Graco 3A0157B User's Manual
Contents
1. 3 695 795 Mark IV 32 WarnirijS 25305 ta Sew eas ae a ae eka 4 Removal 32 Component Identification 7 Installatlott ss mede AI REESE sexe 33 Pressure Relief Procedure 8 Displacement Pump Replacement Groundilld 59S saa us here eine ca DE 9 1095 1595 Mark V 34 Power Requirements 9 Removal errean iest on Eo D SUR ma tois e 34 Extension Cord 0 00 cee eee eee 9 Installation 35 li usupa ogee aw ees AUR eee ae d 9 Hos eB ee uu oe tees e ee erases bu u aska 37 Troubleshooting 10 Removal sbs kim anes eh bod EOS ei sss kasi ss 37 Mechanical Fluid Flow 10 Installation 38 sisse NEEDED Dm 13 Reed Switch Replacement 39 240 VAC and 110 VAC Motor Control Board 21 Removal sexes a baka sa eR e au a 39 240 VAC Filter Board 23 I slallaliohu au sans topi dm ui kas pasasha 39 Pressure Adjust Potentiometer 24 Wiring Diagram Lee 40 Pressure Control Transducer 25 120V Models 40 NoOleS i CC 27 120V Models with 15 20 Amp Switch 41 Drive and Bearing Housing Replacement 28 240V Models 42 DISASSOMDIY a1 2a ierann er Ser Rabeco acr V2. 1 Remove four screws 38 and cover 96 82 82 H5 ti13674a ese 2 Rotate new potentiometer shaft to highest pressure f setting fully clockwise and install knob 34 Use ti13493a allen wrench to tighten two screws on knob 2 Remove two screws and control panel 3 Disconnect potentiometer connector C from motor control board 95 ti13338a ti12997a 3 Connect potentiometer connector C to motor con trol board 4 Use allen wrench to loosen two screws on knob 34 34 A A S j ti12997a ti13207a 4 Install control panel and tighten two screws 5 Install cover 96 with four screws 38 5 Remove gasket 115 nut and potentiometer 82 from control panel 68 ti13493a 24 3A0157B Troubleshooting Pressure Control Transducer Removal 4 Remove four screws 39 and control box 61 Allow control panel 68 to hang down freely Perform Pressure Relief Procedure page 8 Wait 5 minutes before servicing 1 Remove four screws 38 and cover 96 ti13493a 5 Remove grommet 40 from control box then 2 Disconnect transducer connector E from motor remove transducer 86 and o ring 20 from filter control board 95 base 67 ti3495a ti12999a 95 3 Disconnect potentiometer connector C WatchDog 6 Remove grommet 40 from transducer and save for switch and reed switch connecto
3. T lt e We oU Do not modify plug Tampering with the plug will result in earth ground a voided warranty If plug will not fit in outlet have grounded outlet installed by a qualified electrician Do not use an adapter Power Requirements e 100 120V units require 100 120 VAC 50 60 Hz 15A 1 phase e 230V units require 230 VAC 50 60 HZ 10A ti14840a 1 phase i To maintain grounding continuity when flushing or Extension Cord relieving pressure hold metal part of spray gun firmly to side of a grounded metal pail Then trigger gun Use an extension cord with an undamaged ground con tact If an extension cord is necessary use a 3 wire 12 AWG 2 5 mm minimum Ground x fj D 120 volt plug x x 3A0157B 9 Troubleshooting Troubleshooting Mechanical Fluid Flow Perform Pressure Relief Procedure page 8 WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK go to next check When check is not OK refer to this column E XX is displayed 1 Fault condition exists 1 Determine fault correction from table page 13 False tripping of WatchDog 1 Operating conditions out of 1 Turn pressure down Refer to operation system EMPTY is dis WatchDog parameters Pump manual for adjusting Operate without played Pump does not output is low see below WatchDog active see operation manual run 10 3A0157B Troubleshooting WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK go to
4. 2 times repeatedly Check transducer and connections to control board Disconnect transducer from control board socket Check that transducer and control board contacts are clean and secure Reconnect transducer to control board socket Connect power set sprayer ON and control knob 1 2 turn clockwise If sprayer does not run properly set sprayer to OFF and go to next step Install new transducer Connect power set sprayer ON and control knob 1 2 turn clockwise Replace control board if sprayer does not run properly 3A0157B 13 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK Sprayer does not run at all Check transducer or transducer Digital display shows E 03 connections control board is not detecting a pressure signal Control board status light blinks 3 times repeatedly 14 HOW TO CHECK Set sprayer to OFF and disconnect power to sprayer Check transducer and connections to control board Disconnect transducer from control board socket Check to see if transducer and control board contacts are clean and secure Reconnect transducer to control board socket Connect power set sprayer ON and control knob to 1 2 turn clockwise If sprayer does not run set sprayer to OFF and go to next step Connect a confirmed working transducer to control board socket Set sprayer ON and control knob to 1 2 turn clockwise If sprayer runs install new transducer Replace control board if sprayer does not run C
