Page 1
REPAIR
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
First choice when
quality counts.t
309063F
- For portable spray applications of architectural paints and coatings -
190ESt
Airless Paint Sprayers
3000 psi (207 bar, 20.7 MPa ) Maximum Working Pressure
120 VAC
232900, A, B, C, D, E, F
232901, A, B, C, D, E
233797, A, B, C, D, E
233815, A, B, C, D, E
100 --120 VAC
232903, A, B
220 --240 VAC
232906, A, B
Table of Contents
Component Function and Identification 5............
Pressure Relief Procedure 6.......................
General Repair Information 7......................
Grounding 8.....................................
Troubleshooting 9................................
Spin Test 12.....................................
Motor Brush Replacement 12.....................
On/Off Switch Replacement 14....................
ti7400a
232900
309365.......
309045.......
309064.....................
309065.......
Pressure Control Repair 19.......................
Drive Housing Replacement 24....................
Motor Replacement 25............................
Displacement Pump Replacement 26...............
Technical Data 27................................
Graco Phone Number 28..........................
Graco Warranty 28...............................
309060.......
Page 2
Specifications
This equipment is not intended for use with flammable or combustible materials used in places such as
cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of
application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and
combustible materials.
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
2 309063
Page 3
The following are general Warnings related to the safe setup, use, maintenance and repair of this equipment.
Additional, more specific warnings may be found throughout the text of this manual where applicable.
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:
D Use equipment only in well ventilated area.
D When flammable liquid is used in or near sprayer or for flushing or cleaning, keep sprayer at least
20 feet (6 m) away from explosive vapors.
D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop clothes (potential static arc).
D Keep work area free of debris, including solvent, rags and gasoline.
D Do not plug or unplug power cords, or turn lights on or off when flammable fumes are present.
D Ground equipment and conductive objects in work area. See Grounding instructions.
D Use only grounded hoses.
D Hold gun firmly to side of grounded pail when triggering into pail.
D If there is static sparking or you feel a shock, stop operating immediately. Do not use equipment
until you identify and correct the problem.
D Keep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
D Turn off and disconnect power cord before servicing equipment.
D Use only grounded electrical outlets
D Use only 3--wire extension cords.
D Ensure ground prongs are intact on sprayer and extension cords.
SKIN INJECTION HAZARD
High pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
D Do not point gun at anyone or any part of the body.
D Do not put your hand over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove, or rag.
D Do not spray without tip guard and trigger guard installed.
D Engage trigger lock when not spraying.
D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.
3309063
Page 4
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
D Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. Read Technical Data in all equipment manuals.
D Use fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in
all equipment manuals. Read fluid and solvent manufacturer’s warnings.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not alter or modify equipment.
D Use equipment only for its intended purpose. Call your Graco distributor for information.
D Route hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces.
D Do kink or overbend hoses or use hoses to pull equipment.
D Keep children and animals away from work area.
D Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious
chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
BURN HAZARD
Equipment surfaces can become very hot during operation. To avoid sever burns, do not touch hot
equipment. Wait until equipment has cooled completely.
TOXIC FLUID HAZARD
Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
D Read MSDS’s to know the specific hazards of the fluids you are using.
D Store hazardous fluid in approved containers and dispose of it according to all applicable guide-
lines.
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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes, but is not limited to:
D Protective eye wear.
D Clothing and respirator as recommended by the fluid and solvent manufacturer.
D Gloves.
D Hearing protection.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
D Keep clear of moving parts.
D Do not operate equipment with protective guards or covers removed.
D Pressurized equipment can start without warning. Before checking, moving, or servicing equip-
ment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
4 309063
Page 5
Component Identification and Function
H
A
J
V
U
PR
S
T
K
F
ti7400a
B
D
ti5914a
N
M
A Motor DC motor, permanent magnet, fan cooled
B Drive Assembly Transfers power from DC motor to displacement pump
D Displacement Pump Transfers fluid to be sprayed from source through spray gun
E Fluid Outlet Spray gun is connected here
F Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when
open
G Fluid Filter (optional) Final filter of fluid to spray gun
H Pressure Adjusting Knob Controls fluid outlet pressure
J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
K ON/OFF Switch Power switch that controls main power to sprayer
M 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
N Spray Gun High pressure spray gun with gun safety latch
P RAC IV Switch Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
R Tip Guard Tip guard reduces risk of injection injury
S Thumb Lock Safety Gun safety latch inhibits accidental triggering of spray gun
T Power Cord Rack Holds wrapped power cord for storage
U Suction Hose Transfers fluid to be sprayed from source to pump
V Drain Tube Fluid outlet used to drain and prime the sprayer
G
E
5309063
Page 6
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Follow this Pressure Relief Procedure
whenever you are instructed to relieve
pressure, stop spraying, check or service equipment, or install or clean spray tip. read
Injection Hazard Warning.
