Repair 3A0157B Electric Airless Sprayers EN 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 IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual. Save these instructions.
Models: Models: Model 258719 258720 258722 258872 258873 258874 258876 258877 826124 826125 826127 Model 258723 258724 258878 258879 258881 258882 826128 826129 Model 258727 258728 258883 258884 258886 826130 826131 Model 258763 258764 258765 258766 826132 826133 826134 826135 Model 258729 Model 258730 258887 2 695 ULTRA MAX lIl QuikReel Hi-Boy ✓ ✓ ✓ Lo-Boy ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 795 ULTRA MAX III QuikReel Hi-Boy ✓ ✓ ✓ ✓ ✓ Lo-Boy ✓ ✓ ✓ ✓ ✓ 1095 ULTRA MAX III QuikReel Hi-Boy ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 159
Table of Contents Table of Contents Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Identification . . . . . . . . . . . . . . . . . . . . 7 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power Requirements . . . . . . . . .
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 applicable. WARNING GROUNDING This product must be grounded.
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: • • • • • • • • • • • • • Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment. Paint or solvent flowing through the equipment is able to result in static electricity.
Warnings 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.
Component Identification Component Identification 13. 12. 1. 2. 11. 3. 4. 5. 6. 7. 8. 9. 10.
Pressure Relief Procedure Pressure Relief Procedure 1. Turn power OFF. Wait 7 seconds for power to dissipate. ti4265a 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.
Grounding Grounding The sprayer must be grounded. Grounding reduces the 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. The sprayer cord includes a grounding wire with an appropriate grounding contact. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. Pails Solvent and oil/based fluids: follow local code.
Troubleshooting Troubleshooting Mechanical/Fluid Flow Perform Pressure Relief Procedure; page 8. 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 E=XX is displayed 1. Fault condition exists 1. Determine fault correction from table, page 13. False tripping of WatchDog system. EMPTY is displayed. Pump does not run. 1. Operating conditions out of WatchDog parameters. Pump output is low, see below. 1. Turn pressure down.
Troubleshooting TYPE OF PROBLEM Pump output is low WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column 1. Spray tip worn 1. Follow Pressure Relief Procedure on page 8, then replace tip. See your separate 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.
Troubleshooting TYPE OF PROBLEM Motor runs but pump does not stroke Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column 1. Displacement pump pin (32) damaged or missing; see pump manual 310643 or 310894. 1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod; see pump manual 310643 or 310894. 2.
Troubleshooting Electrical Symptom: Sprayer does not run or stops running. Perform Pressure Relief Procedure; page 8. • Plug sprayer into correct voltage, grounded outlet • Set power switch OFF for 30 seconds and then ON again (this ensures sprayer is in normal run mode).
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=03 Control board status light blinks 3 times repeatedly 14 WHAT TO CHECK Check transducer or transducer connections (control board is not detecting a pressure signal). HOW TO CHECK 1. Set sprayer to OFF and disconnect power to sprayer. 2. Check transducer and connections to control board. 3. Disconnect transducer from control board socket. Check to see if transducer and control board contacts are clean and secure.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=05 WHAT TO CHECK HOW TO CHECK Control is commanding motor to run 1. but motor shaft does not rotate. Possibly locked rotor condition, an open connection exists between 2. motor and control, there is a problem with motor or control board, or motor amp draw is excessive. 3. Control board status light blinks 5 times repeatedly Remove pump and try to run sprayer.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=05 Control board status light blinks 5 times repeatedly WHAT TO CHECK Control is commanding motor to run 6. 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 7. motor amp draw is excessive. HOW TO CHECK Perform Field Short Test: Test at large 4-pin motor field connector.
Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Allow sprayer to cool. If sprayer runs NOTE: Motor must be cooled down for the test. when cool, correct cause of Digital display shows E=06 1. 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.
Troubleshooting TYPE OF PROBLEM Sprayer does not run at all Digital display shows E=10 WHAT TO CHECK HOW TO CHECK Check to see if control board is over 1. heating. 2. Control board status light blinks 10 times repeatedly Make sure motor air intake is not blocked. Make sure fan has not failed. 3. Make sure control board is properly connected to back plate and that conductive thermal paste is used on power components. 4. Replace control board. 5. Replace motor. Sprayer Will Not Shut Off 1.