5. Disconnect display connector A from motor control board 52 Remove bottom two screws 39 disconnect poten tiometer connector C from motor control board 52 Disconnect power cord connectors D and fil ter board connectors J from ON OFF switch 33 and remove control panel 68 Disconnect WatchDog switch connector X and reed switch connector L from motor control board Disconnect motor control board power connectors K from filter board 146 240 VAC 3A0157B 6 Remove four screws 163 from filter board 146 Installation Install filter board 146 with four screws 163 Connect motor control board power connectors K to filter board 146 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 Connect potentiometer connector C to motor con trol board 52 Connect WatchDog switch X and reed switch con nector L to motor control board Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 Install cover 96 with four screws 38 ti14890a 23 Troubleshooting Pressure Adjust Potentiometer Removal Installation 1 Install gasket 115 nut and potentiometer 82 on control panel 68 Torque nut to 30 35 in Ib 3 25 4 0 Nem Perform Pressure Relief Procedure page 8 Wait 5 minutes before servicing
6. trol board ti14697a 3A0157B 21 Troubleshooting 10 11 12 22 Make switch dip switch is moved to the left toward inside of board See Wiring Diagram page 40 Connect motor connectors F G and H and install into baffle Connect transducer connector E to motor control board Connect motor control board power connectors K to filter board 146 Install control box 61 with top two screws 39 Connect filter board power connectors J and power cord connectors D to ON OFF switch 33 Connect potentiometer connector C to motor con trol board Connect WatchDog switch X and reed switch con nector L to motor control board AN 1595 MAR 13 14 15 16 KV AZ Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 Install cover 96 with four screws 38 Install Motor Shroud for units equipped with Hose Reel only a Loosen but do not remove four nuts on shelf and slide shelf forward Replace shroud Slide shelf back and tighten four nuts on shelf Replace bottom screw from toolbox and tighten o o0 5 Replace pressure tube from sprayer D Replace bolts from motor shroud J A AN DL Flush h local 23 3 3A0157B Troubleshooting 240 VAC Filter Board Perform Pressure Relief Procedure page 8 Removal j 2 Remove four screws 38 and cover 96
7. green ground 40 3A0157B Wiring Diagram 120V Models with 15 20 Amp Switch Digital Display Potentiometer Pressure Transducer G Black JD E zi Watchdog L 20A 15A 1595 Switch ti12980b Black Power Plug END l green ground gt 3A0157B 41 Wiring Diagram 240V Models Thermal Switch Digital Display Potentiometer Pressure Transducer Motor Leads Dip i ul OOOO o e lt Brown A Blue S3 ON OFF amp Switch Brown Power Plug 42 3A0157B Notes Notes 4 3A0157B Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco com
8. follow board socket Make sure contacts are clean and Step 1 secure Control board status light blinks 6 times repeatedly Measure resistance of the thermal device If reading is not correct replace motor Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each model see table below ue Resistance Table ti13140a NN Reconnect thermal device connector to control board socket Connect power turn sprayer ON and control knob 1 2 turn clockwise If sprayer does not run replace control board Sprayer does not run at all Check the connections Control Turn power OFF yu is not receiving a motor position Digital display shows E 09 Sensor cial 9 P Disconnect motor position sensor and inspect for damage at connectors F lO LI Control board status light blinks Turn power ON If error continues replace motor 9 times repeatedly Heconnect sensor 3A0157B 17 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Check to see if control board is over 1 Make sure motor air intake is not blocked Digital display shows E 10 Make sure fan has not failed Make sure control board is properly connected to back plate and that conductive thermal paste is used on power components Control board status light blinks 10 times repeatedly Replace control board Replace motor Spraye
