Graco 190ES 309063F User's Manual
Contents
1. A CAUTION 9 Inspect commutator for excessive pitting burning or gouging A black color on commutator is normal When installing brushes follow all steps carefully to Have commutator resurfaced by a motor repair avoid damaging parts shop if brushes wear too fast 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 a Remove pump 13 Displacement Pump 10 Test brushes 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 D 11 Break in brushes raroa a Operate sprayer 1 hour with no load b Install pump 13 Displacement Pump Re TI0053 Fig 9 placement page 26 309063 13 On Off Switch Replacement 120 Vac Removal hn 1 W RE Relieve pressure page 6 Fig 10 and 11 Remove four screws 18 and pressure control cover 39 Disconnect two wires A from ON OFF switch 23 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 Installation 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 14 309063 ti0057b On O2. 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 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 Troubleshooting Relieve pressure page 6 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 Basic Fluid Pressure Pressure control knob setting Motor will notrun 1 Slowly increase pressure setting to see if mo Problems if at minimum setting fully counterclockwise tor starts 2 Spray tip or fluid filter may be clogged 2 Relieve pressure and clear clog or clean fil ter refer to separate gun or tip instruction manual Basic Mechanical 1 Pump 13 frozen or hardened paint 1 Thaw sprayer if water or water based paint Problems has frozen in spraye
3. 4 Fig 16 Install shroud 74 with two screw 18a Tip sprayer up Install two screws 18b placement page 26 5 Install pump 13 Displacement Pump Replace 3 Fig 16 Remove two screws 18a Tip sprayer up Remove two screws 18b and remove shroud ment pagea 74 6 Install new access cover 10a with two screws 4 Remove two front screws 22 10b 18a i a Re 18b tib915a 22 Fig 16 24 309063 Motor Replacement Disassembly 7 Remove three screws 22 behind board and remove control housing 21 N frame 63 2 Remove pump Displacement Pump Replace Assembly ment page 26 1 Install new motor 1 on frame 63 with four screws 22 A CAUTION 2 Install control housing 21 with three screws 22 Do not drop gear cluster 7 when removing drive 3 Install strain relief 37 Fig 10 13 or 14 and motor housing 10 Gear cluster may stay engaged in fan 2 motor front end bell or drive housing 4 Install fluid manifold Pressure Control Replace 3 Remove drive housing Drive Housing Replace ment page 23 ment page 24 5 Install control board Control Board Replace 4 Remove fluid manifold Pressure Control Re ment page 20 or 22 placement page 23 6 Install drive housing 10 Drive Housing Re 5 Remove control board Control Board Replace placement page 24 ment page 20 or 22 7 Install pump 13 Displacement Pump Replace 6 Remove strain relief 37 Fig 10
4. all equipment manuals 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 Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do kink or overbend hoses or use hoses to pull equipment Keep children and animals away from work area 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 pif Equipment surfaces can become very hot during operation To avoid sever burns do not touch hot idi 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 e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to all applicable guide lines PERSON
5. to top of pump rod at A or inside connecting rod tib916a Fig 21 tib916a TIO062 Fig 20 Fig 22 tib916a 2 Fig 18 Install pump pin 9a Verify retainer spring 9b is in groove of pump pin 8 Fig 18 Rotate cover 10a tighten screws 10b 26 309063 Technical Data 100 120V 2 220 240V Generator Motor HP Cycles per gallon Maximum Maximum Fluid Outlet Minimum W W liter Delivery gpm Tip size npsm Ipm 1 15 50 60 1 10 50 60 3000 7 8 653 680 180 0 38 1 25 0 019 Basic Sprayer Wetted Parts 00 0 aaa zinc plated carbon steel polyurethane polyethylene stainless steel PTFE Delrin chrome plating leath er V Max UHMWPE aluminum stainless steel tungsten carbide NOTE Delrin is a registered trademarks of the DuPont Co Dimensions Weight Ib 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 309063 27 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 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea www graco com Revised 1 2006 28 309063
