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REPAIR 



Important Safety Instructions 

Read all warnings and instructions in this 
manual. Save these instructions. 


<3 309063F 

GRACO 

First choice when 
quality counts. ” 


- 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, 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 


C€ 

C€ 



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 


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 























































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 


A 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 







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. 


A WARNING 


M 





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 instructions. 

• 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. 

• Keep a fire extinguisher in the work area. 


ELECTRIC SHOCK HAZARD 

Improper grounding, setup, or usage of the system can cause electric shock. 

• Turn off and disconnect power cord before servicing equipment. 

• Use only grounded electrical outlets 

• Use only 3-wire extension cords. 

• 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. 

• 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. 


INSTRUCTIONS 




Do not exceed the maximum working pressure or temperature rating of the lowest rated system 
component. Read Technical Data in 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 

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. 


• Read MSDS’s to know the specific hazards of the fluids you are using. 


• 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: 

• 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. 


309063 
















Component Identification and Function 



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 


309063 


5 




















































Pressure Relief Procedure 


A WARNING 

vice equif 
Injection 1 

SKIN INJECTION HAZARD 

Follow this Pressure Relief Procedure 
whenever you are instructed to relieve 
pressure, stop spraying, check or ser- 
Dment, or install or clean spray tip. read 
Hazard Warning. 


1. Turn OFF power and turn pressure control to low¬ 
est pressure setting. 

2. Hold gun against side of grounded metal flushing 
pail. Trigger gun to relieve pressure. 



Fig. 1 FLUSH 


3. Turn prime valve down 



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 gradu¬ 
ally, then loosen completely. Clear tip or hose obstruc¬ 
tion. 

4. Engage trigger safety lock on gun if unit is being 
shut down or left unattended. _ 

A CAUTION 

To reduce risk of pressure control malfunction: 

• 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. 

• Route wires carefully to avoid interference with 
other connections of pressure control. Do not pinch 
wires between cover and control box. 


6 


309063 



















General Repair Information 


A WARNING 



Read Electric Shock Warning and 
Burn Hazard Warning. 


A 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. 


• 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: 

• Do not touch moving or electric parts 
with fingers or tools while testing repair 



Unplug sprayer when power is not 
required for testing 


• 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 openings, 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 










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. 



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. 



Recommended extension cords for use with this 
sprayer: 

• 110-120V: 3-wire, 12 AWG (2.5 mm 2 ) minimum, 
300 ft. (90 m) maximum length. 

• 240V: 3-wire, 16 AWG (1.0 mm 2 ) minimum, 300 ft. 
(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. 



Never use an outlet that is not grounded or an 
adapter. 



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. 


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 



8 


309063 




Troubleshooting 


A ^ 


Relieve pressure; page 6. 


MOTOR WONT OPERATE 


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 

Basic Fluid Pressure 
Problems 

1. Pressure control knob setting. Motor will not run 
if at minimum setting (fully counterclockwise). 

1. Slowly increase pressure setting to see if mo¬ 
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 

Problems 

1. Pump (13) frozen or hardened paint. 

1. Thaw sprayer if water or water-based paint 
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. Displacement pump connecting rod pin (9a). 
Pin must be completely pushed into connecting 
rod (9) and retaining spring (9b) must be firmly 
in groove of pump pin. See Fig. 18. 

2. Push pin into place and secure with spring re¬ 
tainer. 


3. Motor (1). Remove drive housing assembly 
(10). See page 24. Try to rotate fan by hand. 

3. Replace motor (1) if fan won’t turn. See page 
25. 

Basic Electrical Problems 
See Wiring Diagram, pages 

1. Motor control board. Board shuts down and dis¬ 
plays error code on some models. 

1. See Motor Control Board Diagnostics, 

page 19. 

15 to 18. 

2. Electrical supply. Meter must read 100-130 

VAC for 110-120 VAC models and 210-255 
VAC for 240 VAC models. 

2. Reset building circuit breaker; replace build¬ 
ing fuses. Try another outlet. 


3. Extension cord. Check extension cord continu¬ 
ity with volt meter. 

3. Replace extension cord. 


4. Sprayer power supply cord. Inspectfordamage 
such as broken insulation or wires. 

4. Replace power supply cord. 


5. Fuse. Check replaceable fuse on control board. 

5. Replace fuse after completing motor inspec¬ 
tion. 


6. Motor leads are securely fastened and properly 
connected to control board. 

6. Replace loose terminals; crimp to leads. Be 
sure terminals are firmly connected. 

Clean circuit board terminals. Securely re¬ 
connect leads. 