1. Turn OFF power and turn pressure control to lowest pressure sett ing.
2. Hold gun against side of grounded metal flushing
pail. Trigger gun to relieve pressure.
Fig. 2
If suspected that spray tip or hose is clogged or that
pressure has not been fully relieved after following
steps above , VERY SLOWLY loosen tip guard retain-
ing nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear tip or hose obstruction.
4. Engage trigger safety lock on gun if unit is being
shut down or left unattended.
CAUTION
To reduce risk of pressure control malfunction:
ti7401a
Fig. 1
3. Turn prime valve down
FLUSH
D Use needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
D Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
D Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
6 309063
Page 7
General Repair Information
WARNING
Read Electric ShockWarning and
Burn Hazard Warning.
WARNING
Flammable materials spilled on hot,
bare, motor could cause fire or
explosion. T o reduce risk of burns, fire or
explosion, do not operate sprayer with
cover removed.
D Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures.
These parts usually are not provided with replacement kits.
D test repairs after problems are corrected.
D If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Troubleshooting, page 9.
D Overspray may build up in the air passages. Re-
move any overspray and residue from air passages
and openings in the enclosures whenever you
service sprayer.
D Do not operate the sprayer without the motor
shroud in place. replace if damaged. Motor shroud
directs cooling air around motor to prevent overheating and insulate the control board from accidental electric shock.
WARNING
To reduce risk of serious injury , including
electric shock:
D Do not touch moving or electric parts
with fingers or tools while testing repair
D Unplug sprayer when power is not
required for testing
D Install all covers, gaskets, screws and
washers before you operate sprayer
CAUTION
D Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
D Protect the internal drive parts of this sprayer
from water. openings in the cover allow for air
cooling of the mechanical parts and electronics
inside. If water gets in these openings, sprayer
could malfunction or be permanently damaged.
D Prevent pump corrosion and damage from freez-
ing. Never leave water or water--base paint in
sprayer when it is not in use in cold weather.
Freezing fluids can seriously damage sprayer.
Store sprayer with Pump armour to protect sprayer during storage.
D Do not operate the sprayer without the motor
shroud or control box cover in place. Replace if
damaged. Motor shroud directs cooling air around
motor to prevent overheating and the control box
cover insulates the control board from accidental
electric shock.
7309063
Page 8
Grounding and Electric Requirements
WARNING
Your system must be grounded. Read
warnings, page 3.
The sprayer cord includes: a grounding wire with an
appropriate grounding contact.
Fig. 3
The sprayer requires:
1 10--120V units: 100--130 VAC, 50/60 Hz, 15A, 1
phase, circuit with a grounding receptacle.
240V Units: 210--255 VAC, 50/60 Hz, 7.5A, 1 phase,
circuit with a grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
ti7480a
Fig. 5
Recommended extension cords for use with this
sprayer:
D 1 10--120V: 3--wire, 12 AWG (2.5 mm
300 ft. (90 m) maximum length.
D 240V: 3--wire, 16 AWG (1.0 mm
(90 m) maximum length.
Smaller gauge or longer extension cords may
reduce sprayer performance.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent and Oil--based fluids: follow local code. Use
only conductive metal pails placed on a grounded
surface such as concrete. Do not place the pail on a
nonconductive surface such as paper or cardboard,
which interrupts grounding continuity.
Grounding the metal pail: connect a ground wire to
the pail by clamping one end to pail and other end to
ground such as a water pipe.
ti7482a
2
) minimum,
2
) minimum, 300 ft.
ti7481a
Fig. 4
Do not use the sprayer if the electrical cord has a
damaged ground contact. Only use an extension cord
with an undamaged ground contact.
