Graco 1095 Premium Hi-Boy Instruction Manual Download Page 32 | Manualshive

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Displacement Pump Replacement for 695/795/Mark IV

32

3A0157A

Displacement Pump Replacement for 695/795/Mark IV

See pump manual 310643 or 310894 for pump repair
instructions.

See manual 3A0158 for applicable sprayer part number
references.

Removal

1.

Flush pump.

2.

Perform Relieve Pressure Procedure; page 8.

3.

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

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.

6.

Loosen pump jam nut (56). Unscrew pump.

108

31

ti14894a

43

44

94

76

56

ti7167b

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Summary of Contents for 1095 Premium Hi-Boy

Page 1: ...A Electric Airless Sprayers For Portable Airless Spraying of Architectural Coatings and Paints 3300 psi 227 bar 22 7 MPa Maximum Working Pressure Repair Related Manuals Operation 3A0156 Parts 3A0158 Gun 311861 695 795 Premium Hi Boy 695 795 MARK V 1095 1595 Premium Hi Boy ti15036a ti15034a ti15035a ti14838a ENG ...

Page 2: ...QuikReel Hi Boy Lo Boy 258723 258724 258878 258879 258881 258882 826128 826129 1095 ULTRA MAX III Model QuikReel Hi Boy Lo Boy 258727 258728 258883 258884 258886 826130 826131 1595 ULTRA MAX III Model QuikReel Hi Boy Lo Boy 258763 258764 258765 258766 826132 826133 826134 826135 MARK IV Model QuikReel Hi Boy Lo Boy 258729 MARK V Model QuikReel Hi Boy Lo Boy 258730 258887 ...

Page 3: ...re Adjust Potentiometer 24 Pressure Control Transducer 25 Drive and Bearing Housing Replacement 27 Disassembly 27 Assembly 27 Motor Replacement 29 Removal 29 Installation 29 Displacement Pump Replacement 695 795 Mark V 31 Removal 31 Installation 32 Displacement Pump Replacement 1095 1595 Mark V 33 Removal 33 Installation 34 Hose Reel 36 Removal 36 Installation 37 Reed Switch Replacement 38 Removal...

Page 4: ...operly 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...

Page 5: ...le 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 used in or near the sprayer or for flushing or clean i...

Page 6: ...ne 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 reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage Do not use 1 1 1 trichloroethane methylene chloride other halogenated...

Page 7: ... 1 2 4 5 6 7 8 9 3 ti14839a 1 Premium Digital Display 2 ON OFF switch 3 WatchDog Switch not available on Mark V 4 Pressure Control 5 Prime Spray Valve 6 Filter 7 Siphon Tube 8 Pump 9 Bearing Housing ProConnect 10 Drain Tube 11 Trigger Lock 12 Model serial tag 13 Hose Reel ...

Page 8: ...OFF Wait 7 seconds for power to dissipate 2 Lock gun trigger safety Remove guard and SwitchTip 3 Turn pressure to lowest setting Trigger gun to relieve pressure 4 Put drain tube in pail Turn prime valve down to DRAIN position ti4265a ti10166a ti2769a ti14841a ti2595a ti14842a ...

Page 9: ...uirements 100 120V units require 100 120 VAC 50 60 Hz 15A 1 phase 230V units require 230 VAC 50 60 HZ 10A 1 phase Extension Cord Use an extension cord with an undamaged ground con tact If an extension cord is necessary use a 3 wire 12 AWG 2 5 mm2 minimum Pails Solvent and oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place ...

Page 10: ...ck 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 dis played Pump does not run 1 Operating conditions out of WatchDog parameters Pump output is low see below 1 Turn pressure down Refer to operation manual for adjusting Operate without WatchDog active see operation manual ...

Page 11: ...g nut which may indicate worn or damaged packings 10 Replace packings see pump manual Also check piston valve seat for hardened paint or nicks and replace if necessary Tighten packing nut wet cup 11 Pump rod damage 11 Repair pump See pump manual 310643 or 310894 12 Low stall pressure 12 Turn pressure knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise...

Page 12: ...amaged 3 Replace rod see pump manual 310643 or 310894 Fluid is spitting from gun 1 Air in pump or hose 1 Check and tighten all fluid connections Cycle pump as slowly as possible during priming 2 Tip is 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...