Troubleshooting 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). No light Once Normal operation Light on Continuously Control board commanding motor to run Flashing See Error Code section for further troubleshooting See Step 1. Do you have over 100 AC volts (200 for 220V units)? NO See Step 2. Do you have over 100 AC volts? NO Repair or replace power cord.
Troubleshooting V - 110-120 AC V - STEP 2: Plug power cord in and turn switch ON. Connect wires to control board and on/off switch. Turn meter to AC Volts. 100k ohm - - Thermal Switch Black Black STEP 3: Check motor thermistor. Unplug yellow wires. Meter should read according to Resistance Table on page 17. NOTE: Motor should be cool during reading. - + 110-120 AC STEP 1: Plug power cord in and turn switch ON. Connect wires to control board and on/off switch. Turn meter to AC Volts.
Troubleshooting 240 VAC and 110 VAC Motor Control Board Removal Installation 1. Use acetone or equivalent 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): ti14695a a. Remove bolts from motor shroud. b. Remove pressure tube from sprayer. c. Remove bottom screw from toolbox. 2. Apply new thermal paste into both pockets of powerbar. d.
Troubleshooting 5. Make switch dip switch is moved to the left (toward inside of board). See Wiring Diagram, page 40. 6. Connect motor connectors (F, G and H) and install into baffle. 7. Connect transducer connector (E) to motor control board. 13. Install control panel (68) with two screws (39). 14. Connect display connector (A) to motor control board (52). 15. Install cover (96) with four screws (38) 16. Install Motor Shroud (for units equipped with Hose Reel only): 8.
Troubleshooting 240 VAC Filter Board 6. Remove four screws (163) from filter board (146). Installation 1. Install filter board (146) with four screws (163). Perform Pressure Relief Procedure; page 8. 2. Connect motor control board power connectors (K) to filter board (146). Removal 3. 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. 1. Remove four screws (38) and cover (96). 2.
Troubleshooting Pressure Adjust Potentiometer Removal Installation 1. Install gasket (115), nut and potentiometer (82) on control panel (68). Torque nut to 30-35 in-lb (3.25 4.0 N•m). 68 Perform Pressure Relief Procedure; page 8. Wait 5 minutes before servicing. 1. Remove four screws (38) and cover (96). 82 82 115 96 ti13674a 38 2. Rotate new potentiometer shaft to highest pressure setting (fully clockwise) and install knob (34). Use allen wrench to tighten two screws on knob. ti13493a 2.
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). ti7458a 68 39 ti13494a 61 96 38 ti13493a 2. Disconnect transducer connector (E) from motor control board (95). 5. Remove grommet (40) from control box then remove transducer (86) and o-ring (20) from filter base (67).
Troubleshooting Installation 1. Install o-ring (20) and transducer (86) in filter base (67). Torque to 35-45 ft-lb (47-61 N•m). Install grommet onto transducer (86) and transducer into control box. 40 4. Connect potentiometer connector (C), WatchDog switch, and reed switch connector to control board. 67 C ti7447a ti13722a 86 ti13496a 20 5. Install cover (96) with four screws (38). 2. Connect transducer connector (E), WatchDog switch, and reed switch connector to control board (95).
Notes Notes 3A0157B 27
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. Disassembly 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. 1.
Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement 72 158 84 51 90 6 31 85 12 14 83 24 31 108 55 91 ti14892a 3A0157B 29
Motor Replacement Motor Replacement Removal 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). Perform Pressure Relief Procedure; page 8. Installation 1. Remove pump (91); see Displacement Pump Replacement, page 32 (695/795) page 34 (1095/1595/Mark V). 1. Slide new motor (84) under two screws (23) in cart frame (62) near control.
Motor Replacement Motor Replacement 58 158 84 19 36 61 90a 28 96 89 30 158 51 90 6 12 14 68 31 23 39 19 90 6 12 14 91 ti14893a 3A0157B 31
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 instructions. 6. Loosen pump jam nut (56). Unscrew pump. 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. 56 76 ti7167b 31 108 ti14894a 4.