6. try 210 255 Vac for 220 240 Vac models another outlet 85 130 Vac for 100 120 Vac models Low volt ages reduce sprayer performance Extension cord size and length mustbe atleast 7 Replace with a correct grounded exten 12 gauge wire and no longer than 300 ft Longer sion cord cord lengths reduce sprayer performance Leads from motor to pressure control circuit B Be sure male terminal blades are centered board 35 for damaged or loose wires or con and firmly connected to female terminals nectors Inspect wiring insulation and terminals Replace any loose terminal or damaged for signs of overheating wiring Securely reconnect terminals 9 Forloose motor brush leads and terminals See 9 Tighten terminal screws Replace brushes page 12 if leads are damaged See page 12 10 Forworn motor brushes which must be 1 4 in 6 10 Replace brushes See page 12 mm minimum See page 12 11 For broken or missing motor brush caps 11 Replace brushcap if broken Realign spring with brush See page 12 12 Motor brushes for binding in brush holders See 12 Clean brush holders remove carbon dust page 12 with small cleaning brush Align brush lead with slot in brush holder to assure free verti cal brush movement 13 Low stall pressure 13 Do either or both a Turn pressure control knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise position Try a new transducer 14 Mo
7. 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 Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions 2 309063 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 Use equipment only in well ventilated area 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 Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop clothes potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground equipment and conductive objects in work area See Grounding i
8. 13 or 14 and motor fan 2 ment page 26 35 36 AN Liberally apply grease ti0054b Fig 17 309063 25 Displacement Pump Replacement See manual 309060 for pump repair instructions See manual 309064 or 309065 for sprayer part num ber references Removal 1 Flush pump 13 5 Fig 19 Remove suction tube 78 and hose 19 TN 6 Loosen pump jam nut 12 Unscrew pump 2 UN Ny Relieve pressure page 6 3 Fig 18 Loosen two screws 10b and rotate cover 10a N We NSS fA Fig 18 SEA 4 Cycle pump until pump pin 9a is in position to be Fig 19 removed Remove pump pin 9a Installation 3 Push pump up until pump threads engage A WARNING 4 Screw in pump until threads are flush with drive housing opening Align pump outlet to back If pin works loose parts could break off due to force of pumping action Parts could project 5 Fig 21 Install suction tube 78 and hose 19 through the air and result in serious injury or prop 6 erty damage 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 approxi If the pump locknut loosens during operation the gy threads of the drive housing will be damaged NS t 7 Fig 22 Fill packing nut with Graco TSL until fluid flows onto top of seal 1 Fig 20 Extend pump piston rod fully Apply grease
9. AL 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 Protective eye wear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed 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 Component Identification and Function GP 9 ti7400a tib914a DC motor permanent magnet fan cooled Transfers power from DC motor to displacement pump Transfers fluid to be sprayed from source through spray gun Spray gun is connected here Prime Valve Used to prime and drain sprayer also relieves fluid outlet pressure when open Fluid Filter optional Final filter of fluid to spray gun Pressure Adjusting Knob Controls fluid outlet pressure Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet Works with pressure adjusting knob ON OFF Switch Power swi
10. REPAIR Important Safety Instructions manual Save these instructions f P For portable spray applications of architectural paints and coatings 190ES Airless Paint Sprayers 3000 psi 207 bar 20 7 MPa Maximum Working Pressure 120 VAC 232900 A B B C D E F 232901 A B C D B C D C D 233797 A B 233815 A B E E E E 100 120 VAC 232903 A B Read all warnings and instructions in this C 309063F GRACO First choice when quality counts 220 240 VAC C ti7400a 232906 A B lA PEE 309365 El k anes 309045 eRRXd AERE EAS wee 309064 tel ides 309065 Table of Contents Component Function and Identification 5 Pressure Control Repair 2 00000 19 Pressure Relief Procedure lesse 6 Drive Housing Replacement P oie eee wee 24 rios Repair Information 5 Motor Replacement issssssse eese 25 ro nding 2 ees Lettre gp pud des odie cand Troubleshooting 00 cece eects 9 Uisplagemeri Pnp ep EENE a enata a STRIS MERE NEQNE TTE ES 12 Technical Data cece eee 27 Motor Brush Replacement 12 Graco Phone Number uusssllesessss 28 On Off Switch Replacement 14 Graco Warranty sssssssssssesse sees 28 Specifications This equipment is not intended for use with flammable or combustible materials