8 309063
To maintain grounding continuity when flushing
or relieving pressure: hold metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
Fig. 6
ti7483a
Page 9
Relieve pressure; page 6.
gg,pg
MOTOR WON’T OPERATE
Troubleshooting
TYPE OF PROBLEM
Basic Fluid Pressure
Problems
Basic Mechanical
Problems
Basic Electrical Problems
See Wiring Diagram, pages
15 to 18.
WHAT TO CHECK
If check is OK, go to next check
1. Pressure control knob setting. Motorwill not run
if at minimum setting (fully counterclockwise).
2. Spray tip or fluid filter may be clogged. 2. Relieve pressure and clear clog or clean fil-
1. Pump (13) frozen or hardened paint. 1. Thaw sprayer if water or water-based paint
2. Displacement pump connecting rod pin (9a).
Pin mustbe completely pushed into connecting
rod (9) and retaining spring (9b) must be firmly
in groove of pump pin. See Fig. 18.
3. Motor (1). Remove drive housing assembly
(10). See page 24. Try to rotate fan by hand.
1. Motor control board.Board shuts down and displays error code on some models.
2. Electrical supply. Meter must read 100--130
VAC for 110--120 VAC models and 210--255
VAC for 240 VAC models.
WHAT TO DO
When check is not OK refer to this column
1. Slowly increase pressuresetting to see if motor starts.
ter; refer to separate gun or tip instruction
manual.
has frozen in sprayer. Place sprayer in warm
area to thaw. Do not start sprayer until
thawed completely. If paint hardened (dried)
in sprayer, replace pump packings. See
page 26 (Displacement Pump Replace-
ment).
2. Push pin into place and securewith spring retainer.
3. Replace motor (1) if fan won’t turn. See page
25.
1. See Motor Control Board Diagnostics,
page 19.
2. Reset building circuit breaker; replace building fuses. Try another outlet.
3. Extension cord. Check extension cord continuity with volt meter.
4. Sprayer power supply cord. Inspect for damage
such as broken insulation or wires.
5. Fuse. Check replaceable fuseon control board. 5. Replace fuse after completing motor inspec-
6. Motor leads are securely fastened and properly
connected to control board.
7. Motor thermal switch. Yellow motor leads must
have continuity through thermal switch.
8. Brush cap missing or loose brush lead connections.
9. Brush length which must be 1/4 in. (6 mm) minimum.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
10.Motor armature commutator for burn spots,
gouges and extreme roughness.
11.Motor armature for shorts using armature tester
(growler) or perform spin test, page 12.
3. Replace extension cord.
4. Replace power supply cord.
tion.
6. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
7. Replace motor. See page 25, Motor Replacement.
8. Install brush cap or replace brushes if leads
are damaged. See page12, Motor BrushReplacement.
9. Replace brushes. See page 12, Motor Brush
Replacement.
10. Remove motor and have motor shop resurface commutator if possible. See page 25,
Motor Replacement.
11.Replace motor. See page 25, Motor Replacement.
12.Pressure control notplugged into controlboard. 12. Insert pressure control connectorinto control
board.
9309063
Page 10
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF PROBLEM
Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn-
WHAT TO CHECK
If check is OK, go to next check
2. Verify pump does not continue to stroke when
gun trigger is released.
3. Filter clogged (If optional filter is installed). 3. Relieve pressure. Check and clean filter.
4. Prime valve leaking. 4. Relieve pressure. Repair prime valve.
5. Suction hose connections. 5. Tighten any loose connections.
6. Electrical supply with volt meter.
Meter must read:
210-- 255 Vac for 220 --240 Vac models.
85-- 130 Vac for 100 --120 Vac models. Low voltages reduce sprayer performance.
7. Extension cord size and length; must be at least
12 gauge wire and no longer than 300 ft. Longer
cord lengths reduce sprayer performance.
8. Leads from motor to pressure control circuit
board (35) for damaged or loose wires or connectors. Inspect wiring insulation and terminals
for signs of overheating.
9. For loose motor brush leads and terminals. See
page 12.
WHAT TO DO
When check is not OK refer to this column
ing, then replace tip. See your separate
gun or tip manual.
2. Service pump. See page 26.
6. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or try
another outlet.
7. Replace with a correct, grounded extension cord.
8. Be sure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or damaged
wiring. Securely reconnect terminals.
