Graco Inc. 1095 Premium Hi-Boy manual

IMPORT ANT SAFETY INSTRUCTIONS Read all w ar nings and instructions in this manual. Sa v e these instructions. 3A0157A Electric Airless Spra yer s - For Portable Airless Spr aying of Architectural Coatings and Paints - 3300 psi (2 27 bar, 22 .7 MPa) Ma ximum Workin g Pressure Repair Related Man uals: Operation 3A0156 P arts 3A0158 Gun 311861 695/79[...]

Models: 2 3A0157A Models: 695 UL TRA MAX lIl Model QuikReel Hi-Bo y Lo-Bo y 258719 ✓✓ 258720 ✓ 258722 ✓ 258872 ✓ 258873 ✓ 258874 ✓ 258876 ✓ 258877 ✓✓ 826124 ✓✓ 826125 ✓ 826127 ✓ 795 UL TRA MAX III Model QuikReel Hi-Bo y Lo-Bo y 258723 ✓✓ 258724 ✓ 258878 ✓✓ 258879 ✓ 258881 ✓ 258882 ✓✓ 826128 ✓✓ 82612[...]

Table of Contents 3A0157A 3 T able of Contents Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T able of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Ident ification . . . . . . [...]

Warnings 4 3A0157A Wa r n i n g s The f ollowing w arnings are f or the setup , use, g rounding, mainten ance and repair of this equipment . The e xclamation point symbol alerts you to a ge neral w ar ning and the hazard symbo l ref ers to procedure-specif ic risks. Ref er bac k to these w ar nings. Addit ional, product-specific w ar nings ma y be [...]

Warnings 3A0157A 5 FIRE AND EXPLOSION HAZARD Flammable fumes , such as solvent and paint fumes , in work area can ignite or e xplode. T o help p rev ent fire and e xplosion: • Do not spra y flammab le or combustib le materials near an open flame or sources of ignition such as cig- arettes, motors , and electrical equipment. • P aint or solvent [...]

Warnings 6 3A0157A W ARNING EQUIPMENT MISU SE HAZARD Misuse can cause death or serious injur y . • Alwa ys wear appropriate glov es, ey e protection, and a respirator or mask when painting. • Do not operate or spra y near children. K eep children aw a y from equipment at all times. • Do not ov erreach or stand on an unstable support. K eep ef[...]

Component Identi fication 3A0157A 7 Component Identification 11. 12. 10. 13. 1. 2. 4. 5. 6. 7. 8. 9. 3. ti14839a 1 Premium Digital Display 2 ON/OFF s witch 3 W atchDog ™ Switch (not av ailab le on Mark V) 4 Pressure Control 5 Prime / Spra y V alve 6 Filter 7 Siphon T ub e 8P u m p 9 Bearing Housing / ProConne ct ™ 10 Drain T ube 11 T rigge r Lo[...]

Pressure Relief Procedure 8 3A0157A Pressure Relief Pr ocedure 1. T urn power OFF . Wait 7 seconds for power to dissipate. 2. Lock gun trigger sa f ety . Rem ov e guard and SwitchTip . 3. T urn pr essure to lowest set ting. T rigge r gun to relie ve pressure. 4. Put dr ain tube in pail. T urn pr ime valv e down to DRAIN position. ti4265a ti10166a t[...]

Grounding 3A0157A 9 Gr ounding The spra yer must be g rounded. Grounding reduces the risk of static and electric shock by pro viding an escape wire f or the electrical current due to static b uild up or in the e v ent of a short circuit. The spra yer cord includes a ground ing wire with an appropriate gro unding contact. The plug must be plugged in[...]

Troubleshooting 10 3A0157A T r oub leshooting Mechanical/Fluid Flo w Pe r fo r m Pressure Relief Pr ocedure ; p age 8. TYPE OF PR OBLEM WHA T T O CHECK If chec k is OK, go to next ch eck WHA T T O DO When check is not OK, refer to this column E=XX is display ed 1. F ault condition exists 1. Deter mine fault correction from table, page 13. F alse tr[...]