11. Relieve pressure page 6 a fF OP 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 309063 21 Pressure Control Repair For these models and series only 232900 F 232901 E 233797 E 233815 E Motor Control Board Removal Installation 1 A 1 Assemble control board 8 with 4 screws 9 w WA Relieve pressure page 6 2 Remove 4 screws 17 and control cover 16 2 Connect motor connector pressure control con nector white wire to control board 8 and black 3 Disconnect motor connector pressure control wire to switch 4 connector white wire to control board 8 and black wire to switch 4 4 Remove 4 screws 9 and control board 8 3 Install cover 16 with 4 screws 17 Fig 15 ti7414a 22 309063 Pressure Control Repair For these models and series only 232900 F 232901 E 233797 E 233815 E Pressure Control Removal See Fig 15 l 1 DN UK Relieve pressure page 6 2 Remove 4 screws 17 and control cover 16 3 Disconnect pressure control connector from con trol 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 f
12. able materials spilled on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed Keep all screws nuts washers gaskets and electrical fittings removed during repair procedures These parts usually are not provided with replace ment kits test repairs after problems are corrected If sprayer does not operate properly review repair procedure to verify you did it correctly See Trouble shooting page 9 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 Do not operate the sprayer without the motor shroud in place replace if damaged Motor shroud directs cooling air around motor to prevent over heating and insulate the control board from acci dental electric shock A WARNING To reduce risk of serious injury including electric shock e Do not touch moving or electric parts with fingers or tools while testing repair e Unplug sprayer when power is not m required for testing e Install all covers gaskets screws and washers before you operate sprayer A CAUTION Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings 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 op
13. enings sprayer could malfunction or be permanently damaged 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 spray er during storage 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 309063 7 Grounding and Electric Requirements A WARNING Your system must be grounded Read warnings page 3 The sprayer cord includes a grounding wire with an appropriate grounding contact E wu QU aw Fig 3 ti7480a The sprayer requires 110 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 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 ti7482a Fig 5 Recommended extension cords for use with this sprayer e 110 120V 3 wire 12 AWG 2 5 mm minimum 300 ft 90 m maximum length e 240V 3 wire 16 AWG 1 0 mm minimum 300 ft
14. ff Switch Replacement 120 Vac 60 Capacitor on Motor Su 35 232900 A B 34 L2 LI 7 232901 A 233797 A Power v s a 233815 A Plug gt Black o T Sue uet 6 4 Jalir E SV Pressure f MI W Transducer T E Fane Ty Ens Lz me White T E Yellow from Motor Black a Potentiometer Capacitor TIOO60 N ayer Wiring Diagram Switch Capacitor on PC board i O 232900 C D E o Capacitor 232901 B C D s 233797 B C D il M M TO TO2 233815 B C D Power GER l4 Plug amp A Term E O araen SV y Red Pressure Hand Transducer from Motor d Yellow ti2159a Fig 11 Potentiometer 309063 15 Wiring Diagram Capacitor on PC board 232900 F 232901 E r Black 233797 E T 7 233815 E White B L WT Ue oye UTU A ON OFF lack Switch Green o 4 Power Cord Pressure Switch Fig 12 16 309063 On Off Switch Replacement 100 Vac 232903 Removal 1 Na e I Relieve pressure page 6 Fig 13 Re
15. freely armature is shorted Replace motor page 25 Connect red and black motor leads together with test lead Turn motor fan by hand at about two revolutions per second 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 If still uneven or no resistance replace motor page 25 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 In 2 Ww WA Relieve pressure page 6 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 Continued on page 13 12 309063 Fig 8 TIOO53 Motor Brush Replacement 6 Fig 9 Insert brush B Push cap A into place 8 If replacement brush harness has 2 yellow wires over brush Orient each cap with the 2 projections C cut strip and crimp the 2 yellow wires D on either side of the brush lead You will hear a from the motor and butt splice E on the replace snap when cap is securely in place ment harness