9. Tighten terminal screws. Replace brushes
if leads are damaged. See page 12.
10.For wornmotor brushes which must be 1/4 in. (6
mm) minimum. See page 12.
11.For broken or missing motor brush caps. 11.Replace brushcapif broken. Realign spring
12.Motor brushes for binding in brush holders.See
page 12.
13.Low stall pressure. 13. Do either or both:
14.Motor armature for shorts by using an armature
tester (growler) or perform spin test. See page
12.
10. Replace brushes. See page 12.
with brush. See page 12.
12.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brushholder toassure free vertical brush movement.
a. Turn pressure control knob fully
clockwise. Make sure pressure
control knob is properly installed to
allow full clockwise position.
b. Try a new transducer.
14.Replace motor. See page 25.
10 309063
Page 11
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF PROBLEM
Motor runs and pump strokes 1. Paint supply. 1. Refill and reprime pump.
Motor runs but pump does not
stroke
WHAT TO CHECK
If check is OK, go to next check
2. Intake strainer clogged. 2. Remove and clean, then reinstall.
3. Suction tube or fittings loose. 3. Tighten; use thread sealant or sealing tape
4. To see if intake valve ball and piston ball are
seating properly. See page 26.
5. Leaking around throat packing nut which may
indicate worn or damaged packings. See
page 26.
6. Pump rod damage. 6. Repair pump, page 26.
7. Capacitor failure. Visually inspect capacitor
near terminals. Ensure that orange safety relief plug is intact.
1. Displacement pump pin (9a) (damaged or
missing), page 26.
2. Connecting rod assembly (9) for damage,
page 24.
WHAT TO DO
When check is not OK refer to this column
on threads if necessary.
4. Remove intake valve and clean. Check
balls and seats for nicks; replace if necessary, page 26. Strain paint before using to
remove particles that could clog pump.
5. Replace packings, page 26. Also check
piston valve seat for hardened paint or
nicks and replace if necessary. Tighten
packing nut/wet-cup.
7. Replace capacitor.
1. Replace pump pin if missing. Be sure retainer spring (9b) is fully in groove all
around connecting rod, page 26.
2. Replace connecting rod assembly,
page 24.
Motor is hot and runs intermittently
3. Gears or drive housing, page 24. 3. Inspect drive housing assembly and gears
1. Be sure ambient temperature where sprayer
is located is not more than 115 _F(46_C) and
sprayer is not located in direct sun.
2. Motor has burned windings indicated by removing positive (red) brush and seeing
burned adjacent commutator bars.
3. Tightness of pump packing nut. Overtightening tightens packings on rod, restricts pump
action and damages packings.
for damage and replace if necessary,
page 24.
1. Move sprayerto shaded, cooler area if possible.
2. Replace motor. See page 25, Motor Re-
placement.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings if
necessary. See pump manual 309060.
11309063
Page 12
Spin Test
Setup
Electric Shock Hazard; page 6.
To check armature, motor winding and brush electrical
continuity:
1.
2. Remove drive housing; page 24.
3. Fig. 7. Remove pressure control cover (39). Disconnect red and black motor leads from control
board.
4. Fig. 8. Remove motor shroud (74).
Relieve pressure; page 6.
Armature Short Circuit Test
Quickly turn motor fan by hand. If no electrical shorts,
motor coasts two or three revolutions before complete
stop. If motor does not spin freely, armature is
shorted. Replace motor; page 25.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Connect red and black motor leads together with
test lead. Turn motor fan by hand at about two
revolutions per second.
2. If uneven or no resistance, check for: broken brush
springs, brush leads, motor leads; loose brush
terminal screws, motor lead terminals; worn
brushes. Repair as needed; page 12.
3. If still uneven or no resistance, replace motor;
page 25.
39
F
G
Fig. 7
9578A
Motor Brush Replacement
Motor Brush Removal
Replace brushes worn to less than 1/4 in. (6 mm).
Check both sides. See Parts List 309064 for correct
brush kit for your series of sprayer.
1. Read General Repair Information; page 7.
2.
3. Fig. 8. Remove four screws (18) and motor
shroud (74).
4. Pry off two brush caps (A). Tag locations of red (+)
and black (--) motor leads. Cut tie wrap.
