Graco 278680 User manual

332257A
EN
Repair
Electric Airless Sprayer
- For the application of architectural paints and coatings -
- For professional use only -
Model 278680
3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
ti21026a

2332257A
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Requirements . . . . . . . . . . . . . . . . . . . . . 6
Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8
General Repair Information . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Displacement Pump Replacement . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Housing Replacement . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ON/OFF Switch/Power Cord Board Kit . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Control Diagnostics . . . . . . . . . . . . . . . . . . 21
Pressure Control Transducer . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Adjust Potentiometer . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Warnings
332257A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these sym-
bols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard sym-
bols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNINGWARNINGWARNING
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:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as ciga-
rettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates
a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system, including
the pump, hose assembly, spray gun, and objects in and around the spray area shall be properly
grounded to protect against static discharge and sparks. Use Graco conductive or grounded high-pres-
sure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge. Do not use pail
liners unless they are are antistatic or conductive.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump
assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets
(MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents manu-
facturer’s safety instructions.
• Fire extinguisher equipment shall be present and working.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or clean-
ing, keep sprayer at least 20 feet (6 m) away from explosive vapors.
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors
• Wait five minutes after disconnecting power cord before servicing large capacitor units.

Warnings
4332257A
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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at 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.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equip-
ment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
EQUIPMENT MISUSE HAZAR
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See
Technical Data in all equipment manuals.
• Use fluid and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manu-
als. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS
from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replace-
ment parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend 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
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and
equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for
compatibility.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing
loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNINGWARNINGWARNING
WARNING

Component Identification
332257A 5
Component Identification
HJ
K
M
N
S
T
P
R
F
E
D
B
C
ps
A
G
ti21027a
A Pressure control
BPowerCord
C ON/OFF switch
D Digital Display
E Prime/Spray valve
FFilter
G Fluid outlet
H Siphon tube
J Drain tube
KPump
MHose
NSprayGun
PSwitchTip
R Tip Guard
S Trigger lock
T Serial Tag

Grounding
6332257A
Grounding
Sprayer Cord: The sprayer cord includes a grounding
wire with an appropriate grounding contact.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Power Requirements
230V units require 220-240 VAC, 50/60 Hz, 8A, 1 phase.
Extension Cords
If an extension cord is necessary, use a 3-wire, 12 AWG
(2.5 mm
2
) minimum.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
The plug must be plugged into an outlet that is prop-
erly installed and grounded in accordance with all
local codes and ordinances.
Do not modify plug! If it will not fit in outlet, have
grounded outlet installed by a qualified electrician.
Do not use an adapter.
ti11730a

Grounding
332257A 7
Pails
Solvent and oil/based fluids: follow local code. Use
only conductive metal pails, placed on a grounded sur-
face. Do not place the pail on a nonconductive surface,
such as paper or cardboard, which interrupts grounding
continuity.
Grounding a metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to a true
earth ground such as a water pipe.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of spray gun firmly
to side of a grounded metal pail. Then trigger gun.
ti5850b
ti5851a
TIAB

Pressure Relief Procedure
8332257A
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn power OFF and unplug sprayer.
2. Turn pressure to lowest setting. Trigger gun to
relieve pressure. Turn prime valve down.
3. If you suspect spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following these steps,
VERY SLOWLY loosen
tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose obstruction.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief Pro-
cedure when you stop spraying and before cleaning,
checking, or servicing the equipment.
ti2707a
ti11730a
WASTE
WASTE
ti2719a
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General Repair Information
332257A 9
General Repair Information
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 elec-
trical 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 10.
• Install motor shroud before operation of sprayer and
replace if damaged. Motor shroud directs cooling air
around motor to prevent overheating. It can reduce
risk of burns, fire or explosion, or cut fingers.
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 test-
ing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
NOTICE
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 or pressure control. Do not
pinch wires between cover and control box.
NOTICE
• 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, the 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 its not in use in cold weather. Freez-
ing fluids can seriously damage sprayer. Store
sprayer with Pump Armor to protect sprayer during
storage.