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 threads of the drive housing will be damaged. ti7169a 1. Extend pump piston rod 1.5 in. Apply grease to top of pump rod at (A) or inside connecting rod.
Displacement Pump Replacement 1095/1595/Mark V Displacement Pump Replacement 1095/1595/Mark V Removal 6. Raise latch lock. Push latch open. ti6369a 1. Flush pump. 2. Stop pump with piston rod in its lowest position. 3. Perform Pressure Relief Procedure, page 8. ti6370a 4. Separate drain hose from sprayer. 7. Ratchet open pump door. a. Ratchet pump door forward. ti6373a 5. Disconnect paint hose from pump. ti6300a b. Twist latch u-bolt out of pump door recess. c.
Displacement Pump Replacement 1095/1595/Mark V f. Place u-bolt on pump door protrusion. Installation 1. Adjust piston rod with pin holder to pull out piston rod. Tap piston rod on hard surface to push in piston rod. 2. Push pump collar flush with bearing housing ledge to be able to close pump door. ti6325a ti6375a 8. Ratchet pump door forward. ti6377a ti5492a 9. Open pump door. 3. Slide pump into connecting rod. Push pump pin until it is fully retained. NOTE: Pin will snap into position.
Displacement Pump Replacement 1095/1595/Mark V 4. Close pump door and rotate latch into position. Do not tighten latch. 7. Attach drain hose to sprayer. ti7329a ti6313a ti7330a 5. Rotate pump to align with paint hose. Connect paint hose and hand tighten to 70 in-lb. 8. Fill pump with Graco TSL until fluid flows onto top of seal. ti6299a ti5493a 6. Tighten latch and rotate latch lock into locked position.
Hose Reel Hose Reel Removal 5. Remove snap ring. Be sure to keep your head clear of hose reel while winding up hose. 1. Remove hose fitting from swivel cap and completely remove hose. ti13542a 6. Remove hose reel. ti13539a 2. Remove cap from swivel. ti15024a ti13675a 3. Remove E-clip from swivel shaft. ti13538a 4. Remove swivel.
Hose Reel Installation 6. Install hose to swivel. Make sure to route hose through side arm of hose reel. 1. Grease shaft. ti13537a ti13539a 2. Make sure two washers and wave spring are on hub before hose reel is installed. 7. Turn hose reel clockwise to wrap up hose. Make sure hose is routed through hose guide. ti13545a 3. Install hose reel onto frame. Place C-clamp on reel and frame to allow snap ring to fit into place. Install snap ring. ti13504a ti13536a 4. Install swivel. ti13543a 5.
Reed Switch Replacement Reed Switch Replacement Removal Installation 1. Apply thread sealant to end of reed switch. Hand tighten reed switch until it is tight against control panel. 1. Remove four screws and remove display cover. ti13574a ti13568a 2. Add thread sealant and tighten jam nut against threaded bus. 2. Remove two screws and remove control panel. ti13576a 3. Connect reed switch to control board. ti13571a 3. Unplug reed switch from control board. ti13572a 4.
Wiring Diagram Wiring Diagram 120V Models: Potentiometer Thermal Switch Digital Display Pressure Transducer Motor Black ON Dip Switch AutoClean Motor Leads Watchdog Motor Sensor Leads ti13484b green/ground ON/OFF Switch Black white ti13485a Black + Power Plug green/ground 40 3A0157B
Wiring Diagram 120V Models (with 15/20 Amp Switch): Digital Display Potentiometer Motor Pressure Transducer ON Black Dip Switch Watchdog 20A 15A 1595 Switch ti12980b green/ground ON/OFF Switch Black white Black + Power Plug green/ground 3A0157B 41
Wiring Diagram 240V Models: Thermal Switch Digital Display Potentiometer Pressure Transducer Motor Black ON Dip Switch AutoClean Motor Leads Watchdog Motor Sensor Leads Blue Black ti13485a Blue Brown Blue ON/OFF Switch Brown + green/ground 42 Power Plug 3A0157B
Notes Notes 3A0157B 43
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.