Troubleshooting 3A0157A 11 Pump output is low 1. Spra y tip wor n 1. F ollow Pre ssure Relief Pro cedure on page 8, then replace t ip . See your sepa - rate gun or tip manual. 2. Spra y tip clogged 2. Relie ve pressure . Chec k and clean spra y tip . 3. P aint supply 3. Refill and reprime pump. 4. Intak e stra iner clogged 4. Remo ve a nd clean, th[...]

Troubleshooting 12 3A0157A Motor runs b ut pump does not strok e 1. Displacement pump pin ( 32) damaged or missing; see pump manual 310643 or 310894. 1. Replace pump pin if missing. Be sure retainer spr ing ( 31) is fully in groov e all around connecting rod; see pump manua l 310643 or 310894 . 2. Connecting rod assemb ly (43) damaged; se e pump ma[...]

Troubleshooting 3A0157A 13 Electrical Symptom: Sp rayer does not run or stops ru nning. Perform Pressure Rel ief Procedure ; pa ge 8. • Plug spra yer into correct voltage , ground ed outlet • Set pow er s witch OFF f or 30 seconds and then ON again (this ensures spra ye r is in normal r un mode). • T ur n pressure control knob cloc kwise 1/2 [...]

Troubleshooting 14 3A0157A Spra yer does not run at all Chec k transducer or transducer connections (contro l board is not detecting a pressure signal). 1. Set spray er to OFF and disconnect power to spray er . 2. Check transducer and connections to control board. 3. Disconnect transducer from control board sock et. Check to see if transducer and c[...]

Troubleshooting 3A0157A 15 Spra yer does not run at all Control is commanding motor to run but motor shaft does not rotate . P ossib ly locked rotor condition, an open connection exists between motor and control, there is a prob lem with motor or control board, or motor amp draw is e xcessiv e. 1. Remov e pump and try to r un spray er . If motor r [...]

Troubleshooting 16 3A0157A Spra yer does not run at all Control is commanding motor to r un but motor shaft does not rotate. P ossibly lock ed rotor condition, an open connection exists between motor and control, there is a problem with motor or cont rol bo ard, or motor amp draw is e xcessive. 6. P erform Field Short T est: T est at large 4 -pin m[...]

Troubleshooting 3A0157A 17 Spra yer doe s not run at all Allow spra yer to cool. If spray e r runs when cool, correct cause of ov erheating. K eep spray er in cooler location with good ventilation. Make sure motor air intake is not bloc ked. If spra yer still does not r un, follo w Step 1. NO TE: Motor must b e cooled down for the test. 1. Check th[...]

Troubleshooting 18 3A0157A Spra yer Will Not Shut Off 1. P erf or m Pressure Relief Pr ocedure ; page 8. Lea v e prime v alve open and power s witch OFF . 2. Remov e control bo x cov er so the control board status light can be view ed if av ailable. T roubleshooting Pr ocedure Spra yer does not r un at al l Check to see if control board is over hea[...]

Troubleshooting 3A0157A 19 Spra yer Will Not Run (See f ollowing page f or steps) Remove control box cover. Turn sprayer ON. Observe control board status l ight on control bo ard (see page 13). No light Once Normal operation Light on Continuousl y Control board commanding motor to r un Flashing See Error Code section f or further troubles hooting C[...]

Troubleshooting 20 3A0157A 110-120 AC V - + - 110-120 AC V - + - - 100k ohm + - STEP 1: Plug power cord in and turn switch ON. Connect wires to control board and on/off switch. T ur n meter to A C V olts. STEP 2: Plug power cord in and tur n switch ON. Connect wires to control board and on/off switch. T ur n meter to A C V olts. STEP 3: Check motor[...]