Troubleshooting
10 332257A
Troubleshooting
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)
Basic fluid pressure problems Pressure control knob setting. Motor
will not run if at minimum setting (fully
counter-clockwise).
Slowly increase pressure to see if
motor starts.
Spray tip or fluid filter may be
clogged.
Relieve pressure, page 8 and clear
clog, or clean filter; refer to separate
gun or tip instruction manual.
Basic Mechanical Problems Pump frozen or paint hardened in
pump.
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 Dis-
placement Pump Replacement,
page 15.
Displacement pump connecting rod
pin must be completely pushed into
connecting rod and retaining spring
must be firmly in groove of pump pin.
See page 15.
Push pin into place and secure with
spring retainer.
Motor. Remove drive housing assem-
bly. See page 17. Try to rotate fan by
hand.
Replace motor if fan won’t turn. See
page 17.
Motor control board. Board shuts
down and displays error code.
See Motor Control Board Diagnos-
tics, page 21.

Troubleshooting
332257A 11
Basic Electrical Problems Electric supply. Meter must read:
• 210-255 VAC for 220-240V
models
Reset building circuit breaker.
Replace building fuse. Try another
outlet.
Extension cord. Check extension
cord continuity with volt meter.
Replace extension cord.
Sprayer power supply cord. Inspect
for damage such as insulation or
wires.
Replace power supply cord, page 24.
Motor leads are securely fastened
and properly mated.
Replace loose terminals; crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.
NOTE: For the following electric
problems, refer to Wiring Diagram,
page 24, to identify Test Points (TP).
Power supply cord. Connect volt
meter between L1 and L2. Plug in
sprayer. Meter must read:
• 210-255 VAC for 220-240V
models
Unplug sprayer.
Replace power supply cord, page 24.
ON/OFF Switch. Connect volt meter
between L1 and L2 terminal on
ON/OFF switch. Plug in sprayer and
turn ON. Meter must read:
• 210-255 VAC for 220-240V
models
Replace ON/OFF switch. See page
19.
All terminals for damage or loose fit. Replace damaged terminals and
reconnect securely.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)

Troubleshooting
12 332257A
Low Output For worn spray tip. Relieve pressure, page 8. Then
replace tip. See your separate gun
manual for additional instruction.
Verify pump does not continue to
stroke when gun trigger is released.
Service pump. See page 15.
Filter clogged. Relieve pressure, page 8. Check
and clean filter.
Prime valve leaking. Relieve pressure, page 8. Repair
prime valve.
Suction hose kinks and/or loose
connection.
Correct kink and/or tighten any loose
connections.
Electric supply with volt meter. Low
voltages reduce sprayer
performance. Meter must read:
• 210-255 VAC for 220-240V
models
Reset building circuit breaker;
replace building fuse. Repair
electrical outlet or try another outlet.
Extension cord size and length; must
be at least 12 gauge wire and no
longer than 300 ft. Longer cord
lengths reduce sprayer performance.
Replace with a correct, grounded,
extension cord.
Low Output Leads from motor to pressure control
circuit board for damaged or loose
wires or connectors. Inspect wiring
insulation and terminals for signs of
overheating.
Be sure male terminal blades are
centered and firmly connected to
female terminals. Replace any loose
terminal or damaged wiring. Securely
reconnect terminals.
Low stall pressure. 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.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)

Troubleshooting
332257A 13
Motor runs and pump strokes Low paint supply. Refill and reprime pump.
Intake strainer clogged. Remove and clean, then reinstall.
Suction tube or fittings loose. Tighten; use thread sealant or
sealing tape on threads if necessary.
See if intake valve ball and piston ball
are seating properly. See pump
manual.
Remove intake valve and clean.
Check balls and seats for nicks,
replace if necessary. Strain paint
before using to remove particles that
could clog pump. See pump manual.
Leaking around throat packing nut
which may indicate worn or damaged
packings. See pump manual.
Replace packings. Also check piston
valve seat for hardened paint or nicks
and replace if necessary. Tighten
packing nut/wet-cup. See pump
manual.
Pump rod damage. Replace pump, page 15.
Motor runs but pump does not stroke Displacement pump pin damaged or
missing.
Replace pump pin if missing. Be sure
retainer spring is fully in groove all
around connecting rod, page 15.
Connecting rod assembly damaged. Replace connecting rod assembly.
See pump manual.
Gears or drive housing, page 17. Inspect drive housing assembly and
gears for damage and replace if
necessary, page 17.
Motor is hot and runs intermittently Determine if sprayer was operated at
high pressure with small tips, which
causes low motor RPM and
excessive heat buildup.
Decrease pressure setting or
increase tip size.
Be sure ambient temperature where
sprayer is located is not more than
90°F (32.22°C) and sprayer is not
located in direct sun.
Move sprayer to shaded, cooler area
if possible.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)