7. Motor thermal switch. Yellow motor leads must 
have continuity through thermal switch. 

7. Replace motor. See page 25, Motor Re¬ 
placement. 


8. Brush cap missing or loose brush lead connec¬ 
tions. 

8. Install brush cap or replace brushes if leads 
are damaged. See page 12, Motor Brush Re¬ 
placement. 


9. Brush length which must be 1/4 in. (6 mm) mini¬ 
mum. 

NOTE: Brushes do not wear at the same rate on 
both sides of motor. Check both brushes. 

9. Replace brushes. See page 12, Motor Brush 
Replacement. 


10. Motor armature commutator for burn spots, 
gouges and extreme roughness. 

10. Remove motor and have motor shop resur¬ 
face commutator if possible. See page 25, 
Motor Replacement. 


11. Motor armature for shorts using armature tester 
(growler) or perform spin test, page 12. 

11. Replace motor. See page 25, Motor Re¬ 
placement. 


12. Pressure control not plugged in to control board. 

12. Insert pressure control connector into control 
board. 












































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 Warn¬ 
ing, then replace tip. See your separate 
gun or tip manual. 


2. Verify pump does not continue to stroke when 
gun trigger is released. 

2. Service pump. See page 26. 


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 volt¬ 
ages reduce sprayer performance. 

6. Reset building circuit breaker; replace 
building fuse. Repair electrical outlet or try 
another outlet. 


7. Extension cord size and length; must be at least 

12 gauge wire and no longerthan 300 ft. Longer 
cord lengths reduce sprayer performance. 

7. Replace with a correct, grounded exten¬ 
sion cord. 


8. Leads from motor to pressure control circuit 
board (35) for damaged or loose wires or con¬ 
nectors. Inspect wiring insulation and terminals 
for signs of overheating. 

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. For loose motor brush leads and terminals. See 
page 12. 

9. Tighten terminal screws. Replace brushes 
if leads are damaged. See page 12. 


10. For worn motor brushes which must be 1/4 in. (6 
mm) minimum. See page 12. 

10. Replace brushes. 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 
page 12. 

12.Clean brush holders, remove carbon dust 
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. 



b. Try a new transducer. 


14. Motor armature for shorts by using an armature 
tester (growler) or perform spin test. See page 
12. 

14. Replace motor. See page 25. 


10 309063 





































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 
seating properly. See page 26. 

4. Remove intake valve and clean. Check 
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 
indicate worn or damaged packings. See 
page 26. 

5. Replace packings, page 26. Also check 
piston valve seat for hardened paint or 
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 
near terminals. Ensure that orange safety re¬ 
lief plug is intact. 

7. Replace capacitor. 

Motor runs but pump does not 
stroke 

1. Displacement pump pin (9a) (damaged or 
missing), page 26. 

1. Replace pump pin if missing. Be sure re¬ 
tainer spring (9b) is fully in groove all 
around connecting rod, page 26. 


2. Connecting rod assembly (9) for damage, 
page 24. 

2. Replace connecting rod assembly, 
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¬ 
tently 

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. 

1. Move sprayerto shaded, cooler area if pos¬ 
sible. 


2. Motor has burned windings indicated by re¬ 
moving positive (red) brush and seeing 
burned adjacent commutator bars. 

2. Replace motor. See page 25, Motor Re¬ 
placement. 


3. Tightness of pump packing nut. Overtighten¬ 
ing tightens packings on rod, restricts pump 
action and damages packings. 

3. Loosen packing nut. Check for leaking 
around throat. Replace pump packings if 
necessary. See pump manual 309060. 


309063 11 





































Setup 


Spin Test 



Electric Shock Hazard; page 6. 


To check armature, motor winding and brush electrical 
continuity: 


Relieve pressure; page 6. 


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 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. 



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. 


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 



























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. 


A 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. 


A 



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 replace¬ 
ment 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. 

11. Break in brushes. 

a. Operate sprayer 1 hour with no load. 

b. Install pump (13); Displacement Pump Re¬ 
placement, page 26. 


309063 13 






On/Off Switch Replacement 


120 Vac 


Relieve pressure; page 6. 


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). 3. Install pressure control cover (39) with four 

Remove ON/OFF switch (23). screws (18). 



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. 


Removal 


A ^ 


14 


309063 


































On/Off Switch Replacement 


120 Vac 



N 



309063 15 



Wiring Diagram 

(Capacitor on PC board) 
232900, F, 



Pressure 

Switch 


12 


16 309063 







On/Off Switch Replacement 


100 Vac (232903) 

Removal 


Relieve pressure; page 6. 


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). 



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). 



Wiring Diagram 


Jk Caution 


Heat from inductor coil of filter board 
may destroy wire insulation that 
comes in contact with it. Exposed 
wires could cause shorts and com¬ 
ponent damage. Bundle and tie all 
ioose wires so none lay in contact 
with inductor coil of filter board. 



Brown 


Green/ 

Yellow 


Potentiometer 


Capacitor 


TI0059 


Fig. 


309063 17 


































































































































On/Off Switch Replacement 


240 Vac (232906) 

Removal 


Relieve pressure; page 6. 