9. the green wire is not used in this test If all spin test is positive continue to step 6 Green Blue Red Black STEP 2 DN 432 1 I i STEP 3 15 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Control is commanding motor to run 6 Perform Field Short Test Test at large 4 pin motor Digital display shows E 05 but motor shaft does not rotate field connector There should not be continuity from Possibly locked rotor condition pin 4 the ground wire and any of the remaining an open connection exists between 3 pins If motor field connector tests fail motor and control there is a problem replace motor with motor or control board or motor amp draw is excessive Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the Control board status light blinks proper resistance for each model see table below 5 times repeatedly Resistance Table NNNM 16 3A0157B Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Allow sprayer to cool If sprayer runs NOTE Motor must be cooled down for the test a when cool correct cause of I Digital display shows E 06 Check thermal device connector yellow wires overheating Keep sprayer in cooler at control board location with good ventilation Make sure motor air intake is not blocked 2 Disconnect thermal device connector from control If sprayer still does not run
10. 7 Repair GRACO EN 3A0157B irless Sprayers ic A Electr For Portable Airless Spraying of Architectural Coatings and Paints For professional use only Not approved for use in European explosive atmoshere locations 3300 psi 227 bar 22 7 MPa Maximum Working Pressure e IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual Save these instructions ti15034a cO LO os o ct 5 e c Ke jmd amp Q tc 3A0158 311861 Boy 695 795 Premium Hi 1095 1595 Premium Hi Boy MARK V ti15036b ce pp Intertek PROVEN QUALITY LEADING TECHNOLOGY Models Models HI Boy UJ O lt 25887 25887 25887 25887 826124 826125 82612 N N ol O1 ol O1 lt CO CO CO NI NI Ni O NI N N O OINI NI O O SN lt gt 795 ULTRA MAX III QuikReel Hi Boy 25872 25872 25887 25887 258881 25888 826128 82612 cO EIE mnn m Y 1095 ULTRA MAX III QuikReel Lo Boy 7 258727 258728 258883 258884 258886 826130 4 NEN GEN 826131 4 1595 ULTRA MAX III QuikReel Hi Boy HII Lo Boy oo C1 lt FEEEEEEEE ANAM n MARK IV QuikReel Lo Boy 7 MARK V rB J A G QuikReel lt 3A0157B Table of Contents Table of Contents MOGBIS wipe gh dex HA XC s upip S oh uysha 2 Displacement Pump Replacement for Table of Contents
11. Pressure Control Prime Spray Valve Siphon Tube 8 Pump TM Bearing Housing ProConnect Drain Tube Trigger Lock Model serial tag 3A0157B Pressure Relief Procedure Pressure Relief Procedure 1 Turn power OFF Wait 7 seconds for power to dissipate ti4265a AN 2 Lock gun trigger safety Remove guard and SwitchTip ti10166a ti2769a 3 Turn pressure to lowest setting Trigger gun to relieve pressure ti14841a 4 Put drain tube in pail Turn prime valve down to DRAIN position ti2595a ti14842a 3A0157B Grounding Grounding The sprayer must be grounded Grounding reduces the Pails risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit Solvent and oil based fluids follow local code Use only conductive metal pails placed on a grounded sur NES Qs C face such as concrete e Ya Sa XQ Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continu The plug must be plugged into an outlet that is properly Ity installed and grounded in accordance with all local codes and ordinances ti2810a x k de Grounding a metal pail connect a ground wire to the ti2810a t4297a pail by clamping one end to pail and other end to a true The sprayer cord includes a grounding wire with an appropriate grounding contact
12. familiar with the controls rFSI 3A0157B 5 Warnings AX WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Always wear appropriate gloves eye protection and a respirator or mask when painting Do not operate or spray near children Keep children away from equipment at all times Do not overreach or stand on an unstable support Keep effective footing and balance at all times Stay alert and watch what you are doing Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not kink or over bend the hose Do not expose the hose to temperatures or to pressures in excess of those specified by Graco Do not use the hose as a strength member to pull or lift the equipment ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regula tions PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical react
