Prime valve leaking.
5. Suction hose connections.
4. Relieve pressure. Repair prime valve.
5. Tighten any loose connections.
6. Electrical supply with volt meter.
Meter must read 85–130 Vac.
Low voltages reduce sprayer performance.
6. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.
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.
7. Replace with a correct, grounded extension cord.
8. Leads from motor to pressure control circuit board (49) for damaged or loose wires or connectors. Inspect wiring insulation and terminals for signs of overheating.
8. Be sure male terminal blades are centered and firmly connected to female terminals.
Replace any loose terminal or damaged wiring. Securely reconnect terminals.
9. For loose motor brush leads and terminals. See page 10.
10.For worn motor brushes which must be 1/2 in.
minimum. See page 10.
9. Tighten terminal screws. Replace brushes if leads are damaged. See page 10.
10. Replace brushes. See page 10.
11. For broken and misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.
11. Replace spring if broken. Realign spring with brush. See page 10.
12.Motor brushes for binding in brush holders. See page 10.
12.Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.
13.Low stall pressure.
13. 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 transducer.
14.Motor armature for shorts by using an armature tester (growler) or perform spin test. See page 10.
14.Replace motor. See page 17.
309714 7
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Motor runs and pump strokes 1. Paint supply.
2. Intake strainer clogged.
WHAT TO DO
When check is not OK refer to this column
1. Refill and reprime pump.
2. Remove and clean, then reinstall.
3. Suction tube or fittings loose.
3. Tighten; use thread sealant or sealing tape on threads if necessary.
4. To see if intake valve ball and piston ball are seating properly. See page 18.
4. 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.
5. Leaking around throat packing nut which may indicate worn or damaged packings. See page 18.
5. Replace packings, page 18. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.
6. Pump rod damage.
6. Repair pump, page 18.
Motor runs but pump does not stroke
1. Displacement pump pin (32) (damaged or missing), page 18.
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 16.
2. Replace connecting rod assembly, page 16.
3. Gears or drive housing, page 16.
3. Inspect drive housing assembly and gears for damage and replace if necessary, page 16.
8 309714
Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
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
Motor is hot and runs intermittently.
1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up.
1. Decrease pressure setting or increase tip size.
2. Be sure ambient temperature where sprayer is located is no more than 90 F and sprayer is not located in direct sun.
2. Move sprayer to shaded, cooler area if possible.
ELECTRICAL SHORT
.
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 as soon as sprayer switch is turned on.
1. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page
17.
1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.
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.
2. For missing inspection plate gasket (see page
17), bent terminal forks or other metal to metal contact points which could cause a short.
2. Correct faulty conditions.
3. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page
10. Inspect windings for burns.
3. Replace motor. See page 17.
4. Motor control board (49) by performing motor control board diagnostics on page 13. If diagnostics indicate, substitute with a good board.
4. Replace with a new pressure control board
(35). See page 13.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature can burn out a good board.
1. Basic Electrical Problems on page 5.
1. Perform necessary procedures.
2. ON/OFF switch (58) See page 12. Be sure sprayer is unplugged!
Disconnect wires from switch. Check switch with ohmmeter. Reading must be infinity with ON/OFF switch OFF, and zero with switch ON.
Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.
3. For damaged or pinched wires in pressure control. See page 13.
Sprayer quits after sprayer operates for 5 to 10 minutes.
1. Basic Electrical Problems on page 5.
2. Replace ON/OFF switch. See page 12.
3. Replace damaged parts. See page 13.
1. Perform necessary procedures.
2. Electrical supply with volt meter.
Meter must read 85–130 Vac.
2. If voltage is too high, do not operate sprayer until corrected.
3. Tightness of pump packing nut. Over tightening tightens packings on rod, restricts pump action, and damages packings.
3. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary. See page 18.
309714 9
1.
Setup
Electric Shock Hazard; page 4.
Spin Test
To check armature, motor winding and brush electrical continuity:
Relieve pressure ; page 4.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1.
Connect red and black motor leads with test lead.
Turn motor fan by hand at about two revolutions per second.
2.
If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair as needed; page 10.
3.
If still uneven or no resistance, replace motor; page 17.
2.
Remove drive housing; page 16.
3.
Fig. 3. Remove pressure control cover (50). Disconnect connector (F).