Troubleshooting
14 332257A
Building circuit breaker opens as
soon as sprayer switch is turned on
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 replacing
control board.
All electrical wiring for damaged
insulation and all terminals for loose
fit or damage. Also, wires between
pressure control and motor. See
page 20.
Repair or replace any damaged
wiring or terminals. Securely
reconnect all wires.
For missing inspection plate gasket,
see page 22, bent terminal forks or
other metal to metal contact points
which case a short.
Correct faulty conditions.
Motor control board by performing
control board diagnostics. See page
15. If diagnostics indicate, substitute
with a good board.
NOTICE: Do not perform this check
until motor armature is determined to
be good. A bad motor armature can
burn out a good board.
Replace with a new pressure control
board. See page 22.
Building circuit breaker opens as
soon as sprayer is plugged into outlet
and sprayer is NOT turned on.
Basic Electric Problems, page 10 of
Troubleshooting.
Perform necessary procedures.
ON/OFF switch. See page 19.
Be
sure sprayer is unplugged!
Disconnect wires from switch. Check
switch with ohmmeter. Reading must
be infinity with ON/OFF switch OFF,
and zero when switch is ON.
Replace ON/OFF switch. See page
19.
For damaged or pinched wires in
pressure control. See page 22.
Replace damaged parts. See page
22.
Sprayer quits after sprayer operates
for 5 to 10 minutes.
Basic Electric Problems, page 10 of
Troubleshooting.
Perform necessary procedures.
Electrical supply volt meter. Meter
must read:
• 210-255 VAC for 220-240V
models
If voltage is too high, do not operate
sprayer until corrected.
Tightness of pump packing nut. Over
tightening tightens packings on rod,
restricts pump action, and overloads
motor.
Loosen packing nut. Check for
leaking around throat. Replace pump
packings, if necessary. See pump
manual.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)

Displacement Pump Replacement
332257A 15
Displacement Pump Replacement
See manual 309250 for pump repair instructions.
Removal
1. Cycle motor until pump pin (32)is in position to be
removed.
2. Perform Pressure Relief Procedure, page 8.
3. Loosen screws (12). Push cover (70) up and pull off
sprayer.
4. Remove suction tube (60) and hose (45).
5. Using a flat screwdriver, push retaining spring (31)
up. Push out pump pin (32).
6. Loosen pump jam nut (29). Unscrew and remove
pump (41).
32
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70
12
ti21095a
60
45
ti21096a
32
31
41
29
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ti21094a

Displacement Pump Replacement
16 332257A
Installation
1. Extend pump piston rod full. Apply grease to top of
pump rod at (A) or inside connecting rod (43). Install
jam nut (29) on pump threads.
2. Install pump rod (A) into connecting rod (43).
3. Install pump pin (32). Slide retainer spring (31)
down into groove over pump pin.
4. Push pump (41) up until pump threads engage.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet (P) to back.
7. Turn jam nut (29) counter-clockwise until it stops.
Tighten jam nut by hand, then tap 1/8 to 1/4 turn
with a 20 oz (maximum) hammer to approximately
75 ft-lb (102 N•m).
8. Install suction tube (60) and high pressure hose
(45). Tighten fittings.
9. Fill packing nut with Graco TSL until fluid flows onto
top of seal.
10. Replace cover (70) over screws. Push cover down
into place. Tighten screws (12).
If pump pin works loose, parts could break off due to
force of pumping action, project through the air, and
result in serious injury or property damage. To avoid,
ensure the retainer spring is installed properly.
NOTICE
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
29
A
43
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43
A
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32
31
ti6111a
P
ti21087a
29
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60
45
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Drive Housing Replacement
332257A 17
Drive Housing Replacement
Removal
1. Perform Pressure Relief Procedure, page 8.
2. Remove pump (41), Displacement Pump
Replacement, page 15.
3. Remove screws (12) from front cover (22).
4. Remove bracket (147) and screw (148).
5. Remove screws (47).
6. Pull drive housing (42) off motor (54).
7. Remove gear cluster (44) and (40) and thrust
washer (25) from drive housing.
Installation
1. Apply a heavy coat of grease to gears and needle
bearing surfaces.
2. Install washers (8, 10) on back of gear (40). Install
gear in motor end bell. Using grease for retention,
place washer (10) over bearing inside housing (42).
3. Install washers (1, 9) on back of gear (44). Install in
motor endbell.
4. Install thrust washer (25) on gear (44).
5. Push drive housing (42) on motor endbell as you
guide gear crank (44) through hole in connecting
rod (43).
6. Install screws (47). Torque to 16 - 18 N•m.
7. Install bracket (147) and screw (148).
Torque to 16 - 18 N•m.
8. Install cover (22) and screws (12).
Torque to 1 - 1.2 N•m.
9. Install pump (41); Displacement Pump
Replacement, page 15.
NOTICE
Do not drop gear cluster (44) and (40) when removing
from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing.
54
9
1
8
10
40
10
25
42
47
22
12
23
117
70
12
A
12
44
43
147
148
ti21090a