5. Fig. 5. Remove screw (C) and discard brush (B)
for motor with capacitor attached. Remove brush
leads from control box for motor without capacitor
attached.
Relieve pressure; page 6.
(Continued on page 13)
74
Fig. 8
18
A
TI0053
12 309063
Page 13
Motor Brush Replacement
A
6. Fig. 9. Insert brush (B). Push cap (A) into place
over brush. Orient each cap with the 2 projections
on either side of the brush lead. You will hear a
“snap” when cap is securely in place.
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
7. Fig. 9. Install red (+) and black (--) motor leads
according to tags. Install brush lead end with
screw (C) to motor-mounted capacitor or route
lead into control box and connect to board.
C
B
E
To Mo t or (D )
8. If replacement brush harness has 2 yellow wires
(C), cut, strip, and crimp the 2 yellow wires (D)
from the motor and butt splice (E) on the replacement harness.
9. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a motor repair
shop if brushes wear too fast.
10. Test brushes.
a. Remove pump (13); Displacement Pump
Replacement, page 26.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
1 1. Break in brushes.
Fig. 9
ti7479a
a. Operate sprayer 1 hour with no load.
C
TI0053
b. Install pump (13); Displacement Pump Re-
placement, page 26.
13309063
Page 14
120 Vac
Removal
On/Off Switch Replacement
Installation
1.
2. Fig. 10 and 11. Remove four screws (18) and
pressure control cover (39).
3. Disconnect two wires (A) from ON/OFF
switch (23).
4. Remove toggle boot (25) and locking ring (24).
Remove ON/OFF switch (23).
25
24
23
Relieve pressure; page 6.
35
37
A
36
36
1. Install new ON/OFF switch (23). Install locking ring
(24) and toggle boot (25).
2. Connect two wires (A) to ON/OFF switch.
3. Install pressure control cover (39) with four
screws (18).
Fig. 10
18
39
52
22
D
E
ti0057b
14 309063
Page 15
120 Vac
Power
Plug
ON/OFF
Switch
On/Off Switch Replacement
Wiring Diagram
60
35
Black
34
L2 L1
(Capacitor on Motor)
232900, A, B
232901, A
233797, A
233815, A
Pressure
Transducer
ON/OFF
Switch
Power
Plug
Green
from Motor
Black
White
Black (--)
White
Green
Red (+)
M+ M--
Yellow
Potentiometer
Capacitor
N
L
Capacitor
J7
TO1 TO2
Wiring Diagram
(Capacitor on PC board)
232900, C, D, E,
232901, B, C, D
233797, B, C, D
233815, B, C, D
J8
TI0060
Fig. 11
Red (+)
Black (--)
from Motor
Yellow
Pressure
Transducer
ti2159a
Potentiometer
15309063
Page 16
Black
Wiring Diagram
(Capacitor on PC board)
232900, F,
232901, E
233797, E
233815, E
White
ON/OFF
Switch
Power Cord
Black
Green
Motor
Connector
ti7415a
White
Pressure
Switch
Black
Fig.
12
16 309063
Page 17
100 Vac (232903)
On/Off Switch Replacement
Removal
1.
2. Fig. 13. Remove four screws (18) and pressure
control cover (39).
3. Disconnect four wires (A) from ON/OFF
switch (23).
4. Remove toggle boot (25) and locking ring (24).
Remove ON/OFF switch (23).
25
24
Relieve pressure; page 6.
37
35
A
36
23
Installation
1. Install new ON/OFF switch (23). Install locking ring
(24) and toggle boot (25).
2. Connect four wires (A) to ON/OFF switch (23).
3. Install pressure control cover (39) with four
screws (18).
18
39
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 inductor coil of filter board.
Fig.
ON/OFF
Switch
Blue
Power
Plug
Brown
52
Green/
Yellow
22
D
Yellow
from Motor
E
ti0056b
Filter Board
Blue
Black (--)
Red (+)
Wiring Diagram
TP2
Brown
TP1
L1L2
Red (+)
Capacitor
Brown
Blue
Pressure
Transducer
Potentiometer
TI0059
17309063
Page 18
240 Vac (232906)
On/Off Switch Replacement
Removal
1.
2. Fig. 14. Remove pressure control cover (39).
3. Disconnect four wires (A) at ON/OFF switch (23).
4. Remove toggle boot (25) and locking ring (24).
Remove ON/OFF switch (23).