4.
Fig. 4. Remove motor shroud (23) and inspection covers (A).
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 17.
Fig. 3
50
F
Motor Brush Removal
Motor Brush Replacement
Replace brushes worn to less than 1/2 in. Brushes wear differently on each side of motor, check both sides. Brush Repair Kit 287016 is available. Spring clip, 112766, may be purchased separately.
1.
Read General Repair Information ; page 4.
23 ti2572a
2.
Relieve pressure ; page 4.
3.
Fig. 4. Remove motor shroud (23) and two inspection covers (A).
(Continued on page 11)
Fig. 4
A ti2571a
10 309714
Motor Brush Replacement
4.
Fig. 5. Push in spring clip (A) to release hook (B) from brush holder (C). Pull out spring clip (A).
5.
Fig. 5. Pull brush lead (D) out of terminal (E).
Remove brush (F).
1 Motor lead; do not disconnect
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair Kit
F
D
3
A
B
2
1
C
D
A
1
B
F
C
Fig. 6
E
03881
4.
Repeat for other side.
5.
Test brushes.
a.
Remove pump (41); Displacement Pump
Replacement , page 18.
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.
E
Fig. 5 ti2542
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.
Motor Brush Installation
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).
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 (41); Displacement Pump Replacement , page 18.
309714 11
Removal
1.
On/Off Switch Replacement
Relieve pressure ; page 4.
Installation
1.
Install new ON/OFF switch (58). Install locking ring and toggle boot (30).
2.
Fig. 7. Remove four screws (12) and pressure control cover (50).
3.
Disconnect two wires (A) from ON/OFF switch (58).
4.
Remove toggle boot (30) and locking ring. Remove
ON/OFF switch (58).
2.
Connect two wires (A) to ON/OFF switch.
3.
Install pressure control cover (50) with four screws (12).
11
37a
30
37
A
19
58
49
6
47
50
D
E
38
12 ti2509a
Power
Plug
Ref 56
ON/OFF
Switch
Ref 58
Black
Black
Potentiometer Ref 37
L2 L1
TP1
Black
Green
Red (+)
Black (–)
White from Motor
2 x White
Fig. 7
12 309714
20
Black
Pressure
Transducer
Ref 38 ti2471
1.
Pressure Control Repair
Motor Control Board
Removal
Refer to Fig. 7 or 8 depending on sprayer voltage.
Installation
1.
Clean pad on rear of motor control board. Apply small amount of thermal compound 073019 to pad.
Relieve pressure ; page 4.
2.
Fig. 7. Install motor control board (49) with five screws (6).
2.
Remove four screws (12) and cover (50).
3.
Disconnect at motor control board (49):
Four motor leads: two white, black (–), or black/white (–), and red (+).
Lead (D) from potentiometer.
Lead (E) from transducer.
3.
Connect to motor control board (49):
Lead (E) to transducer.
Lead (D) to potentiometer.
Four motor leads: two white, black (–), or black/white (–), and red (+).
Lead (B) from display to plug (C), if display is installed.
Lead (B) from display to plug (C), if display is installed.
4.
Remove five screws (6) and circuit board (49).
4.
Install cover (50) with four screws (12).
Motor Control Board Diagnostics
Note: Keep a new transducer on hand to use for test.
CAUTION
Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if test transducer is used.
2.
Remove four screws (12) and cover (50).
See Fig. 7.
3.
Turn ON/OFF switch ON.
4.
Observe LED operation and reference following table:
1.
For sprayers with digital display, see Digital Display Messages , page 14.
5.
Relieve pressure and unplug sprayer before servicing control board ; page 4.
LED
BLINKS
Once
Two times repeatedly
Three times repeatedly
Four times repeatedly
Five times repeatedly
SPRAYER OPERATION
Sprayer runs
Sprayer shuts down and LED continues to blink two times repeatedly
Sprayer shuts down and LED continues to blink three times repeatedly
Sprayer shuts down and LED continues to blink four times repeatedly
Sprayer does not start or shuts down and LED continues to blink five times repeatedly
INDICATES
Normal operation
Run away pressure. Pressure greater than 4500 psi
(310 bar, 31 MPa) or damaged pressure transducer.
Pressure transducer is faulty or missing
Line voltage is too high
Motor fault
WHAT TO DO
Do nothing
Replace motor control board or pressure transducer.