13. if necessary see pump manual 310643 or 310894 Excessive paint leakage 1 Throat packing nut is loose 1 Remove throat packing nut spacer into throat packing nut Tighten throat packing nut just enough to stop leakage 2 Throat packings are worn or 2 Replace packings see pump manual damaged 310643 or 310894 3 Displacement rod is worn or 3 Replace rod see pump manual 310643 or damaged 310894 Air in pump or hose 1 Check and tighten all fluid connections Cycle pump as slowly as possible during Fluid is spitting from gun priming 2 Tipis partially clogged 2 Clear tip see tip guard manual 309640 3 Fluid supply is low or empty 3 Refill fluid supply Prime pump see pump manual 310643 or 310894 Check fluid supply often to prevent running pump dry 1 Airin pump or hose 1 Check and tighten all fluid connections Cycle pump as slowly as possible during priming Pump is difficult to prime 2 Intake valve is leaking 2 Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve 3 Pump packings are worn 3 Replace pump packings see pump man ual 310643 or 310894 4 Paint is too thick 4 Thin the paint according to supplier rec ommendations No display sprayer operates 1 Display is damaged or has bad 1 Check connections Replace display connection 12 3A0157B Troubleshooting Electrical Symptom Sprayer does not run or stops running Perf
14. next check When check is not OK refer to this column 1 Follow Pressure Relief Procedure on page 8 then replace tip See your sepa Pump output is low 1 Spray tip worn rate gun or tip manual 2 Spray tip clogged 2 Relieve pressure Check and clean spray tip 3 Paint supply 3 Refill and reprime pump 4 Intake strainer clogged 4 Remove and clean then reinstall 5 Intake valve ball and piston ball 5 Remove intake valve and clean Check are not seating properly balls and seats for nicks replace if neces sary see pump manual 310643 or 310894 Strain paint before using to remove particles that could clog pump 6 Suction hose connections 6 Tighten any loose connections Check for missing or damaged seals 7 Fluid filter tip filter or tip is 7 Clean filter see operation manual clogged or dirty 8 Prime valve leaking 8 Relieve pressure Repair prime valve 9 Verify pump does not continue to 9 Service pump see pump manual 310643 stroke when gun trigger is or 310894 released Prime valve not leak ing 10 Leaking around throat packing 10 Replace packings see pump manual Also nut which may indicate worn or check piston valve seat for hardened paint damaged packings or nicks and replace if necessary Tighten packing nut wet cup 11 Pump rod damage 11 Repair pump See pump manual 310643 or 310894 12 Low stall pressure 12 Turn pressure knob fully clockwise Make sure pressu
15. within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco produc
16. Installation 1 Adgjust piston rod with pin holder to pull out piston rod Tap piston rod on hard surface to push in piston rod XL 2 Push pump collar flush with bearing housing ledge to be able to close pump door ti6375a sa 8 Ratchet pump door forward ti6377a ti5492a 3 Slide pump into connecting rod Push pump pin until it is fully retained NOTE Pin will snap into position 3A0157B 35 Displacement Pump Replacement 1095 1595 Mark V 4 Close pump door and rotate latch into position Do 7 Attach drain hose to sprayer not tighten latch ti7329a a sa By dest3a Q 1 ji P amp 21 U SJ NS lt c ti7330a 8 Fillpump with Graco TSL until fluid flows onto top of 5 Rotate pump to align with paint hose Connect paint seal hose and hand tighten to 70 in Ib ti6299a tib493a 6 Tighten latch and rotate latch lock into locked posi tion TI6312a 36 3A0157B Hose Reel Hose Reel Removal 5 Remove snap ring 1 Remove hose fitting from swivel cap and completely remove hose ti13542a ti13539a 2 ti15024a lt wW ti13675a 3 ti13538a 4 ti13543a 3A0157B 37 Hose Reel Installation 1 Grease shaft Install hose to swivel Make sure to route hose through side arm of hose reel D ti13537a P d ti13539a 2 Make sure two washers an
17. d in or near the sprayer or for flushing or clean ing keep sprayer at least 20 feet 6 m away from explosive vapors SKIN INJECTION HAZARD N Do not aim the gun at or spray any person or animal Keep hands and other body parts away from the discharge For example do not try to stop leaks with G2 any part of the body Always use the nozzle tip guard Do not spray without nozzle tip guard in place 9 Use Graco nozzle tips Use caution when cleaning and changing nozzle tips in the case where the nozzle tip clogs while spray ing follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit High pressure spray is able to inject toxins into the body and cause serious bodily injury In the event that injection occurs get immediate surgical treatment Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3300 psi Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections are secure before operating the unit Know how to stop the unit and bleed pressure quickly Be thoroughly
