Graco 246737 Use and care manual

Repair and Parts
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
230E Airless Paint Sprayer
Model 246737
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
309860C
Read warnings and instructions.
Related Manuals
309859 – Operation
309646 – Tool Tips
309060 – Pump Repair
TI3477c
Parts

2309860
EQUIPMENT MISUSE HAZARD
Misuse can cause the equipment to rupture or
malfunction and result in serious injury.
To help prevent injury
Do not modify or use parts not designed for
this equipment.
Do not use 1,1,1–trichloroethane, methylene
chloride, other halogenated hydrocarbon sol-
vents or fluids containing such solvents in this or
any other pressurized aluminum equipment.
Such use could result in a chemical reaction,
with the possibility of explosion.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in eyes
eyes or on skin, inhaled, or swallowed.
To help prevent injury or death from
toxic fluids
Know specific hazards of fluid you are using; store hazardous fluid
in approved container; dispose of hazardous fluid according to all
local, state, and national guidelines.
Always wear protective eyewear, gloves, clothing, and respirator as
recommended by fluid and solvent manufacturer.
SKIN INJECTION HAZARD
If high-pressure fluid pierces skin, the injury might
look like “just a cut” but is a serious wound. Get
immediate surgical treatment.
To help prevent injection
Always lock gun trigger safety latch when not
spraying.
Always shut off power and relieve pressure when
you stop spraying and before you service or clean
sprayer, remove parts, or repair leaks. See
Pressure Relief Procedure, page 5.
Do not allow children to use this equipment.
Keep clear of tip and/or roller frame. Never point at
yourself or anyone else.
pressure
FLUID SPLASHBACK HAZARD
To avoid splashing fluid when spraying
into pail, always aim at inside wall of pail.
Make sure gun is assembled with correct
gasket for fluid being sprayed.
FIRE AND EXPLOSION HAZARD
A Fire and explosion hazard exists any time you
spray or flush flammable fluids.
To help prevent fire or explosion when spraying
flammable fluids
Do not use plastic drop cloths when
spraying or flushing flammable fluids.
Avoid all ignition sources, such as pilot lights,
cigarettes, and plastic drop cloths (static arc
hazard). Do not plug in or unplug power cords or
turn lights on or off in spray area.
Tape wall switches to prevent them from being
turned off or on.
Do not smoke in spray area.
Use only Graco airless paint hoses.
Use outdoors or in a well-ventilated area.
PRESSURIZED EQUIPMENT HAZARD
This sprayer is capable of
producing up to 3000 psi (20.7 MPa, 207 bar)
maximum working pressure. To avoid
component rupture and injury, do not operate sprayer
with components rated less than pressure of sprayer.
Sprayer is equipped with a pressure drain that automatically relieves
overpressure in the event of a fault condition. This automatic pressure
relief may cause splashing of fluid. Correct fault before you resume
spraying.
NOTE: Inadequate flushing and/or dried paint in drain
system may prevent proper overpressure relief.
SHOCK HAZARD
Failure to observe the following electrical hazards
could result in serious injury, including burns or
electrocution.
To help prevent harmful electric shock
Use only grounded electrical outlets.
Only use 3-wire extension cords.
Make sure ground prongs are intact on sprayer and extension cords.
Keep electrical connections and inside of shroud dry.
Avoid contact with power lines.
Only use Graco airless paint hoses.
Unplug sprayer before servicing.
PINCH HAZARD
Do not touch moving parts with fingers or tools while
testing or repairing. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
Do not operate equipment under the influence of alcohol or while taking
medication that impairs your senses or reactions.
ALCOHOL AND DRUG HAZARD

3309860
Component Identification and Function
RPS
N
M
D
B
H
T
F
E
A
U
V
J
G
K
ti7235a
AMotor DC motor, permanent magnet, fan cooled
BDrive Assembly Transfers power from DC motor to displacement pump
DDisplacement Pump Transfers fluid to be sprayed from source through spray gun
EFluid Outlet Spray gun is connected here
FPrime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when
open
GFluid Filter Final filter of fluid to spray gun
HPressure Adjusting Knob Controls fluid outlet pressure
JPressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
KON/OFF Switch Power switch that controls main power to sprayer
M50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
NSG3 Spray Gun High pressure spray gun with gun safety latch
P413 Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
RReversible Tip Guard Tip guard reduces risk of injection injury
SGun Safety Lock Gun safety latch prevents accidental triggering of spray gun
THour Meter Every 40 hours flashes, indicating it is time to change pump throat packings,
and inspect filter and ball checks.
USuction Hose Transfers fluid to be sprayed from source to pump
VDrain Tube Fluid outlet used to drain and prime the sprayer