Check transducer connection.
Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.
Check for voltage supply problems
Check for locked rotor, shorted wiring or disconnected motor. Repair or replace failed parts.
309714 13
Pressure Control Repair
Digital Display Messages
No display does not mean that sprayer is not pressurized. Relieve pressure before repair ; page 4.
DISPLAY
No Display
SPRAYER OPERATION
Sprayer stops. Power is not applied.
Sprayer may be pressurized.
INDICATION
Loss of power
ACTION
Check power source. Relieve pressure before repair or disassembly.
Spray psi bar
MPa
Sprayer is pressurized. Power is applied.
(Pressure varies with tip size and pressure control setting.)
Sprayer may continue to run. Power is applied.
Sprayer stops. Power is applied.
Normal operation
Pressure greater than 4500 psi (310 bar, 31 MPa) or pressure transducer faulty
Pressure transducer faulty, bad connection or broken wire.
Replace pressure control board or pressure transducer.
1.
Sprayer stops. Power is applied.
Power is applied.
Sprayer stops. Power is applied.
Pressure Control Transducer
Removal
Refer to Fig. 7 or 8 depending on sprayer voltage.
Relieve pressure ; page 4.
Line voltage too high
Sprayer does not start or stops. Power is applied.
Motor fault
Pressure less than
200 psi (14 bar, 1.4 MPa)
Empty paint pail. Loss of pressure.
Check transducer connection.
Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.
Check for voltage supply problem
Check for locked rotor, shorted wiring or disconnected motor.
Repair or replace failed parts.
Increase pressure if desired.
Drain valve may be open.
Refill paint pail. Check for leaks or clogged pump inlet. Repeat
Startup procedure.
4.
Connect lead (E) to motor control board (49).
5.
Install cover (50) with four screws (12).
Pressure Adjust Potentiometer
Removal
Refer to Fig. 7 or 8 depending on sprayer voltage.
1.
2.
Remove four screws (12) and cover (50).
3.
Disconnect lead (E) from motor control board (49).
4.
Remove two screws (47) and filter housing (15).
5.
Thread transducer lead plastic connector down through transducer grommet (20).
6.
Remove pressure control transducer (38) and packing o-ring (3) from filter housing.
Installation
1.
Install packing o-ring (3) and pressure control transducer (38) in filter housing (15). Torque to
30–35 ft-lb.
2.
Thread transducer lead plastic connector up through transducer grommet (20).
3.
Install filter housing (15) with two screws (47).
14 309714
Relieve pressure ; page 4.
2.
Remove four screws (12) and cover (50).
3.
Disconnect all leads from motor control board (49).
4.
Remove five screws (6) and board (49)
5.
Remove potentiometer knob (11), nut (37a) and pressure adjust potentiometer (37).
Installation
1.
Install pressure adjust potentiometer (37), nut
(37a) and potentiometer knob (11).
a.
Turn potentiometer fully clockwise.
b.
Install knob at full clockwise position.
2.
Install board (49) with five screws (6).
3.
Connect all leads to motor control board (49).
4.
Install cover (50) with four screws (12).
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.
4.
Release display button about 1 second after turning on sprayer.
Relieve pressure ; page 4.
2.
Plug in sprayer.
Sprayer model number displays (U395, U495) for a few seconds and then data point 1 is displayed.
5.
Push display button and next data point displays.
6.
Turn sprayer OFF and then ON to leave stored data mode.
3.
Hold down display button and turn sprayer ON.
2
3
4
Data Point
1
Definition
Number of hours power switch has been ON with power applied
Number or hours motor has been running
Last error code. Press and hold display button to clear error code to E=00
Software revision
309714 15
Drive Housing Replacement
CAUTION
Do not drop gear cluster (44) when removing drive housing (42). Gear cluster may stay engaged in motor front end bell or drive housing.
Disassembly
1.
Relieve pressure ; page 4.
2.
Remove two screws (12) and pump rod cover (70).
3.
Remove pump (41); Displacement Pump Replacement , page 18.
4.
Fig. 8. Remove two screws (12) and shroud (23).
5.
Remove two front screws (47).
6.
Remove two back screws (47).
7.
Pull drive housing (42) off of motor (54).
Assembly
1.
