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Repair
395/495/595t Airless Sprayers
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Vac
395
233960
495
233966
120
595
240 CEE 7/7
395
233955
Hopper
395
234176
495
233956
595
395
233963
495
233957
240 Europe
595
395
233972
495
233973
110 UK
595
395
234180
495
234183
240 Asia
595
100 Asia
495
234186
All models not available in all countries.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
233961
233962
233967
233968
234490
234435
248662
Related manuals
233970
233971
248661
234437
234178
234438
233975
234436
234181
234182
248660
234439
233974
ti2399
. . . . . . .
309709
. . . . . . .
309365
. . . . . . .
309665
. . . . . . .
309639
. . . . . . . . . . . . . . . . . . . . .
. . . . . . .
309706, 309707
309674
Rev. E
233960
. . . . . . .
309250
. . . . . . .
309640
. . . . . . .
309055
309675
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Table of Contents
Related Manuals for Graco 395 233960
Summary of Contents for Graco 395 233960
- Page 1 ..309706, 309707 234183 234181 234182 240 Asia 248660 234439 100 Asia 234186 233974 All models not available in all countries. GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001...
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Page 2: Fire And Explosion Hazard
The following Warnings are for the safe setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure–specific risks. Refer back to these Warnings. Additional, product–specific warnings may be found throughout the body of this manual where applicable. -
Page 3: Personal Protective Equipment
Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer. D Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only. D Do not alter or modify equipment. - Page 4 Component Identification and Function ti2377a ti2399 Fig. 1 Motor DC motor, permanent magnet, totally enclosed, fan cooled Drive Assembly Transfers power from DC motor to displacement pump Displacement Pump Transfers fluid to be sprayed from source through spray gun Fluid Outlet Spray gun is connected here Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open...
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Page 5: General Repair Information
General Repair Information Pressure Relief Procedure 1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair proce- dures. These parts are not normally provided with WARNING replacement assemblies. INJECTION HAZARD WARNING System pressure must be manually relieved to prevent system from starting ELECTRIC SHOCK HAZARD or spraying accidentally. - Page 6 Grounding WARNING Your system must be grounded. Read Warnings, page 2. The sprayer requires: Grounded Outlets Grounded Grounding Plug Outlets Grounding Plug ti3001b 240 VAC 120 VAC Fig. 2 D 100–120 VAC, 50/60 Hz, 15A circuit with a ground- Solvent pails used when flushing: follow local ing receptacle.
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Page 7: Troubleshooting
Troubleshooting Relieve pressure; page 5. MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1. Pressure control knob setting. Motor will not run 1. - Page 8 Troubleshooting MOTOR WON’T OPERATE (Continued) 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 Basic Electrical Problems 1. That motor leads are securely fastened and 1.
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Page 9: Low Or Fluctuating Output
Troubleshooting LOW OR FLUCTUATING OUTPUT 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 Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn- ing, then replace tip. - Page 10 Troubleshooting LOW OR FLUCTUATING OUTPUT 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 and pump strokes 1. Paint supply. 1. Refill and reprime pump. 2.
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Page 11: Motor Is Hot And Runs Intermittently
Troubleshooting MOTOR IS HOT AND RUNS INTERMITTENTLY 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 is hot and runs intermit- 1. Determine if sprayer was operated at high 1. - Page 12 Spin Test Setup Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) 1. Connect red and black motor leads with test lead. Electric Shock Hazard; page 5. Turn motor fan by hand at about two revolutions per second. 2. If uneven or no resistance, check for: broken brush To check armature, motor winding and brush electrical springs, brush leads, motor leads;...
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Page 13: Motor Brush Replacement
Motor Brush Replacement The 395/495/595 sprayer’s motors are supplied by two different motor manufacturers. Style A motor has brush caps held on with screws. Style B has brush caps that snap onto the motor. Determine which style motor you are servicing and refer to the appropriate illustration in the following instructions. - Page 14 Motor Brush Replacement Motor Brush Installation CAUTION When installing brushes, follow all steps carefully to avoid damaging parts. ti4195a ti4194a Style B Style A Fig. 7 1. Fig. 7. Install new brush (F) with lead into brush c. Turn sprayer ON. Slowly increase pressure holder (C).
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Page 15: On/Off Switch Replacement
On/Off Switch Replacement 100, 120 Vac (See page 1 for models) Removal Installation 1. Install new ON/OFF switch (58). Install locking ring Relieve pressure; page 5. and toggle boot (30). 2. Fig. 8. Remove four screws (12) and pressure control cover (50). 2. - Page 16 On/Off Switch Replacement 110, 240 Vac (See page 1 for models) Removal Installation 1. Install new ON/OFF switch (58). Install locking ring Relieve pressure; page 5. and toggle boot (30). 2. Fig. 9. Remove four screws (12) and pressure 2. Connect four wires (A) to ON/OFF switch (58). control cover (50).
- Page 17 CAUTION Heat from inductor coil of filter board may destroy wire insulation that comes in contact with it. Exposed wires could cause shorts and component damage. Bundle and tie all loose wires so none lay in contact with ti2478a inductor coil of filter board. Black ON/OFF Switch...
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Page 18: Pressure Control Repair
Pressure Control Repair Motor Control Board Removal Installation 1. Clean pad on rear of motor control board. Apply Refer to Fig. 8 or 9 depending on sprayer voltage. small amount of thermal compound 073019 to pad. 2. Fig. 8. Install motor control board (49) with six screws (6). - Page 19 Pressure Control Repair Digital Display Messages No display does not mean that sprayer is not pressurized. Relieve pressure before repair; page 5. DISPLAY INDICATION ACTION SPRAYER OPERATION No Display Loss of power Check power source. Relieve pres- Sprayer stops. Power is not applied. sure before repair or disassembly.
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Page 20: Pressure Control Transducer
Pressure Control Repair Pressure Control Transducer Pressure Adjust Potentiometer Removal Removal Refer to Fig. 8 or 9 depending on sprayer voltage. Refer to Fig. 8 or 9 depending on sprayer voltage. Relieve pressure; page 5. Relieve pressure; page 5. 2. Remove four screws (12) and cover (50). 2. -
Page 21: Drive Housing Replacement
Drive Housing Replacement 5. Remove two screws (12) and cover (22). CAUTION 6. Remove four front screws (47). Do not drop gear cluster (44) and (40) when remov- ing drive housing (42). Gear cluster may stay en- 7. Pull drive housing (42) off of motor (54). gaged in motor front end bell or drive housing. -
Page 22: Motor Replacement
Motor Replacement Disassembly 7. Remove two screws (47) and control housing (48). 8. Remove two screws (47) and manifold (15). Relieve pressure; page 5. 9. Remove four screws (47) and motor (54) from frame (59). 2. Remove pump (13); Displacement Pump Re- Assembly placement, page 23. -
Page 23: Displacement Pump Replacement
1. Fig. 14. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod. ti2568a Fig. 15 7. Fig. 16. Fill packing nut with Graco TSL until fluid flows onto top of seal. ti2568a ti2615a Fig. -
Page 24: Technical Data
Handle up Graco Phone Number TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call 1–800–690–2894 to identify the nearest distributor. All written and visual data contained in this document reflects the latest product information available at the time of publication.