4309860
Maintenance
Daily:
1. Inspect, clean and replace as needed
Manifold filter, gun filter and inlet stainer.
Wet cup for leakage, tighten if needed.
Hour meter. Will flash after every 40 hours of
operation. When flashing, change throat pack-
ings, check filter, inspect ball checks.
Gun trigger safety.
Tip wear, replace if necessary.
Electric cord and plug.
2. Fill throat packing nut with Graco TSL to pre-
vent premature packing wear.
Do this each time you spray.
Weekly:
Check tightness of wet cup.
Inspect all high pressure paint hoses.
Annually:
Schedule maintenance check at an
authorized Graco repair center.
Approximate Fill Level
ti7236a

5309860
General Repair Information
Pressure Relief Procedure
WARNING
Page 2
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
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.
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
WARNING
Page 2
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting Guide,
pages 6 – 10, for other possible solutions.
WARNING
Page 2
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shroud before operation of spray-
er and replace if damaged. Motor shroud prevents
overheating, and protects operator from possible
electrical shock by touching terminals of capacitor.
It can also reduce risk of burns, fire or explosion;
see preceding WARNING.

6309860
Grounding
WARNING
Page 2
1. 100–120 Vac models require a 50/60 Hz, 15A
circuit with a grounding receptacle. See Fig. 1.
2. Do not alter ground prong or use adapter. Fig. 1
grounding prong
grounded outlets
3. 120 Vac: A 12 AWG, 3 wires with grounding prong,
300 ft (90 m) extension cord may be used. Long
lengths reduce sprayer performance.
Troubleshooting
WARNING
Page 2
MOTOR WON’T 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. Pressure control knob setting. 1. Motor stops running when pressure setting is
reached.
2. Pump (13) for frozen or hardened paint. 2. 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. (Dis-
placement Pump Replacement, page 20.)
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. 8.
2. Push pin into place and secure with spring re-
tainer.
3. Motor (1). Remove drive housing assembly
(10). See page 18. Try to rotate fan by hand.
3. Replace motor (1) if fan won’t turn. See page
19.
Basic Electrical Problems 1. Motor control board. Board shuts down and dis-
plays error code.
1. Motor Control Board Diagnostics, page 15.
2. Electrical supply. Meter must read 85–130 Vac
for 100–120 Vac models.
2. Reset building circuit breaker; replace build-
ing fuse. Try another outlet.
3. Extension cord. Check extension cord continu-
ity with volt meter.
3. Replace extension cord.
4. Sprayer power supply cord (29). Inspect for
damage such as broken insulation or wires.
4. Replace power supply cord.

7309860
Troubleshooting
MOTOR WON’T OPERATE (Continued)
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 Electrical Problems
(continued)
5. That motor leads are securely fastened and
properly mated.
5. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely re-
connect leads.
6. For loose motor brush lead connections and ter-
minals. See page 11.
6. Tighten terminal screws. Replace brushes if
leads are damaged. See page 11.
7. Brush length which must be 1/2 in. minimum.
See page 11.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
7. Replace brushes. See page 11.
8. For broken or misaligned motor brush springs.
Rolled portion of spring must rest squarely on
top of brush. See page 11.
8. Replace spring if broken. Realign spring with
brush. See page 11.
9. Motor brushes may be binding in brush holders.
See page 11.
9. Clean brush holders. Remove carbon with
small cleaning brush. Align brush leads with
slot in brush holder to assure free vertical
brush movement.
10.Motor armature commutator for burn spots,
gouges and extreme roughness.
See page 11.
10.Remove motor and have motor shop resur-
face commutator if possible, page 19.
11. Motor armature for shorts using armature tester
(growler) or perform spin test. See page 11.
11. Replace motor, page 19.
Refer to wiring diagram on
page 26, to identify test
points (TP).
1. Power supply cord (29). Connect volt meter be-
tween TP1 (neutral) and TP2 (L2, 120 Vac).
Plug in sprayer. Meter must read 85–130 Vac for
100–120 Vac models.
Unplug sprayer2
1. Replace power supply cord.
2. ON/OFF switch (23). Connect volt meter be-
tween L1 or L and L2 or N terminal on ON/OFF
switch. Plug in sprayer and turn ON.
Meter must read 85–130 Vac for 100–120 Vac
models.
2. Replace ON/OFF switch, page14.
3. Motor thermal cutoff switch. Turn sprayer OFF.
Check for continuity between TO1 and TO2 with
ohmmeter.
3. If thermal switch is open (no continuity), allow
motor to cool. If switch remains open after
motor cools, replace motor. If thermal switch
closes after motor cools, correct cause of
overheating.
4. All terminals for damage or loose fit. 4. Replace damaged terminals and reconnect
securely.

