REPAIR 309063F Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. First choice when quality counts.t - 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 ti7400a 232906, A, B 232900 . . . . . . .
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.
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.
EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. INSTRUCTIONS 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.
Component Identification and Function H A J B V U R P S T K F D ti7400a ti5914a N E G 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 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 setting. 2. Hold gun against side of grounded metal flushing pail. Trigger gun to relieve pressure. Fig.
General Repair Information WARNING Read Electric Shock Warning and Burn Hazard Warning. 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 WARNING Flammable 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.
Grounding and Electric Requirements WARNING Your system must be grounded. Read warnings, page 3. ti7482a Fig. 5 Recommended extension cords for use with this sprayer: The sprayer cord includes: a grounding wire with an appropriate grounding contact. D 110--120V: 3--wire, 12 AWG (2.5 mm2) minimum, 300 ft. (90 m) maximum length. D 240V: 3--wire, 16 AWG (1.0 mm2) minimum, 300 ft. (90 m) maximum length. Smaller gauge or longer extension cords may reduce sprayer performance. ti7480a Fig.
Troubleshooting Relieve pressure; page 6. MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check Basic Fluid Pressure Problems 1. Pressure control knob setting. Motor will not run 1. Slowly increase pressure setting to see if moif at minimum setting (fully counterclockwise). tor starts. Basic Mechanical Problems WHAT TO DO When check is not OK refer to this column 2. Spray tip or fluid filter may be clogged. 2.
Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK refer to this column Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warning, then replace tip. See your separate gun or tip manual. 2. Verify pump does not continue to stroke when 2. Service pump. See page 26. gun trigger is released. 3. Filter clogged (If optional filter is installed). 3. Relieve pressure. Check and clean filter. 4.
Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO 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.
Spin Test Setup Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) Electric Shock Hazard; page 6. To check armature, motor winding and brush electrical continuity: 1. Relieve pressure; page 6. 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.
Motor Brush Replacement 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. 8.
On/Off Switch Replacement 120 Vac Removal Installation 1. 1. Install new ON/OFF switch (23). Install locking ring (24) and toggle boot (25). Relieve pressure; page 6. 2. Fig. 10 and 11. Remove four screws (18) and pressure control cover (39). 2. Connect two wires (A) to ON/OFF switch. 3. Disconnect two wires (A) from ON/OFF switch (23). 4. Remove toggle boot (25) and locking ring (24). Remove ON/OFF switch (23). 3. Install pressure control cover (39) with four screws (18).
On/Off Switch Replacement 120 Vac Wiring Diagram Power Plug (Capacitor on Motor) 232900, A, B 232901, A 233797, A 233815, A 60 ON/OFF Switch 35 L2 L1 34 Black Pressure Transducer Green White Yellow from Motor Black (--) Potentiometer Red (+) Capacitor TI0060 N ON/OFF Switch Wiring Diagram L White Capacitor J7 M+ Black Power Plug M-- TO1 TO2 J8 (Capacitor on PC board) 232900, C, D, E, 232901, B, C, D 233797, B, C, D 233815, B, C, D Green Red (+) Pressure Transducer Black (--) fr
Wiring Diagram (Capacitor on PC board) 232900, F, 232901, E 233797, E 233815, E White Black ON/OFF Switch Power Cord Black Green Motor Connector White ti7415a Pressure Switch Black Fig.
On/Off Switch Replacement 100 Vac (232903) Removal 1. Installation 1. Install new ON/OFF switch (23). Install locking ring (24) and toggle boot (25). Relieve pressure; page 6. 2. Connect four wires (A) to ON/OFF switch (23). 2. Fig. 13. Remove four screws (18) and pressure control cover (39). 3. Install pressure control cover (39) with four screws (18). 3. Disconnect four wires (A) from ON/OFF switch (23). 4. Remove toggle boot (25) and locking ring (24). Remove ON/OFF switch (23).
On/Off Switch Replacement 240 Vac (232906) Removal Installation 1. 1. Install new ON/OFF switch (23). Install locking ring (24) and toggle boot (25). Relieve pressure; page 6. 2. 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. 4. Remove toggle boot (25) and locking ring (24). Remove ON/OFF switch (23). 3. Install pressure control cover (39).
Pressure Control Repair Motor Control Board Diagnostics 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 1. Remove four screws (18) and cover (39). 2. Turn ON/OFF switch ON. 3. Observe LED operation and reference following table: 4. Relieve pressure and unplug sprayer before servicing control board; page 6. Note: Keep a new transducer on hand to use for test.
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 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): Removal Refer to Fig. 10 and 11, 13 or 14 depending on sprayer voltage. D Lead (E) to transducer.
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. 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.
Pressure Control Repair For these models and series only: 232900 F 232901 E 233797 E 233815 E Motor Control Board Installation Removal 1. 1. Assemble control board (8) with 4 screws (9). Relieve pressure; page 6. 2. Remove 4 screws (17) and control cover (16). 2. Connect motor connector, pressure control connector white wire to control board (8) and black wire to switch (4). 3. Disconnect motor connector, pressure control connector white wire to control board (8) and black wire to switch (4). 4.
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. 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.
Drive Housing Replacement 5. Remove two back screws (22). CAUTION 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 1. Push drive housing (10) onto motor (1) Disassembly 2. Install two front screws (22). 1. Relieve pressure; page 6. 3. Install two back screws (22). 4. Fig. 16. Install shroud (74) with two screw (18a).Tip sprayer up. Install two screws (18b). 2.
Motor Replacement Disassembly 7. Remove three screws (22) behind board and remove control housing (21). 1. Relieve pressure; page 6. 2. Remove pump; Displacement Pump Replace- 8. Remove four screws (22) and motor (1) from frame (63). Assembly 1. Install new motor (1) on frame (63) with four screws (22). ment, page 26. CAUTION 2. Install control housing (21) with three screws (22). Do not drop gear cluster (7) when removing drive housing (10).
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). 5. Fig. 19. Remove suction tube (78) and hose (19). 6. Loosen pump jam nut (12). Unscrew pump. 2. Relieve pressure; page 6. 3. Fig. 18. Loosen two screws (10b) and rotate cover (10a). 19 b 12 10a 78 Fig. 18 9a 9573A 4. Cycle pump until pump pin (9a) is in position to be removed. Remove pump pin (9a). ti5916a Fig.
Technical Data 100--120V, ∅, A, Hz 220--240V, ∅, A, Hz Generator Minimum W Motor HP (W) Cycles per gallon (liter) Maximum Delivery gpm (lpm) Maximum Tip size Fluid Outlet npsm 1, 15, 50/60 1, 10, 50/60 3000 7/8 (653) 680 (180) 0.38 (1.25) 0.019 1/4 in. Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