Troubleshooting 3A0157A 21 240 V A C and 110 V A C Motor Control Boar d Re m ova l P erform Pressu re Relief Proc edure ; page 8. Wait 5 minutes before servicing. 1. Remov e Motor Shroud (for units equipped wit h Hose Reel only): a. Remov e bolts from motor shroud . b . Remo ve pressure tube from spra yer . c. Remove bottom screw from toolb o x. d.[...]

Troubleshooting 22 3A0157A 5. Make s witch dip s witch is mov ed to the left (to ward inside of board ). See Wiring Diagram , pa ge 40. 6. Connect motor connectors ( F , G and H) and inst all into baffl e. 7. Connect transduc er conne ctor (E) to m otor contr ol board. 8. Connect motor control boar d pow er connectors (K) to filter boar d (146). 9.[...]

Troubleshooting 3A0157A 23 240 V A C Filter Boar d P erform Pressure Re lief Pr ocedure ; page 8. Re m ova l 1. Remove four screws (38) and cover (96). 2. Disconnect display connector (A) from mo tor control board (52). 3. Remove botto m two screws (39). disconnect poten- tiometer con nector (C) from m otor control boar d (52). Disconnect po wer co[...]

Troubleshooting 24 3A0157A Pressure Adjust P otentiometer Re m ova l Pe r fo r m Pressure Relief Pr ocedure ; page 8. Wa it 5 minutes before servicing. 1. Remove four screws (38) and cover (96). 2. Remove two scre ws and control panel. 3. Disconnect potentiometer co nnector (C) from motor control board (95) . 4. Use allen wrench to loosen two scre [...]

Troubleshooting 3A0157A 25 Pressure Contr ol T ransducer Re m ova l P erform Pressu re Relief Proc edure ; page 8. Wait 5 minutes before servicing. 1. Remove four screws (38) and cover (96). 2. Disconnect transducer connector (E) from motor control board (95) . 3. Disconnect potentiometer co nnector (C), W atchDog s witch, and reed s w itch connect[...]

Troubleshooting 26 3A0157A Installation 1. Install o-ring (20) and transducer (86) in filter base (67). T or que to 35-45 ft-lb (4 7-61 N•m). Inst all grom- met onto tr ansducer (86) an d transducer into control box. 2. Connect transducer connector (E), W atchDog s witch, and reed s witch connector to contr ol board (95). 3. Install control bo x [...]

Notes 3A0157A 27 Notes[...]

Drive and Bearing Ho using Replacement 28 3A0157A Drive and Bearing Housing Replacement Disassembl y Pe r fo r m Pressure Relief Pr ocedure ; p age 8. 1. Remov e screw (31), tw o nuts (24 ), pail hanger (55) and pump rod co v er (108). 2. Remove pump (91); see Displacement Pump Replacement , page 32 (695/795) page 34 (1095/1595/ Mark V). 3. Remov e[...]

Drive and Bearing Housing Replacement 3A0157A 29 158 55 24 31 72 91 108 51 14 12 83 85 6 90 84 31 ti14892 a Drive and Bearing Housing Replacement[...]

Motor Replacement 30 3A0157A Motor Replacement Remo val Pe r fo r m Pressure Relief Pr ocedure ; p age 8. 1. Remove pump (91); see Displacement Pump Replacement , page 32 (695/795) page 34 (1095/1595/ Mark V). 2. Remov e drive housing (90); see Drive Ho using Replacement , page 28 . 1. Remov e Motor Shroud : a. Remov e bolts from motor shroud . b .[...]

Motor Replacement 3A0157A 31 ti14893a 158 90 28 90a 36 19 61 84 58 14 12 158 6 68 39 30 89 51 31 19 23 12 6 90 91 14 96 Motor Replacement[...]

Displacement Pump Replacem ent for 695/795/Mark IV 32 3A0157A Displacement Pump Replacement f or 695/795/Mark IV See pump manu al 310643 or 310894 f or pump repair instru ctions. See manual 3A01 58 f or applicable spra ye r par t number references. Remo val 1. Flush pump . 2. P erf or m Relieve Press ure Procedure ; page 8. 3. Remov e screw (31) an[...]