25
24
23
Relieve pressure; page 6.
A
35
36
37
Installation
1. Install new ON/OFF switch (23). Install locking ring
(24) and toggle boot (25).
2. Connect four wires (A) to ON/OFF switch.
3. Install pressure control cover (39).
18
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 inductor coil of filter board.
39
Caution
ON/OFF
Switch
Power
Plug
D
52
Green/Yellow
Yellow
C
E
ti0055b
22
Blue
L1L2
Wiring Diagram
TP1 TP2
Brown
Filter Board
Brown
Blue
Pressure
Transducer
Fig.
14
18 309063
from Motor
Black/White (--)
Red/White (+)
Black (--)
Red (+)
Capacitor
Potentiometer
TI0058
Page 19
Pressure Control Repair
Motor Control Board Diagnostics
For these models and series only:
232900 A, B, C, D, E
1. Remove four screws (18) and cover (39).
2. Turn ON/OFF switch ON.
232901 A, B, C, D
233797 A, B, C, D
233815 A, B, C, D
232903 A, B
232906 A, B
Note: Keep a new transducer on hand to use for test.
3. Observe LED operation and reference following
table:
4.
Relieve pressure and unplug sprayer before servicing control board; page 6.
CAUTION
Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if
test transducer is used.
LED
BLINKS
Once Sprayer runs Normal operation Do nothing
Once and
stays ON
SPRAYER OPERATION INDICATES WHAT TO DO
Sprayer shuts down and LED stays ON Motor open circuit or bad
control board
Check motor brushes and
armature. If OK, replace motor control board.
Two times
repeatedly
Three times
repeatedly
Four times
repeatedly
Five times
repeatedly
Six times
repeatedly
Sprayer shuts down and LED continues
to blink two times repeatedly
Sprayer shuts down and LED continues
to blink three times repeatedly
Sprayer shuts down and LED continues
to blink four times repeatedly
Sprayer shuts down and LED continues
to blink five times repeatedly
Sprayer shuts down and LED continues
to blink six times repeatedly
Run away pressure. Pressure greater than 4500 psi
(310 bar, 31 MPa).
Pressure transducer is
faulty or missing
Line voltage is too high Check for voltage supply
Too much current Check for locked rotor,
Motor thermal switch
open circuit
Replace motor control board.
See following Motor Control
Board procedure.
Check transducer connection.
Open drain valve. Substitute
new transducer for transducer
in sprayer. If sprayer runs,
replace transducer.
problems
shorted wiring or motor. Repair or replace failed parts.
Check for binding in pump or
drive. Check for bad motor.
19309063
Page 20
Pressure Control Repair
Motor Control Board
For these models and series only:
232900 A, B, C, D, E
232901 A, B, C, D
233797 A, B, C, D
233815 A, B, C, D
232903 A, B
232906 A, B
Removal
Refer to Fig. 10 and 11, 13 or 14 depending on sprayer
voltage.
Installation
1. Clean pad on rear of motor control board. Apply
small amount of thermal compound 073019 to pad.
2. Fig. 10. Install motor control board (35) with five
screws (36).
3. Connect to motor control board (35):
D Lead (E) to transducer.
1.
2. Remove four screws (18) and cover (39).
3. Disconnect at motor control board (35):
D Filter board (X) (not 120 Vac sprayers).
D Four motor leads: two yellow, black (--)
and red (+).
D Two line voltage leads.
D Lead (D) from potentiometer.
D Lead (E) from transducer.
4. Remove five screws (36) and circuit board (35).
Relieve pressure; page 6.
D Lead (D) to potentiometer.
D Two line voltage leads.
D Four motor leads: two yellow, black (--)
and red (+).
D Filter board (X) (not 120 Vac sprayers).
4. Bundle and tie all loose wires so none lay in contact with inductor coil on filter board (not 120 Vac
sprayers). See Wiring Diagram CAUTION,
Fig. 13 or 14.
5. Install cover (39) with four screws (18).
20 309063
Page 21
Pressure Control Repair
For these models and series only:
232900 A, B, C, D, E
232901 A, B, C, D
233797 A, B, C, D
233815 A, B, C, D
232903 A, B
232906 A, B
Pressure Control Transducer
Removal
Refer to Fig. 10 and 11, 13 or 14 depending on sprayer
voltage.