Page 13: ...HECK Sprayer does not run at all See flow chart page 19 Digital display is blank Control board status light never lights Sprayer does not run at all Check transducer or transducer connections 1 Make sure there is no pressure in the system see Pressure Relief Procedure page 8 Check fluid path for clogs such as clogged filter 2 Use airless paint spray hose with no metal braid 1 4 in x 50 ft minimum ...

Page 14: ...rol 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 5 Connect a confirmed working transducer to control board socket 6 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 7 Check transducer resistance with ohmmeter le...

Page 15: ... clean and secure continue to step 4 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 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 2 Rotate motor fan at about 2 revolutions per second A cogging resistance t...

Page 16: ...nector There should not be continuity from pin 4 the ground wire and any of the remaining 3 pins If motor field connector tests fail replace motor 7 Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each model see table below Digital display shows E 05 Control board status light blinks 5 times repeatedly TYPE OF PROBLEM WHAT TO CHECK HOW ...

Page 17: ...ould read the proper resistance for each model see table below 3 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 Digital display shows E 06 Control board status light blinks 6 times repeatedly Sprayer does not run at all Check the connections Control is not receiving a motor p...

Page 18: ...ly connected to back plate and that conductive thermal paste is used on power components 4 Replace control board 5 Replace motor Digital display shows E 10 Control board status light blinks 10 times repeatedly TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Plumb pressure gauge into paint hose plug sprayer in and turn power switch ON Does sprayer reach or exceed its maximum pressure Unplug the transduc...

Page 19: ...sducer to the board Does the motor run Replace potentiometer Pressure switch See Step 3 Is the proper reading present through the thermal switch wires Replace the ON OFF switch See step 4 Does the motor run See Step 1 Do you have over 100 AC volts 200 for 220V units See Step 2 Do you have over 100 AC volts Repair or replace power cord If motor is hot let cool and retest If Step 4 still shows incor...

Page 20: ... Table on page 17 NOTE Motor should be cool during reading STEP 4 Plug power cord in and turn switch ON Disconnect potentiometer Black Black Black Black Yellow Black Black Black Black On Off Switch Control Board White Power Cord Control Board Control Board Control Board On Off Switch Power Cord White Thermal Switch Pressure Transducer Potentiometer Motor AutoClean WatchDog Switch On Open Off Close...

Page 21: ...oard 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 6 Disconnect motor control board power connectors K from filter board 146 7 Remove top two screws 39 and control box 61 8 Disconnect transducer connector E from motor control board 9...

Page 22: ...ector C to motor con trol board 12 Connect WatchDog switch X and reed switch con nector L 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 a Loosen but do not remove four nuts on shelf and slide shelf forward b Replace ...

Page 23: ...ors K from filter board 146 6 Remove four screws 163 from filter board 146 Installation 1 Install filter board 146 with four screws 163 2 Connect motor control board power connectors K to filter board 146 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 4 Connect potentiometer connector C to moto...

Page 24: ...iometer 82 from control panel 68 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 2 Rotate new potentiometer shaft to highest pressure setting fully clockwise and install knob 34 Use allen wrench to tighten two screws on knob 3 Connect potentiometer connector C to motor con trol board 4 Install control panel and tighten two screw...

Page 25: ...onnect potentiometer connector C WatchDog switch and reed switch connector from motor con trol board 4 Remove four screws 39 and control box 61 Allow control panel 68 to hang down freely 5 Remove grommet 40 from control box then remove transducer 86 and o ring 20 from filter base 67 6 Remove grommet 40 from transducer and save for reuse 38 96 ti13493a E 95 ti12999a C ti13722a ti7458a 39 61 68 ti13...

Page 26: ...box 2 Connect transducer connector E WatchDog switch and reed switch connector to control board 95 3 Install control box 61 and control panel 68 with four screws 39 4 Connect potentiometer connector C WatchDog switch and reed switch connector to control board 5 Install cover 96 with four screws 38 ti7447a 40 67 20 86 ti13496a E 95 ti12999a ti7458a 39 61 68 ti13494a C ti13722a 38 96 ti13493a ...

Page 27: ...Notes 3A0157A 27 Notes ...