8309860
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, 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, page 20.
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 85–130 Vac for 100–120 Vac
models. Low voltages reduce sprayer perfor-
mance.
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 longer than 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,
page 11.
9. Tighten terminal screws. Replace brushes
if leads are damaged, page 11.
10.For worn motor brushes which must be 1/2 in.
minimum, page 11.
10. Replace brushes, page 11.
11. For broken and misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush.
11. Replace spring if broken. Realign spring
with brush, page 11.
12.Motor brushes for binding in brush holders,
page 11.
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, page 11.
14.Replace motor, page 19.

9309860
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, page 20.
4. Remove intake valve and clean. Check
balls and seats for nicks; replace if neces-
sary, page 20. Strain paint before using to
remove particles that could clog pump.
5. Leaking around throat packing nut which may
indicate worn or damaged packings, page 20.
5. Replace packings, page 20. 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 20.
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 20.
1. Replace pump pin if missing. Be sure re-
tainer spring (9b) is fully in groove all
around connecting rod, page 20.
2. Connecting rod assembly (9) for damage,
page 18.
2. Replace connecting rod assembly,
page 18.
3. Gears or drive housing, page 18. 3. Inspect drive housing assembly and gears
for damage and replace if necessary,
page 18.

10 309860
Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
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 is hot and runs intermit-
tently.
1. Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer
is located is no more than 90F and sprayer
is not located in direct sun.
2. Move sprayer to shaded, cooler area if pos-
sible.
ELECTRICAL SHORT
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
Building circuit breaker opens
as soon as sprayer switch is
turned on.
1. All electrical wiring for damaged insulation, and
all terminals for loose fit or damage. Also wires
between pressure control and motor. See page
19.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. For missing inspection plate gasket (see page
19), bent terminal forks or other metal to metal
contact points which could cause a short.
2. Correct faulty conditions.
3. Motor armature for shorts. Use an armature
tester (growler) or perform spin test, page 11. In-
spect windings for burns.
3. Replace motor, page 19.
4. Motor control board (35) by performing motor
control board diagnostics, page 15. If diagnos-
tics indicate, substitute with a good board.
CAUTION: Do not perform this check until mo-
tor armature is determined to be good. A bad
motor armature can burn out a good board.
4. Replace with a new pressure control board
(35), page 15.
1. Basic Electrical Problems, page 6. 1. Perform necessary procedures.
2. ON/OFF switch (23), page 14. Be sure sprayer
is unplugged! Disconnect wires from switch.
Check switch with ohmmeter. Reading must be
infinity with ON/OFF switch OFF, and zero with
switch ON.
2. Replace ON/OFF switch, page 14
3. For damaged or pinched wires in pressure con-
trol, page 15.
3. Replace damaged parts, page 15.
Sprayer quits after sprayer op-
erates for 5 to 10 minutes.
1. Basic Electrical Problems, page 6. 1. Perform necessary procedures.
2. Electrical supply with volt meter.
Meter must read 85–130 Vac for 100–120 Vac
models.
2. If voltage is too high, do not operate
sprayer until corrected.
3. Tightness of pump packing nut. Over tightening
tightens packings on rod, restricts pump action,
and damages packings.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings, if
necessary, page 20.
.
CAUTION
Any short in any part of the
motor power circuit will cause
the control circuit to inhibit
sprayer operation. Correctly
diagnose and repair all shorts
before checking and replac-
ing control board.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.

11309860
Spin Test
Setup
WARNING
Page 2
To check armature, motor winding and brush electrical
continuity:
WARNING
Page 2
1. Remove drive housing, page 18.
2. Fig. 2. Remove pressure control cover (39). Dis-
connect motor leads (F) and (G).
3. Fig. 3. 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 19.
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.
3. If still uneven or no resistance, replace motor,
page 19.
9578A
Fig. 2
F
G
39
Motor Brush Replacement
Motor Brush Removal
Replace brushes worn to less than 1/2 in. Check both
sides. Brush Repair Kit 245545.
1. Read General Repair Information, page 5.
WARNING
Page 2
1. Fig. 3. Remove four screws (22) and motor
shroud (74).
2. Pry off two brush caps (A). Tag locations of red (+)
and black (–) motor leads.
3. Fig. 4. Remove screw (C) and discard brush (B)
for motor with capacitor attached. Remove brush
lead from control box for motor without capacitor
attached.
(Continued on page 12)
TI0053
A
74
Fig. 3
22

12 309860
Motor Brush Replacement
4. Fig. 4. Insert brush (B). Push clip (A) until it snaps
into place and secures brush.
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
5. Fig. 4. 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.
Fig. 4
A
TI0053
B
C
6. 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.
7. Test brushes.
a. Remove pump (13); Displacement Pump
Replacement, page 20.
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.
8. Break in brushes.
a. Operate sprayer 1 hour with no load.
b. Install pump (13), Displacement Pump Re-
placement, page 20.