1.
2. Remove four screws (18) and cover (39).
3. Disconnect lead (E) from motor control
board (35).
4. Remove two screws (22) and filter housing (45).
5. Thread transducer lead plastic connector down
through transducer grommet (28).
6. Remove pressure control transducer (52) and
packing o-ring (51) from filter housing.
Installation
1. Install packing o-ring (51) and pressure control
transducer (52) in filter housing (45). Torque to
30-- 35 ft-lb.
2. Thread transducer lead plastic connector up
through transducer grommet (28).
3. Install filter housing (45) with two screws (22).
4. Connect lead (E) to motor control board (35).
5. Install cover (39) with four screws (18).
Relieve pressure; page 6.
Pressure Adjust Potentiometer
Removal
Refer to Fig. 10 and 11, 13 or 14 depending on sprayer
voltage.
1.
2. Remove four screws (18) and cover (39).
3. Disconnect all leads from motor control board (35).
4. Remove five screws (36) and board (35)
5. Remove potentiometer knob (27), sealing shaft nut
(33) and pressure adjust potentiometer (26).
Installation
1. Install pressure adjust potentiometer (26), sealing
shaft nut (33) and potentiometer knob (27).
a. Turn potentiometer fully clockwise.
b. Install knob at full clockwise position.
2. Install board (35) with five screws (36).
3. Connect all leads to motor control board (35).
4. Install cover (39) with four screws (18).
Relieve pressure; page 6.
21309063
Page 22
Pressure Control Repair
For these models and series only:
232900 F
232901 E
233797 E
233815 E
Motor Control Board
Removal
Installation
1.
2. Remove 4 screws (17) and control cover (16).
3. Disconnect motor connector, pressure control
connector white wire to control board (8) and black
wire to switch (4).
4. Remove 4 screws (9) and control board (8).
Relieve pressure; page 6.
15
14
13
14a
12
1. Assemble control board (8) with 4 screws (9).
2. Connect motor connector, pressure control connector white wire to control board (8) and black
wire to switch (4).
3. Install cover (16) with 4 screws (17).
5
4
6
3
9
7
1
17
Fig.
15
18
22 309063
16
ti7414a
2
11
8
10
2
19
Page 23
Pressure Control Repair
For these models and series only:
232900 F
232901 E
233797 E
233815 E
Pressure Control
Removal (See Fig. 15)
1.
Relieve pressure; page 6.
Installation (See Fig. 15)
NOTE: The pressure control has been preset at the fac-
tory to the design stall pressure.
1. Apply red thread locking adhesive (provided in kit)
to the brass threads of the pressure control (12).
2. Remove 4 screws (17) and control cover (16).
3. Disconnect pressure control connector from control board (8).
4. Remove clip (13) from control knob (14). Slide
knob (14) off of pressure control (12) and remove
knob (14) and baffle (14a) from control box (1).
5. Disconnect high pressure hose at pump.
6. Remove 2 screws (2) from fluid manifold and
remove manifold from sprayer.
7. Remove pressure control (12) from fitting (11).
2. Assemble pressure control (12) into fitting (11) and
torque to 140 in. lbs (12 ft. lbs). Do not pinch or
damage the wires on the pressure control.
3. Assemble the fluid manifold to the control box with
2 screws (2).
4. Connect the high--pressure hose at pump.
5. Turn pressure control (12) fully clockwise to maximum pressure.
6. Slide knob (14) and baffle (14a) onto stem of
pressure control (12). Install clip 13.
7. Install label (15) on knob (14) with indicator pointing at “+” on the control box (1).
8. Attach pressure control connector to control board
(8).
9. Install cover (16) with 4 screws (17).
23309063
Page 24
Drive Housing Replacement
CAUTION
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
Disassembly
1.
Relieve pressure; page 6.
5. Remove two back screws (22).
6. Pull drive housing (10) off of motor (1).
Assembly
1. Push drive housing (10) onto motor (1)
2. Install two front screws (22).
3. Install two back screws (22).
2. Remove pump (13); Displacement Pump Re-
placement, page 26.
3. Fig. 16. Remove two screws (18a).Tip sprayer up.
Remove two screws (18b) and remove shroud
(74).