18. d wave spring are on hub fore hose reel is installed s b 7 Turn hose reel clockwise to wrap up hose Make sure hose is routed through hose guide lt cg EEE ti13545a 3 Install hose reel onto frame Place C clamp on reel and frame to allow snap ring to fit into place Install 4 Install swivel ti13543a 5 Install E clip and swivel cap ti13538a 38 3A0157B Reed Switch Replacement Removal 1 Remove four screws and remove display cover S SS WAS ANS A ANN X ti13571a ti13572a 4 Unscrew reed switch from control panel ti13573a 3A0157B Installation d Reed Switch Replacement Apply thread sealant to end of reed switch Hand tighten reed switch until it is tight against control panel ti13574a Add thread sealant and tighten jam nut against threaded bus 7Z ti13576a Connect reed switch to control board Ne s ti13572a 2 ti13571a Ud Replace display cover and tighten four screws gt ti13568a 39 Wiring Diagram Wiring Diagram 120V Models Potentiometer Thermal Switch Digital Display Pressure Transducer C Dip Switch K G Son Motor 5 915 Leads E Watchdog Sensor Leads Q ig fact tal ti13484b ON OFF Switch Black Power Plug
19. eg 28 NOTES fees ccd ri E uu Qata taa quri aus Sd e web 43 ASSBIBDIV 25 pg aaa kiss RUE actos de huta kau 28 Graco Standard Warranty 44 Motor Replacement 30 Removal 30 IFistallatlOlt 3 23 9d yuya RERO uuu iwaw aaa 30 3A0157B 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where appli cable o Ay WARNING GROUNDING This product must be grounded In the event of an electrical short circuit grounding reduces the risk of elec tric shock by providing an escape wire for the electric current This product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Improper installation of the grounding plug is able to result in a risk of electric shock When repair or replacement of the cord or plug is required do not connect the grounding wire to either flat blade terminal The wire with insulation having an outer surface that is green with or without yellow stripes is the ground ing wire Check w
20. heck transducer resistance with ohmmeter less than 9k ohm between red and black wires and 3 6k ohm between green and yellow wires 3A0157B TYPE OF PROBLEM WHAT TO CHECK Control is commanding motor to run Digital display shows E 05 but motor shaft does not rotate Possibly locked rotor condition an open connection exists between motor and control there is a problem with motor or control board or motor amp draw is excessive Control board status light blinks 5 times repeatedly 3A0157B Troubleshooting HOW TO CHECK Hemove pump and try to run sprayer If motor runs check for locked or frozen pump or drive train If sprayer does not run continue to step 2 Set sprayer to OFF and disconnect power to sprayer Disconnect motor connector s from control board socket s Check that motor connector and control board contacts are clean and secure If contacts are clean and secure continue to step 4 Set sprayer to OFF and spin motor fan 1 2 turn Restart sprayer If sprayer runs replace control board If sprayer does not run continue to step 5 Perform Spin Test Test at large 4 pin motor field connector Disconnect fluid pump from sprayer Test motor by placing a jumper across pins 1 amp 2 Rotate motor fan at about 2 revolutions per second A cogging resistance to motion should be felt at the fan The motor should be replaced if no resistance is felt Repeat for pin combinations 1 amp 3 and 2 amp 3 Pin 4
21. i7169a threads of the drive housing will be damaged 1 Extend pump piston rod 1 5 in Apply grease to top of pump rod at A or inside connecting rod ti7171a 2 Install pump pin 44 Verify retaining spring 43 is in groove of connecting rod 85 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 Install washers o rings and suction tube 76 and hose 94 6 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 Nem 7 Install pump rod shield 108 with screw 31 3A0157B 33 Displacement Pump Replacement 1095 1595 Mark V Displacement Pump Replacement 1095 1595 Mark V Removal 1 Flush pump 2 Stop pump with piston rod in its lowest position 3 Perform Pressure Relief Procedure page 8 4 Separate drain hose from sprayer ti6300a 34 Raise latch lock Push latch open tio369a Ratchet open pump door a Ratchet pump door forward ti6373a b Twist latch u bolt out of pump door recess c Place u bolt on pump door outer edge d If pump door is stuck do steps e f and 8 other wise go to step 9 e Twist latch u bolt back from pump door outer edge ti6374a 3A0157B Displacement Pump Replacement 1095 1595 Mark V f Place u bolt on pump door protrusion
22. ion and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment fol low the Pressure Relief Procedure and disconnect all power sources 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 hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 6 3A0157B Component Identification Component Identification ti14839b gt amp Q XD OQ S o e 2 A ON OFF switch WatchDog Switch not available on Mark V