Fan Replacement
18 332257A
Fan Replacement
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove four screws (12) and shroud (23).
3. Loosen tensioning screw (126) on fan (125).
4. Pull off fan (125).
Installation
1. Slide new fan (125) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Tighten screw (126). Torque to 1 - 1.2 N•m.
3. Replace shroud (23) and four screws (12).
Torque to 1 - 1.2 N•m.
23
117
12
126
125
12
ti21091a

ON/OFF Switch/Power Cord Board Kit
332257A 19
ON/OFF Switch/Power Cord Board Kit
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove four screws (12) and control box cover
(51).
Power Cord
3. Remove green ground screw (6) and disconnect
blue and black leads.
4. Slide black power cord strain relief out of slot in
control box (48) to remove it.
ON/OFF Switch
5. Remove switchboard mounting screw (128).
6. Using a 5/8 in. deep socket wrench, remove
ON/OFF switch toggle boot (58).
7. Slide switch (30) through opening in control box
housing.
8. Disconnect black and blue leads between control
boards.
9. Remove switch board from box.
Installation
1. Reconnect black and blue leads between control
and switch boards.
2. Slide ON/OFF switch (30) through opening in con-
trol box housing and position switch board.
3. Place toggle boot (58) over ON/OFF switch. Use a
5/8 in. deep socket wrench to tighten securely.
4. Install switchboard mounting screw (128).
Torque to no more than 2.0 N•m.
5. Slide power cord strain relief into opening in control
box (48).
6. Reattach black and blue power cord leads to control
and switch boards.
7. Replace power cord and ground lead and tighten
green ground screw (6). Torque to 3.4 - 4.0 N•m.
8. Install pressure control cover (51) with four screws
(12). Torque to 3.4 - 4.0 N•m.
56
15
38
3
20
48
51
12 47
54
49
37
37a
11
127
58
5
30
129
128
105
113
6
ti21088a

Motor Control Board
20 332257A
Motor Control Board
NOTE: See Wiring Diagram, page 24.
Removal
1. Perform Pressure Relief Procedure, page 8, and
unplug sprayer.
2. Remove four screws (12) and remove display cover
(51).
3. Remove four screws (12) and remove motor shroud
(23).
4. Disconnect motor and thermistor connections.
5. Disconnect pressure transducer (J11) from board.
6. Disconnect potentiometer lead (J12) from board.
7. Remove ground screw (6). Unplug brown and blue
power cord leads from control board and slide
power cord out of strain relief to remove cord.
8. Remove two screws (47) and remove motor control
enclosure. Pull motor control enclosure to the left to
remove from transducer (38).
Installation
1. Connect motor control enclosure to transducer (38)
and tighten two screws (47).
2. Route power cord through strain relief and connect
brown and blue cord leads to control board. Install
and tighten ground screw (6).
Torque to 3.4 - 4.0 N•m.
3. Connect potentiometer lead (J12) to board.
4. Connect pressure transducer (J11) to board.
5. Install motor shroud (23) and tighten four screws
(12). Torque to 1.0 - 1.2 N•m to prevent stripping
plastic bracket.
6. Install display cover (51) and tighten four screws
(12) to 3.4 - 4.0 N•m.