4. Remove two front screws (22).
74
18a
1
22
18b
4. Fig. 16. Install shroud (74) with two screw
(18a).Tip sprayer up. Install two screws (18b).
5. Install pump (13); Displacement Pump Replace-
ment, page 26.
6. Install new access cover (10a) with two screws
(10b).
7
10
Fig. 16
24 309063
ti5915a
10a
10b
18b
22
Page 25
Motor Replacement
Disassembly
1.
2. Remove pump; Displacement Pump Replace-
ment, page 26.
Relieve pressure; page 6.
CAUTION
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
3. Remove drive housing; Drive Housing Replace-
ment, page 24.
4. Remove fluid manifold; Pressure Control Re-
placement, page 23.
5. Remove control board; Control Board Replace-
ment, page 20 or 22.
6. Remove strain relief (37; Fig. 10, 13 or 14) and
motor fan (2).
7. Remove three screws (22) behind board and
remove control housing (21).
8. Remove four screws (22) and motor (1) from
frame (63).
Assembly
1. Install new motor (1) on frame (63) with four
screws (22).
2. Install control housing (21) with three screws (22).
3. Install strain relief (37; Fig. 10, 13 or 14) and motor
fan (2).
4. Install fluid manifold; Pressure Control Replace-
ment, page 23.
5. Install control board; Control Board Replace-
ment, page 20 or 22.
6. Install drive housing (10); Drive Housing Re-
placement, page 24.
7. Install pump (13); Displacement Pump Replace-
ment, page 26.
35
36
18
39
63
1
Liberally apply grease
21
22
1
1
1
22
ti0054b
Fig. 17
25309063
Page 26
Displacement Pump Replacement
See manual 309060 for pump repair instructions.
See manual 309064 or 309065 for sprayer part number references.
Removal
1. Flush pump (13).
2.
3. Fig. 18. Loosen two screws (10b) and rotate
cover (10a).
b
Fig. 18
4. Cycle pump until pump pin (9a) is in position to be
removed. Remove pump pin (9a).
Relieve pressure; page 6.
10a
9a
9573A
Installation
WARNING
If 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.
CAUTION
5. Fig. 19. Remove suction tube (78) and hose (19).
6. Loosen pump jam nut (12). Unscrew pump.
19
12
78
ti5916a
Fig. 19
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. Fig. 21. Install suction tube (78) and hose (19).
6. Fig. 21. Screw jam nut (12) 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).
If the pump locknut loosens during operation, the
threads of the drive housing will be damaged.
1. Fig. 20. Extend pump piston rod fully. Apply grease
to top of pump rod at (A) or inside connecting rod.
ti5916a
A
Fig. 20
2. Fig. 18. Install pump pin (9a). Verify retainer spring
(9b) is in groove of pump pin.
TI0062
26 309063
Fig. 21
7. Fig. 22. Fill packing nut with Graco TSL until fluid
flows onto top of seal.
10b
Fig. 22
8. Fig. 18.Rotate cover (10a); tighten screws (10b).
ti5916a
10a
ti5916a
Page 27
Technical Data
100-- 120V, ∅,
A, Hz
1, 15, 50/60 1, 10, 50/60 3000 7/8 (653) 680 (180) 0.38 (1.25) 0.019 1/4 in.
BasicSprayerWettedParts: ............................
zinc-plated carbon steel, polyurethane, polyethylene,
stainlesssteel, PTFE, Delrin
er, V-Maxt UHMWPE, aluminum, stainless steel,
tungsten carbide
NOTE: Delrin
220-- 240V, ∅,
A, Hz
R is a registered trademarks of the DuPont Co.
Generator
Minimum W
R, chrome plating, leath-
Motor HP
(W)
Cycles per gallon
(liter)
Maximum
Delivery gpm
(lpm)
Maximum
Tip size
Fluid Outlet
npsm
Dimensions
Weight lb (kg) Height in. (cm) Length in. (cm) Width in. (cm)
34.5 (15.7) 17.75 (45.1) 14.5 (36.8) 13.5 (34.3)
27309063
Page 28
Graco Information
TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call 1--888--541--9788 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.
MM 309063
28 309063
International Offices: Belgium, China, Japan, Korea
Graco Headquarters: Minneapolis
www.graco.com
Revised, 1/2006
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