23. ith a qualified electrician or serviceman when the grounding instructions are not completely understood or when in doubt as to whether the product is properly grounded Do not modify the plug provided if it does not fit the outlet have the proper outlet installed by a qualified electrician This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below e Only connect the product to an outlet having the same configuration as the plug e Do not use an adapter with this product Extension Cords Use only a 3 wire extension cord that has a 3 blade grounding plug and a 3 slot receptacle that accepts the plug on the product Make sure your extension cord is not damaged If an extension cord is necessary use 12 AWG 2 5 mm minimum to carry the current that the product draws An undersized cord results in a drop in line voltage and loss of power and overheating 3A0157B Warnings 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 e Do not spray flammable or combustible materials near an open flame or sources of ignition such as cig arettes motors and electrical equipment Paint or solvent flowing through the equipment is able to result in static electricity Static electricity cre ates a risk of fire or explosion in the presence of paint or solvent fumes All parts of
24. lacement page 32 695 795 page 34 1095 1595 Mark V Assembly Make sure gear 89 and thrust washers 28 30 90a 36 see page 29 are in place Brush grease onto gear teeth 1 Push drive housing 90 onto motor 84 and install with five screws 6 Torque to 190 210 in Ib 21 23 Nem 2 Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft Ib 34 40 Nem 3 Install front cover 51 with four screws 31 4 Install shroud 72 with two screws 158 5 Install pump 91 see Displacement Pump Replacement page 32 695 795 page 34 1095 1595 Mark V 6 Install pump rod cover 108 and pail hanger 55 with screw 31 and two nuts 24 28 3A0157B Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement 158 I N O co lt Te 29 3A0157B Motor Replacement Motor Replacement Removal Perform Pressure Relief Procedure page 8 1 Remove pump 91 see Displacement Pump Replacement page 32 695 795 page 34 1095 1595 Mark V NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing 2 30 Remove drive housing 90 see Drive Housing Replacement page 28 Remove Motor Shroud a Remove bolts from motor shroud b Remove pressure tube from sprayer c Remove bottom screw from toolbox d Loosen but do not remove four
25. ncorrect resistance replace motor The motor has a defective thermal device Connect a test transducer to the board Does the motor run Replace the control board Replace the transducer 19 Troubleshooting rcu STEP 1 STEP 2 STEP 3 110 120 AC Plug power cord in 110 1204C Plug power cord in Check motor thermistor and turn switch ON land turn switch ON SSS Unplug yellow wires Meter aye Connect wires to E Connect wires to gt Should read according to control board and D control board and P Resistance Table on page 17 D on off switch Turn on off switch Turn NOTE Motor should be cool 6 meter to AC Volts meter to AC Volts A during reading Thermal Switch On Off On Off Switch Control Board Thermal Switch v di To Optional Potentiometer Display STEP 4 brassnre Plug power cord Transducer in and turn switch Y ON Disconnect X Black SOLD potentiometer Y AutoClean Cart Control WatchDog Switch On Open Off Closed I 7 R L i Switch 9 1 15 Amp Closed RL 20 Amp Open Green Ground D lt On Off Switch ox 1 Black GFI Filter Coil Green Ground ele Power Plug 20 3A0157B Troubleshooting 240 VAC and 110 VAC Motor Control Board Removal Installation 1 Use acetone or equi
26. nuts on shell Carefully slide shelf forward e Remove shroud Slide shelf back and tighten four nuts on shelf Hemove four screws 38 and control cover 96 Remove bottom two screws 39 and allow control panel 68 to hang down freely Disconnect all three motor connectors from motor Hemove top two screws 39 and control housing 61 Hemowve strain relief 29 from motor wires and power bar plate 69 Remove motor wires from baffle 278075 and remove baffle 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 Installation Slide new motor 84 under two screws 23 in cart frame 62 near control Install two screws 23 and nuts 19 on motor side opposite control Install baffle and connect motor wires Tighten all four screws 23 and nuts 19 torque nuts to 115 135 in Ib 13 15 Nem Install strain relief 29 onto motor wires and into power bar plate 69 Install control housing 61 with top two screws 39 Connect all three motor connectors to motor Install control panel 68 with two screws 39 Install control cover 96 with four screws 38 Install drive housing 90 see Drive Housing Replacement page 28 Install pump 91 see Displacement Pump Replacement page 32 695 795 page 34 1095 1595 Mark V Install Motor Shroud a Loosen but do not remove f