16. g 233815 A B C D lab 232903 A B Relieve pressure and un 232906 A B 4 Na plug sprayer before servic ing control board page 6 Note Keep a new transducer on hand to use for test A CAUTION Do not allow sprayer to develop fluid pressure with out transducer installed Leave drain valve open if test transducer is used LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Sprayer shuts down and LED stays ON Motor open circuit or bad Check motor brushes and control board armature If OK replace mo tor control board Two times Sprayer shuts down and LED continues Run away pressure Pres Replace motor control board repeatedly to blink two times repeatedly sure greater than 4500 psi See following Motor Control 310 bar 31 MPa Board procedure Three times Sprayer shuts down and LED continues Pressure transducer is Check transducer connection to blink three times repeatedly faulty or missing Open drain valve Substitute repeatedly new transducer for transducer in sprayer If sprayer runs replace transducer Four times Sprayer shuts down and LED continues Line voltage is too high Check for voltage supply repeatedly to blink four times repeatedly problems Five times Sprayer shuts down and LED continues Too much current Check for locked rotor repeatedly fto blink five times repeatedly shorted wiring or motor Re pair or replace failed parts Six times Sprayer shuts down and LED continues M
17. move four screws 18 and pressure control cover 39 Disconnect four wires A from ON OFF switch 23 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 A Caution Heat from inductor coil of filter board Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 Connect four wires A to ON OFF switch 23 Install pressure control cover 39 with four screws 18 w Wiring Diagram Filter Board TP2 Brown TP1 _ w may destroy wire insulation that L2 L1 Brown comes in contact with it Exposed wires could cause shorts and com ON OFF 7 ponent damage Bundle and tie all Switch J loose wires so none lay in contact 4 Blue ii Blue with inductor coil of filter board TE Blue Yellow O m bs J2 Pressure rom Motor t QO Tran cer Power mm a sdu Plug S 4 O Brown Black Green s iw Potentiometer Yellow Capacitor Red TIO059 Fig 4n 309063 17 On Off Switch Replacement 240 Vac 232906 Removal Installation 1 A 1 Install new ON OFF switch 23 Ins
18. necting rod assembly 9 for damage 2 Replace connecting rod assembly page 24 page 24 3 Gears or drive housing page 24 3 Inspect drive housing assembly and gears for damage and replace if necessary page 24 Motor is hot and runs intermit 1 Be sure ambient temperature where sprayer 1 Move sprayer to shaded cooler area if pos tently is located is not more than 115 F 46 C and sible sprayer is not located in direct sun Motor has burned windings indicated by re 2 Replace motor See page 25 Motor Re moving positive red brush and seeing placement burned adjacent commutator bars Tightness of pump packing nut Overtighten 3 Loosen packing nut Check for leaking ing tightens packings on rod restricts pump around throat Replace pump packings if action and damages packings necessary See pump manual 309060 309063 11 Spin Test Setup Armature Brushes and Motor Wiring Open Circuit Test Continuity ANM Electric Shock Hazard page 6 To check armature motor winding and brush electrical 2 continuity Na b n Relieve pressure page 6 3 2 Remove drive housing page 24 3 Fig 7 Remove pressure control cover 39 Dis connect red and black motor leads from control board 4 Fig 8 Remove motor shroud 74 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
19. nstructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operating immediately Do not use equipment until you identify and correct the problem e Keep a fire extinguisher in the work area ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e 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 e Do not point gun at anyone or any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 309063 3 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury E JR RA INSTRUCTIONS Do not exceed the maximum working pressure or temperature rating of the lowest rated system component Read Technical Data in