13309860
Hour Meter Replacement
The sprayer is equipped with a SenDEC Hour Meter.
Every 40 hours it will flash, signaling the need to
change throat packings, check filter and inspect ball
checks.
To replace the meter:
Disassembly
WARNING
Page 2
1. Unplug sprayer.
2. Unplug wire leads from hour meter (133).
Assembly
1. Plug new hour meter (133) in to wire leads.
2. Attach 2–sided tape (134) to top of meter.
3. Reposition meter under sprayer. Push it firmly into
place making sure the 2–sided tape is adhering
tightly.
Fig. 5
ti7237a
134
133

14 309860
On/Off Switch Replacement
Removal
WARNING
Page 2
1. Fig. 6. Remove four screws (18) and pressure
control cover (39).
2. Disconnect two wires (A) from ON/OFF
switch (23).
3. 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. 6
22
52
29
21
18
25 24
51
28
23
30
33
27
32
39
36
35
26
Ref 1
Ref 45
37
TI3523C
34

15309860
Pressure Control Repair
Motor Control Board Diagnostics
Note: Keep a new transducer on hand to use for test.
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:
WARNING
Page 2
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.

16 309860
Pressure Control Repair
Motor Control Board
Removal
Refer to Fig. 6.
WARNING
Page 2
1. Remove four screws (18) and cover (39).
2. Disconnect at motor control board (35):
Four motor leads: two yellow, black (–)
and red (+).
Two line voltage leads.
Lead (D) from potentiometer.
Lead (E) from transducer.
3. Remove five screws (36) and circuit board (35).
Installation
4. Fig. 6. Install motor control board (35) with five
screws (36).
5. Connect to motor control board (35):
Lead (E) to transducer.
Lead (D) to potentiometer.
Two line voltage leads.
Four motor leads: two yellow, black (–)
and red (+).
6. Install cover (39) with four screws (18).

17309860
Pressure Control Repair
Pressure Control Transducer
Removal
Refer to Fig. 6.
WARNING
Page 2
1. Remove four screws (18) and cover (39).
2. Disconnect lead (E) from motor control
board (35).
3. Remove two screws (22) and filter housing (45).
4. Thread transducer lead plastic connector down
through transducer grommet (28).
5. 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. 6.
WARNING
Page 2
1. Remove four screws (18) and cover (39).
2. Disconnect all leads from motor control board (35).
3. Remove five screws (36) and board (35).
4. 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).

18 309860
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
WARNING
Page 2
1. Remove pump (13), Displacement Pump Replace-
ment, page 20.
2. Fig. 7. Remove two screws (22).Tip sprayer up.
Remove two screws (22) and remove shroud (74).
3. Remove two front screws (22).
4. Remove two back screws (22).
5. 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. 7. Install shroud (74) with two screw (22).Tip
sprayer up. Install two screws (22).
5. Install pump (13) Displacement Pump
Replacement, page 17.
6. Install new access cover (10a) with two screws
(10b).
Fig. 7
ti7238a
74
1
22
7
10
22
74c
A
22

19309860
Motor Replacement
Disassembly
WARNING
Page 2
1. Remove pump (13), Displacement Pump
Replacement, page 20.
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.
2. Remove drive housing (10), Drive Housing Re-
placement, page 18.
3. Remove four screws (18) and cover (39), Fig. 6,
page 14.
4. Disconnect all leads from board (35). Remove five
screws (36) and board.
5. Remove strain relief (37) and motor fan (2), page
23.
6. Remove three screws (22) behind board and
remove control housing (21), Fig. 6, page 14.
7. 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) and motor fan (2), page 23.
4. Install board (35) with five screws (36), Fig. 6,
page 14. Connect all leads to board (35).
5. Install drive housing (10), Drive Housing Replace-
ment, page 18.
6. Install pump (13), Displacement Pump Replace-
ment, page 20.

20 309860
Displacement Pump Replacement
Removal
1. Flush pump (13).
WARNING
Page 2
2. Fig. 8. Loosen two screws (10b) and remove
cover (10a).
Fig. 8
ti7239a
10b
10a
3. Cycle pump until pump pin (9a) is in position to be
removed. Remove pump pin (9a).
4. Fig. 9. Remove suction tube (78) and hose (19).
5. Loosen pump jam nut (12). Unscrew pump.
T
Fig. 9
78
12
19
ti7241a
Installation
CAUTION
If the pump locknut loosens during operation, the
threads of the drive housing will be damaged.
1. Fig. 10. Extend pump piston rod fully. Apply grease
to top of pump rod at (A) or inside connecting rod.
Fig. 10 ti7240a
2. Fig. 8. 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. 9. Install suction tube (78) and hose (19).
6. Fig. 11. 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).
Fig. 11
ti7242a
7. Fig. 12. Fill packing nut with Graco TSL until fluid
flows onto top of seal.
Fig. 12
ti7243a
10a
10b
8. Fig. 8. Replace cover (10a); tighten screws (10b).