27. orm Pressure Relief Procedure page 8 To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting wait 30 sec onds after unplugging power cord for stored electricity to dissipate Keep clear of electrical and moving parts during troubleshooting procedures Plug sprayer into correct voltage grounded outlet oet power switch OFF for 30 seconds and then ON l again this ensures sprayer is in normal run mode ANN If no digital display is available use control Turn pressure control knob clockwise 1 2 turn E board status light to e oo prob jue lems Turn ON OFF switch OFF remove control cover and then turn power back ON Observe status light Blinking LED to tal count equals digital error code i e two blinks equals E202 View digital display TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Control board status light never lights Sprayer does not run at all Check transducer or transducer Make sure there is no pressure in the system see Digital display shows E202 connections Pressure Relief Procedure page 8 Check fluid path for clogs such as clogged filter 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 Set sprayer to OFF and disconnect power to Control board status light blinks sprayer
28. our nuts on shelf and slide shelf forward b Replace shroud c Slide shelf back and tighten four nuts on shelf d Replace bottom screw from toolbox and tighten e Replace pressure tube from sprayer f Replace bolts from motor shroud 3A0157B Motor Replacement Motor Replacement ti14893a 31 3A0157B Displacement Pump Replacement for 695 795 Mark IV Displacement Pump Replacement for 695 795 Mark IV See pump manual 310643 or 310894 for pump repair 6 Loosen pump jam nut 56 Unscrew pump instructions See manual 3A0158 for applicable sprayer part number references Removal 94 1 Flush pump 2 Perform Relieve Pressure Procedure page 8 3 Remove screw 31 and slide pump rod shield 108 forward ti7167b 74V CREA 31 ti14894a 4 Increase pressure slightly to 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 Remove suction tube 76 hose 94 and any wash ers and o rings 32 3A0157B Displacement Pump Replacement for 695 795 Mark IV Installation 8 Fill packing nut with Graco TSL until fluid flows onto top of seal 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 NOTICE If the pump jam nut loosens during operation the t
29. ponent parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought
30. r Will Not Shut Off 1 Perform Pressure Relief Procedure page 8 Leave 2 Remove control box cover so the control board prime valve open and power switch OFF status light can be viewed if available Troubleshooting Procedure Plumb pressure gauge into paint hose plug sprayer in and turn power Mechanical problem See the proper fluid pump manual for the sprayer for further trouble shooting procedures switch ON Does sprayer reach or exceed its maximum pressure YES Unplug the transducer from control NO gt Replace the control board board Does motor stop running YES Bad transducer Replace and test with a new one 18 3A0157B Sprayer Will Not Run See following page for steps Remove control box cover Turn sprayer ON Observe control board status light on control board see page 13 See Step 1 Do Nolight J o you have over Peat for 220V units Light on Control board Continuously commanding motor to run Flashing See Error Code section for further troubleshooting YES See Step 3 Is the proper reading present through the thermal switch wires YES See step 4 Does the motor run YES Replace potentiometer Pressure switch 3A0157B Troubleshooting See Step 2 Do Repair or you have over replace 100 AC volts power cord YES Replace the ON OFF switch If motor is hot let cool and retest If Step 4 still shows i
31. r from motor con reuse trol board 40 ti13722a N V ti13495a 3A0157B 25 Troubleshooting Installation 1 Install o ring 20 and transducer 86 in filter base 4 Connect potentiometer connector C WatchDog 67 Torque to 35 45 ft lb 47 61 Nem Install grom switch and reed switch connector to control board met onto transducer 86 and transducer into control box 40 86 5 Install cover 96 with four screws 38 2 Connect transducer connector E WatchDog switch and reed switch connector to control board 96 95 38 ti13493a ti12999a 3 Install control box 61 and control panel 68 with four screws 39 ti7458a 3 26 3A0157B Notes Notes 2 3A0157B Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing Disassem bly 3 Remove two screws 158 and shroud 72 4 Remove four screws 31 and front cover 51 5 Remove four screws 14 and washers 12 to remove bearing housing 83 and connecting rod 85 Perform Pressure Relief Procedure page 8 6 Remove five screws 6 and pull drive housing 90 1 Remove screw 31 two nuts 24 pail hanger 55 off motor 84 and pump rod cover 108 2 Remove pump 91 see Displacement Pump Rep