20. oard terminals Securely re connect leads 7 Motor thermal switch Yellow motor leads must 7 Replace motor See page 25 Motor Re have continuity through thermal switch placement 8 Brush cap missing or loose brush lead connec 8 Install brush cap or replace brushes if leads tions are damaged See page 12 Motor Brush Re placement 9 Brush length which must be 1 4 in 6 mm mini 9 Replace brushes See page 12 Motor Brush mum Replacement NOTE Brushes do not wear atthe same rate on both sides of motor Check both brushes 10 Motor armature commutator for burn spots 10 Remove motor and have motor shop resur gouges and extreme roughness face commutator if possible See page 25 Motor Replacement 11 Motor armature for shorts using armature tester 11 Replace motor See page 25 Motor Re growler or perform spin test page 12 placement 12 Pressure control not plugged into control board 12 Insert pressure control connector into control board Troubleshooting LOW OR FLUCTUATING OUTPUT 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 Low Output 1 For worn spray tip 1 Follow Pressure Relief Procedure Warn ing then replace tip See your separate gun or tip manual gun trigger is released 6 Electrical supply with volt meter 6 Reset building circuit breaker replace Meter must read building fuse Repair electrical outlet or
21. otor thermal switch Check for binding in pump or repeatedly to blink six times repeatedly open circuit drive Check for bad motor 309063 19 Pressure Control Repair Motor Control Board Installation 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 Ih 1 DN UK Relieve pressure page 6 2 Remove four screws 18 and cover 39 3 Disconnect at motor control board 35 e Filter board X not 120 Vac sprayers e Four motor leads two yellow black and red e Two line voltage leads e Lead D from potentiometer e Lead E from transducer 4 Remove five screws 36 and circuit board 35 20 309063 1 Clean pad on rear of motor control board Apply small amount of thermal compound 073019 to pad Fig 10 Install motor control board 35 with five screws 36 Connect to motor control board 35 e Lead E to transducer e Lead D to potentiometer e Two line voltage leads e Four motor leads two yellow black and red e Filter board X not 120 Vac sprayers Bundle and tie all loose wires so none lay in con tact with inductor coil on filter board not 120 Vac sprayers See Wiring Diagram CAUTION Fig 13 or 14 Install cover 39 with four screws 18 Pressure Control Repair For these model
22. r 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 Displacement pump connecting rod pin 9a 2 Push pin into place and secure with spring re Pin must be completely pushed into connecting tainer rod 9 and retaining spring 9b must be firmly in groove of pump pin See Fig 18 3 Motor 1 Remove drive housing assembly 3 Replace motor 1 if fan won tturn See page 10 See page 24 Try to rotate fan by hand 25 Basic Electrical Problems 1 Motor control board Board shuts down and dis 1 See Motor Control Board Diagnostics See Wiring Diagram pages plays error code on some models page 19 15 to 18 2 Electrical supply Meter must read 100 130 2 Reset building circuit breaker replace build VAC for 110 120 VAC models and 210 255 ing fuses Try another outlet VAC for 240 VAC models 3 Extension cord Check extension cord continu 3 Replace extension cord ity with volt meter 4 Sprayer power supply cord Inspect for damage 4 Replace power supply cord such as broken insulation or wires 5 Fuse Check replaceable fuse on control board 5 Replace fuse after completing motor inspec tion 6 Motor leads are securely fastened and properly 6 Replace loose terminals crimp to leads Be connected to control board sure terminals are firmly connected Clean circuit b
23. rom sprayer 7 Remove pressure control 12 from fitting 11 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 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 maxi mum 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 point amp n ing at on the control box 1 8 Attach pressure control connector to control board 8 9 Install cover 16 with 4 screws 17 309063 23 Drive Housing Replacement A CAUTION 5 Remove two back screws 22 6 Pull drive housing 10 off of motor 1 Do not drop gear cluster 7 when removing drive housing 10 Gear cluster may stay engaged in motor front end bell or drive housing Assembly g 1 Push drive housing 10 onto motor 1 Disassembly 2 Install two front screws 22 1 TA n Relieve pressure page 6 3 Install two back screws 22 2 Remove pump 13 Displacement Pump Re