Displacement Pump Replac ement for 695/795/Mark IV 3A0157A 33 Installation If pump pin works loose, parts could break off d ue to f orce of pumping action . P ar ts could project through t he air and result in serious injury or proper ty damage. 1. Extend pump piston rod 1.5 in. Apply grease to to p of pump rod at (A) or insid e connecting rod. 2. [...]

Displacement Pump Replacement 1095/1595/Mark V 34 3A0157A Displacement Pump Repl acement 1095/1595/Mark V Remo val 1. Flush pump . 2. Stop pump with piston rod in its lowest po sition. 3. P erf or m Pressure Relief Pr ocedure , page 8. 4. Separate dra in hose from spra yer . 5. Disconnect paint hose from pump . 6. Raise latch lock. Push latch open.[...]

Displacement Pump Replacement 1095/1595/Mark V 3A0157A 35 f . Place u-bolt on pum p door protr usion . 8. Ratchet pump door f orw ard. 9. Open pump do or . 10. Pull out pump pin and place in pin holder . Installation 1. Adjust piston rod with pin holder to pull ou t piston rod. T ap piston rod on hard surf ace to push in piston rod. 2. Push pump co[...]

Displacement Pump Replacement 1095/1595/Mark V 36 3A0157A 4. Close pump do or and ro tate latch in to position. Do not tighten latch. 5. Rotate pump to align with paint hose . Connect paint hose and hand ti ghten to 70 in-lb . 6. Tighten latch and rotate la tch lock into lock ed posi- tion. 7. Attach drain hose to spr ay er . 8. Fill pump with Grac[...]

Hose Reel 3A0157A 37 Hose Reel Remo val 1. Remov e hose fitting fr om s wivel cap and completely remov e hose. 2. Remove cap from swiv el. 3. Remove E-clip from s wivel shaft. 4. Remove s wiv el. 5. Remov e snap ring. 6. Remov e hose reel. 7. Remov e rigid fluid tube from s wivel shaft (if ne ces- sar y). 8. Remov e swiv el shaft (if necessary). Be[...]

Hose Reel 38 3A0157A Installation 1. Grease sha ft. 2. Replace swiv el shaft if it was remov ed. 3. Replace r igid fluid tube to s wivel shaft if it w as removed. 4. Make sure two washers and wav e spr ing are on hub bef ore hose reel is installed. 5. Install hose reel onto frame . Place C-clamp on reel and frame to allow snap r ing to fit into pla[...]

Reed Switch Replacement 3A0157A 39 Reed Switch Replacement Remo val 1. Remov e fou r screws and re mov e displa y cov er . 2. Remov e two scre ws and remov e control panel. 3. Unplug reed s witch from control board. 4. Unscrew reed s witch from control panel. Installation 1. Apply thread sealant to en d of reed s witch. Hand tighten reed s witch un[...]

Wiring Diagram 40 3A0157A Wiring Diagram 120V Models: ti13485a Pressure T ransducer Digital Display ON/OFF Switch Power Plug Black + white green/ground Motor green/ground Potentiometer AutoClean Black W atchdog Black Motor Leads Motor Sensor Leads Thermal Switch ON Dip Switch ti13484b[...]

Wiring Diagram 3A0157A 41 120V Models (with 15/20 Amp Switch): Black Pressure T ransducer Digital Display ON/OFF Switch Power Plug Black + white green/ground Motor green/ground Potentiometer 1595 Switch 20A 15A W atchdog Black ON Dip Switch ti12980b[...]

Wiring Diagram 42 3A0157A 240V Models: Black Pressure T ransducer Digital Display ON/OFF Switch Power Plug Motor green/ground Potentiometer AutoClean W atchdog Motor Leads Motor Sensor Leads Thermal Switch Black Blue Blue Brown Brown + Blue ON Dip Switch ti13485a[...]

Notes 3A0157A 43 Notes[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 3A0157 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]