32. re control knob is properly installed to allow full clockwise position If problem persists replace pressure trans ducer 13 Piston packings are worn or 13 Replace packings see pump manual damaged 310643 or 310894 14 O ring in pump is worn or dam 14 Replace o ring see pump manual 310643 aged or 310894 15 Intake valve ball is packed with 15 Clean intake valve see pump manual material 310643 or 310894 16 Pressure setting is too low 16 Increase pressure see pump manual 310643 or 310894 17 Large pressure drop in hose with 17 Use larger diameter hose and or reduce heavy materials overall length of hose Use of more than 100 ft of 1 4 in hose significantly reduces performance of sprayer Use 3 8 in hose for optimum performance 50 ft minimum 3A0157B 11 Troubleshooting WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK go to next check When check is not OK refer to this column Motor runs but pump does 1 Displacement pump pin 32 1 Replace pump pin if missing Be sure not stroke damaged or missing see pump retainer spring 31 is fully in groove all manual 310643 or 310894 around connecting rod see pump manual 310643 or 310894 2 Connecting rod assembly 43 2 Replace connecting rod assembly see damaged see pump manual pump manual 310643 or 310894 310643 or 310894 3 Gears or drive housing dam 3 Inspect drive housing assembly and gears aged page 28 for damage and replace
33. the spray system including the pump hose assembly spray gun and objects in and around the spray area shall be prop erly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless paint sprayer hoses Do not clean with materials having flash points lower than 70 F 21 C Use water based material or mineral spirits type material only For complete information about your fluid request the MSDS from the fluid distributor or retailer Verify that all containers and collection systems are grounded to prevent static discharge Connect to a grounded outlet and use grounded extensions cords Do not use a 3 to 2 adapter Do not use a paint or a solvent containing halogenated hydrocarbons Keep spray area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not spray pump assembly Do not smoke in the spray area Do not operate light switches engines or similar spark producing products in the spray area Keep area clean and free of paint or solvent containers rags and other flammable materials Know the contents of the paints and solvents being sprayed Read all Material Safety Data Sheets MSDS and container labels provided with the paints and solvents Follow the paint and solvents manu facturer s safety instructions Fire extinguisher equipment shall be present and working Sprayer generates sparks When flammable liquid is use
34. ts visit www graco com TO PLACE AN ORDER 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 This manual contains English MM 3A0157 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised 09 201 1
35. valent cleaner to thoroughly remove thermal paste from pockets on powerbar Perform Pressure Relief Procedure page 8 Wait 5 minutes before servicing 1 Remove Motor Shroud for units equipped with Hose Reel only Remove bolts from motor shroud bar a b Remove pressure tube from sprayer 2 c Remove bottom screw from toolbox d Loosen but do not remove four nuts on shelf Carefully slide shelf forward e Remove shroud f Slide shelf back and tighten four nuts on shell 2 Remove all four screws 38 and cover 96 ti14693a 3 Disconnect display connector A from motor control board 52 3 Replace two inner screws to control board and torque to 17 in lb 1 Nem 4 Remove bottom two screws 39 disconnect poten tiometer connector C from motor control board 52 Disconnect power cord connectors D and fil ter board connectors J from ON OFF switch 33 and remove control panel 68 5 Disconnect WatchDog switch connector X and reed switch connector L from motor control board ti14696a 6 Disconnect motor control board power connectors K from filter board 146 4 Replace six outer screws to control board and 7 Remove top two screws 39 and control box 61 torque to 11 in Ib 1 25 Nem 8 Disconnect transducer connector E from motor control board 9 Disconnect motor connectors F G and H 10 Remove six screws 27 two screws 102 and con
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