24. s 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 TA E Uk Relieve pressure page 6 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 Ib 2 Thread transducer lead plastic connector up through transducer grommet 28 3 Install filter housing 45 with two screws 22 Connect lead E to motor control board 35 Install cover 39 with four screws 18 ask Pressure Adjust Potentiometer Removal Refer to Fig 10 and 11 13 or 14 depending on sprayer voltage i AN 3 x Remove four screws 18 and cover 39 Disconnect all leads from motor control board 35 Remove five screws 36 and board 35 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
25. tall locking ring A w A amp E Relieve pressure page 6 24 and toggle boot 25 Fig 14 Remove pressure control cover 39 3 Disconnect four wires A at ON OFF switch 23 2 Connect four wires A to ON OFF switch Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 3 Install pressure control cover 39 Wiring Diagram ti0055b Blue TP1TP2 Filter Board ON OFF ff pss VE ERE I Heat from inductor coil of filter board Switch E k Y may destroy wire insulation that comes in contact with it Exposed Green Yellow wires could cause shorts and com ponent damage Bundle and tie all E P Blue loose wires so none lay in contact T with inductor coil of filter board P O Po Li Pressure ug EA Transducer dem n Yellow 4 4 from di Potentiometer Black White Capacitor TIO058 Fig Red White 14 18 309063 Pressure Control Repair Motor Control Board Diagnostics For these models and series only 1 Remove four screws 18 and cover 39 232900 A B C D E 2 Turn ON OFF switch ON 232901 A B C D 233797 A B C D 3 SERE LED operation and reference followin
26. tch that controls main power to sprayer 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends Spray Gun High pressure spray gun with gun safety latch Y E 309063 5 Pressure Relief Procedure A WARNING SKIN INJECTION HAZARD Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure stop spraying check or ser vice equipment or install or clean spray tip read Injection Hazard Warning Fig 2 If suspected that spray tip or hose is clogged or that pressure has not been fully relieved after following 1 Turn OFF power and turn pressure control to low steps above VERY SLOWLY loosen tip guard retain est pressure setting ing nut or hose end coupling to relieve pressure gradu pail Trigger gun to relieve pressure tion 4 Engage trigger safety lock on gun if unit is being shut down or left unattended CAUTION To reduce risk of pressure control malfunction e Use needle nose pliers to disconnect wire Never pull on wire pull on connector Mate wire connectors properly Center flat blade of insulated male connector in female connector Fig 1 Route wires carefully to avoid interference with other connections of pressure control Do not pinch 3 Turn prime valve down wires between cover and control box 6 309063 General Repair Information A WARNING Read Electric Shock Warning and Burn Hazard Warning A WARNING Flamm
27. tor armature for shorts by using an armature 14 Replace motor See page 25 tester growler or perform spin test See page 12 10 309063 Troubleshooting LOW OR FLUCTUATING OUTPUT 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 Motor runs and pump strokes 1 Paint supply 1 Refill and reprime pump 2 Intake strainer clogged 2 Remove and clean then reinstall 3 Suction tube or fittings loose 3 Tighten use thread sealant or sealing tape on threads if necessary 4 To see if intake valve ball and piston ball are 4 Remove intake valve and clean Check seating properly See page 26 balls and seats for nicks replace if neces sary page 26 Strain paint before using to remove particles that could clog pump 5 Leaking around throat packing nut which may 5 Replace packings page 26 Also check indicate worn or damaged packings See piston valve seat for hardened paint or page 26 nicks and replace if necessary Tighten packing nut wet cup 6 Pump rod damage 6 Repair pump page 26 7 Capacitor failure Visually inspect capacitor 7 Replace capacitor near terminals Ensure that orange safety re lief plug is intact Motor runs but pump does not 1 Displacement pump pin 9a damaged or 1 Replace pump pin if missing Be sure re stroke missing page 26 tainer spring 9b is fully in groove all around connecting rod page 26 2 Con
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