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). 




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 309063 




































































































































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 

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. 


1. Remove four screws (18) and cover (39). 

2. Turn ON/OFF switch ON. 

3. Observe LED operation and reference following 
table: 

Relieve pressure and un¬ 
plug sprayer before servic¬ 
ing control board; page 6. 



LED 

BLINKS 

SPRAYER OPERATION 

INDICATES 

WHAT TO DO 

Once 

Sprayer runs 

Normal operation 

Do nothing 

Once and 
stays ON 

Sprayer shuts down and LED stays ON 

Motor open circuit or bad 
control board 

Check motor brushes and 
armature. If OK, replace mo¬ 
tor control board. 

Two times 
repeatedly 

Sprayer shuts down and LED continues 
to blink two times repeatedly 

Run away pressure. Pres¬ 
sure greater than 4500 psi 
(310 bar, 31 MPa). 

Replace motor control board. 
See following Motor Control 
Board procedure. 

Three times 

repeatedly 

Sprayer shuts down and LED continues 
to blink three times repeatedly 

Pressure transducer is 
faulty or missing 

Check transducer connection. 
Open drain valve. Substitute 
new transducer for transducer 
in sprayer. If sprayer runs, 
replace transducer. 

Four times 
repeatedly 

Sprayer shuts down and LED continues 
to blink four times repeatedly 

Line voltage is too high 

Check for voltage supply 
problems 

Five times 
repeatedly 

Sprayer shuts down and LED continues 
to blink five times repeatedly 

Too much current 

Check for locked rotor, 
shorted wiring or motor. Re¬ 
pair or replace failed parts. 

Six times 
repeatedly 

Sprayer shuts down and LED continues 
to blink six times repeatedly 

Motor thermal switch 
open circuit 

Check for binding in pump or 
drive. Check for bad motor. 


309063 


19 






































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): 

• Lead (E) to transducer. 


Relieve pressure; page 6. 

2. Remove four screws (18) and cover (39). 

3. Disconnect at motor control board (35): 

• Filter board (X) (not 120 Vac sprayers). 

• Four motor leads: two yellow, black (-) 
and red (+). 


• Lead (D) to potentiometer. 

• Two line voltage leads. 

• Four motor leads: two yellow, black (-) 
and red (+). 

• Filter board (X) (not 120 Vac sprayers). 



• Two line voltage leads. 

• Lead (D) from potentiometer. 

• Lead (E) from transducer. 


4. 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. 


4. Remove five screws (36) and circuit board (35). 5. Install cover (39) with four screws (18). 


20 


309063 




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. 


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-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). 



Pressure Adjust Potentiometer 

Removal 

Refer to Fig. 10 and 11, 13 or 14 depending on sprayer 
voltage. 


Relieve pressure; page 6. 

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). 



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. Assemble control board (8) with 4 screws (9). 

Relieve pressure; page 6. 

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). 3. Install cover (16) with 4 screws (17). 



2. Connect motor connector, pressure control con¬ 
nector white wire to control board (8) and black 
wire to switch (4). 



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) 

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 from 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¬ 
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 

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 


i. 



Relieve pressure; page 6. 


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). 


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). 

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). 



24 309063 










































Motor Replacement 

Disassembly 7. Remove three screws (22) behind board and 

remove control housing (21). 

Relieve pressure; page 6. 8 - Remove four screws (22) and motor (1) from 

frame (63). 

2. Remove pump; Displacement Pump Replace- 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- 

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, 13 or 14) and 

motor fan (2). ment, page 26. 


ment, page 26. 

A 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. 


1 



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). 


2 . 

3. 



Relieve pressure; page 6. 


Fig. 18. Loosen two screws (10b) and rotate 
cover (10a). 



4. Cycle pump until pump pin (9a) is in position to be 
removed. Remove pump pin (9a). 


6. Loosen pump jam nut (12). Unscrew pump. 



Installation 


A 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 prop¬ 
erty damage. 


A CAUTION 

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. 


Fig. 20 


ti5916a 



TI0062 


2. Fig. 18. Install pump pin (9a). Verify retainer spring 
(9b) is in groove of pump pin. 


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 approxi¬ 
mately 75 +/-5 ft-lb (102 N-m). 



7. Fig. 22. Fill packing nut with Graco TSL until fluid 
flows onto top of seal. 



8. Fig. 18.Rotate cover (10a); tighten screws (10b). 


26 309063 






Technical Data 


100-120V, 0 , 

A, Hz 

220-240V, 0 , 

A, Hz 

Generator 
Minimum W 

Motor HP 
(W) 

Cycles per gallon 
(liter) 

Maximum 
Delivery gpm 
(Ipm) 

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: . 

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 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) 


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 


28 309063 


www.graco.com 

Revised, 1/2006