Page 28: ...0 off motor 84 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 lb 21 23 N m 2 Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft lb 34 40 N m 3 Install front cover 51 with four screws 31 4 Install shroud 72 with two...

Page 29: ...Drive and Bearing Housing Replacement 3A0157A 29 158 55 24 31 72 91 108 51 14 12 83 85 6 90 84 31 ti14892a Drive and Bearing Housing Replacement ...

Page 30: ...ar control and remove motor 84 from cart frame 62 Installation 1 Slide new motor 84 under two screws 23 in cart frame 62 near control 2 Install two screws 23 and nuts 19 on motor side opposite control 3 Install baffle and connect motor wires 4 Tighten all four screws 23 and nuts 19 torque nuts to 115 135 in lb 13 15 N m 5 Install strain relief 29 onto motor wires and into power bar plate 69 6 Inst...

Page 31: ...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 ...

Page 32: ... 1 Flush pump 2 Perform Relieve Pressure Procedure page 8 3 Remove screw 31 and slide pump rod shield 108 forward 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 6 Loosen pump jam nut 56 Unscr...

Page 33: ...ing 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 N m 7 Install pump rod shield 108 with s...

Page 34: ...ure page 8 4 Separate drain hose from sprayer 5 Disconnect paint hose from pump 6 Raise latch lock Push latch open 7 Ratchet open pump door a Ratchet pump door forward 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 ti6300a ti6369a ti6370a ti637...

Page 35: ...in holder 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 3 Slide pump into connecting rod Push pump pin until it is fully retained NOTE Pin will snap into position ti6375a ti6377a ti7327a ti6325a ti5492a ti7328a ti6378a ...

Page 36: ...ot tighten latch 5 Rotate pump to align with paint hose Connect paint hose and hand tighten to 70 in lb 6 Tighten latch and rotate latch lock into locked posi tion 7 Attach drain hose to sprayer 8 Fill pump with Graco TSL until fluid flows onto top of seal ti7329a ti6313a ti6299a ti6204a TI6312a ti7330a ti5493a ...

Page 37: ...wivel 3 Remove E clip from swivel shaft 4 Remove swivel 5 Remove snap ring 6 Remove hose reel 7 Remove rigid fluid tube from swivel shaft if neces sary 8 Remove swivel shaft if necessary Be sure to keep your head clear of hose reel while winding up hose ti13539a ti13675a ti13538a ti13543a ti13542a ti13540a ti13541a ti13544a ...

Page 38: ...installed 5 Install hose reel onto frame Place C clamp on reel and frame to allow snap ring to fit into place Install snap ring 6 Install swivel 7 Install E clip and swivel cap 8 Install hose to swivel Make sure to route hose through side arm of hose reel 9 Turn hose reel clockwise to wrap up hose Make sure hose is routed through hose guide ti13537a ti13544a ti13541a ti13545a ti13536a ti13543a ti1...

Page 39: ...h from control panel Installation 1 Apply thread sealant to end of reed switch Hand tighten reed switch until it is tight against control panel 2 Add thread sealant and tighten jam nut against threaded bus 3 Connect reed switch to control board 4 Replace control panel and tighten two screws 5 Replace display cover and tighten four screws ti13568a ti13571a ti13572a ti13573a ti13574a ti13576a ti1357...

Page 40: ...m 120V Models ti13485a Pressure Transducer Digital Display ON OFF Switch Power Plug Black white green ground Motor green ground Potentiometer AutoClean Black Watchdog Black Motor Leads Motor Sensor Leads Thermal Switch ON Dip Switch ti13484b ...

Page 41: ...7A 41 120V Models with 15 20 Amp Switch Black Pressure Transducer Digital Display ON OFF Switch Power Plug Black white green ground Motor green ground Potentiometer 1595 Switch 20A 15A Watchdog Black ON Dip Switch ti12980b ...

Page 42: ...0V Models Black Pressure Transducer Digital Display ON OFF Switch Power Plug Motor green ground Potentiometer AutoClean Watchdog Motor Leads Motor Sensor Leads Thermal Switch Black Blue Blue Brown Brown Blue ON Dip Switch ti13485a ...

Page 43: ...Notes 3A0157A 43 Notes ...

Page 44: ... 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 breac...

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