Fig. 8. Push drive housing (42) onto motor (54).
2.
Install two front screws (47).
3.
Install two back screws (47).
4.
Install shroud (23) with two screws (12).
5.
Install pump (41); Displacement Pump Replacement , page 18.
6.
Install pump rod cover (70) with two screws (12).
12
23
54
47
7
A
42
47
70
12 ti2570a
Fig. 8
16 309714
Disassembly
1.
Motor Replacement
7.
Remove two screws (47) and control housing (48).
8.
Remove two screws (47) and manifold (15).
Relieve pressure ; page 4.
2.
Remove pump (13); Displacement Pump Replacement , page 18.
CAUTION
Do not drop gear cluster (44) when removing drive housing (42). Gear cluster may stay engaged in motor front end bell or drive housing.
9.
Remove four screws (47) and motor (54) from frame (59).
Assembly
1.
Install new motor (54) on frame (59) with four screws (47).
2.
Install manifold (15) with two screws (47).
3.
Install control housing (48) with two screws (47).
4.
Install strain relief (19; page 12, 13).
3.
Remove drive housing (42); Drive Housing Replacement , page 16.
4.
Remove four screws (12) and cover (50).
5.
Install board (49) with five screws (6). Connect all leads to board.
6.
Install drive housing (42); Drive Housing Replacement , page 16.
5.
Disconnect all leads from board (49). Remove five screws (6) and board.
7.
Install pump (13); Displacement Pump Replacement , page 18.
6.
Remove strain relief (19; page 12, 13).
54
48
49
6
1
12
50
47
1
47
Fig. 9
47
1
15
Liberally apply grease ti2569a
309714 17
Displacement Pump Replacement
See manual 309053 for pump repair instructions.
See manual 309057 or 309058 for sprayer part number references.
Removal
1.
Flush pump (13).
4.
Cycle pump until pump pin (9a) is in position to be removed. Remove pump pin (9a).
2.
Relieve pressure ; page 4.
5.
Fig. 11. Remove suction tube (78) and hose (19).
6.
Loosen pump jam nut (12). Unscrew pump.
3.
Fig. 10. Loosen two screws (10b) and rotate cover (10a).
10b
10a 19
12
78
Fig. 10
9a ti2568a Fig. 11 ti2568a
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
3.
Push pump up until pump threads engage.
4.
Screw in pump until threads are flush with drive housing opening. Align pump outlet to back.
5.
Fig. 11. Install suction tube (78) and hose (19).
6.
Fig. 13. Screw jam nut (12) 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. 12. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod.
ti2568a
Fig. 13
7.
Fig. 14. Fill packing nut with Graco TSL until fluid flows onto top of seal.
A
10b ti2615a ti2568a
Fig. 12
2.
Fig. 10. Install pump pin (9a). Verify retainer spring
(9b) is in groove of pump pin.
18 309714
10a
Fig. 14 ti2568a
8.
Fig. 10. rotate cover (10a); tighten screws (10b).
Notes
309714 19
Technical Data
Model 100–120V,
∅
, A, Hz
Generator
Minimum W
Motor HP
(W)
395
495
1, 15, 60
1, 15, 60
3000
3750
5/8 (466)
3/4 (560)
Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc-plated carbon steel, nylon, stainless steel, PTFE
, Delrin , chrome plating, leather, UHMWPE, aluminum, tungsten carbide
NOTE: Delrin and PTFE
Cycles per gallon
(liter)
680 (180)
680 (180)
Noise Level
Maximum
Delivery gpm
(lpm)
0.45 (1.7)
0.54 (2.09)
Sound power
Maximum
Tip size
0.021
0.023
Fluid Outlet npsm
1/4 in.
1/4 in
. . . . . . . . . . . . . . . . . . . . . . . . 100 dBa*
Sound pressure . . . . . . . . . . . . . . . . . . . . . . .
* per ISO 3744; measured at 3.1 feet (1 m)
90 dBa*
Dimensions
Stand
Hi–Boy
43 (20)
66 (30)
395
Weight lb (kg)
43 (20)
66 (30)
495
21 (53.3)
29.5 (74.9) Handle down, 39.5 (100.3)
Handle up
15 (38.1)
21 (53.3)
14 (35.6)
20.5 (52.1)
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
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN USA 309714 1/2003
20 309714
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