Graco 190ES User Manual

REPAIR

Important Safety Instructions

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

309063F

First choice when quality counts.t

- For portable spray applications of architectural paints and coatings -

190ESt

Airless Paint Sprayers

3000 psi (207 bar, 20.7 MPa ) Maximum Working Pressure

120 VAC

232900, A, B, C, D, E, F 232901, A, B, C, D, E 233797, A, B, C, D, E 233815, A, B, C, D, E

100-120 VAC

232903, A, B

220-240 VAC

ti7400a

232906, A, B

232900

. . . . . . . 309365	309060
. . . . . . . 309045
. . . . . . . . . . . . . . . . . . . . .	309064
. . . . . . . 309065

Table of Contents

	Component Function and Identification . . . . . . . . . . .	. 5	Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . .	19
	Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . .	. 6	Drive Housing Replacement . . . . . . . . . . . . . . . . . . . .	24
	General Repair Information . . . . . . . . . . . . . . . . . . . . . .	7	Motor Replacement	25
	Grounding	8
			Displacement Pump Replacement	26
	Troubleshooting	9
			Technical Data	27
	Spin Test	12
			Graco Phone Number	28
	Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . .	12
	On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . .	14	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

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

D Use equipment only in well ventilated area.

D 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.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop clothes (potential static arc).

D Keep work area free of debris, including solvent, rags and gasoline.

D Do not plug or unplug power cords, or turn lights on or off when flammable fumes are present. D Ground equipment and conductive objects in work area. See Grounding instructions.

D Use only grounded hoses.

D Hold gun firmly to side of grounded pail when triggering into pail.

DIf there is static sparking or you feel a shock, stop operating immediately. Do not use equipment until you identify and correct the problem.

D Keep a fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

D Turn off and disconnect power cord before servicing equipment.

D Use only grounded electrical outlets

D Use only 3--wire extension cords.

D 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.

D Do not point gun at anyone or any part of the body. D Do not put your hand over the spray tip.

D Do not stop or deflect leaks with your hand, body, glove, or rag. D Do not spray without tip guard and trigger guard installed.

D Engage trigger lock when not spraying.

DFollow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking or servicing equipment.

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EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

DUse fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.

D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not alter or modify equipment.

D Use equipment only for its intended purpose. Call your Graco distributor for information.

D Route hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces. D Do kink or overbend hoses or use hoses to pull equipment.

D Keep children and animals away from work area. D 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.

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

DStore hazardous fluid in approved containers and dispose of it according to all applicable guidelines.

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:

D Protective eye wear.

D Clothing and respirator as recommended by the fluid and solvent manufacturer. D Gloves.

D Hearing protection.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

D Keep clear of moving parts.

D Do not operate equipment with protective guards or covers removed.

DPressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

4 309063

Component Identification and Function

	H
	A
	J
V	B

		U
R	P S	T

		K
		F
		D
		ti7400a
		ti5914a
N		E G
	M
A	Motor	DC motor, permanent magnet, fan cooled
B	Drive Assembly	Transfers power from DC motor to displacement pump
D	Displacement Pump	Transfers fluid to be sprayed from source through spray gun
E	Fluid Outlet	Spray gun is connected here
F	Prime Valve	Used to prime and drain sprayer (also relieves fluid outlet pressure) when
		open
G	Fluid Filter (optional)	Final filter of fluid to spray gun
H	Pressure 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

WARNING

SKIN INJECTION HAZARD

Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure, stop spraying, check or service equipment, or install or clean spray tip. read

Injection Hazard Warning.

1.Turn OFF power and turn pressure control to lowest pressure setting.

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

	ti7401a
Fig. 1	FLUSH

3. Turn prime valve down

Fig. 2

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 retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear tip or hose obstruction.

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

CAUTION

To reduce risk of pressure control malfunction:

DUse needle nose pliers to disconnect wire. Never pull on wire, pull on connector.

DMate wire connectors properly. Center flat blade of insulated male connector in female connector.

DRoute 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

WARNING

Read Electric Shock Warning and

Burn Hazard Warning.

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.

DKeep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts usually are not provided with replacement kits.

D test repairs after problems are corrected.

DIf sprayer does not operate properly, review repair procedure to verify you did it correctly. See Troubleshooting, page 9.

DOverspray may build up in the air passages. Remove any overspray and residue from air passages and openings in the enclosures whenever you service sprayer.

DDo not operate the sprayer without the motor shroud in place. replace if damaged. Motor shroud directs cooling air around motor to prevent overheating and insulate the control board from accidental electric shock.

WARNING

To reduce risk of serious injury, including electric shock:

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

DUnplug sprayer when power is not required for testing

DInstall all covers, gaskets, screws and washers before you operate sprayer

CAUTION

DDo not run sprayer dry for more than 30 seconds. Doing so could damage pump packings.

DProtect 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.

DPrevent pump corrosion and damage from freezing. 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 sprayer during storage.

DDo not operate the sprayer without the motor shroud or control box cover in place. Replace if damaged. Motor shroud directs cooling air around motor to prevent overheating and the control box cover insulates the control board from accidental electric shock.

309063 7

Grounding and Electric Requirements

WARNING

Your system must be grounded. Read warnings, page 3.

The sprayer cord includes: a grounding wire with an appropriate grounding contact.

		ti7480a
	Fig. 3

The sprayer requires:

110--120V units: 100--130 VAC, 50/60 Hz, 15A, 1 phase, circuit with a grounding receptacle.

240V Units: 210--255 VAC, 50/60 Hz, 7.5A, 1 phase, circuit with a grounding receptacle.

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

		ti7482a
	Fig. 5

Recommended extension cords for use with this sprayer:

D110--120V: 3--wire, 12 AWG (2.5 mm2) minimum, 300 ft. (90 m) maximum length.

D240V: 3--wire, 16 AWG (1.0 mm2) 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.

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.

	ti7481a
	Fig. 4
	Do not use the sprayer if the electrical cord has a
	damaged ground contact. Only use an extension cord	Fig. 6	ti7483a
	with an undamaged ground contact.

8 309063

Troubleshooting

Relieve pressure; page 6.

MOTOR WON’T OPERATE

	TYPE OF PROBLEM	WHAT TO CHECK		WHAT TO DO
		If check is OK, go to next check		When check is not OK refer to this column
	Basic Fluid Pressure	1.	Pressure control knob setting. Motor will not run	1.	Slowly increase pressure setting to see if mo-
	Problems		if at minimum setting (fully counterclockwise).		tor starts.
		2.	Spray tip or fluid filter may be clogged.	2.	Relieve pressure and clear clog or clean fil-
					ter; refer to separate gun or tip instruction
					manual.
	Basic Mechanical	1.	Pump (13) frozen or hardened paint.	1.	Thaw sprayer if water or water-based paint
	Problems				has frozen in 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).	2.	Push pin into place and secure with spring re-
			Pin must be completely pushed into connecting		tainer.
			rod (9) and retaining spring (9b) must be firmly
			in groove of pump pin. See Fig. 18.
		3.	Motor (1). Remove drive housing assembly	3.	Replace motor (1) if fan won’t turn. See page
			(10). See page 24. Try to rotate fan by hand.		25.
	Basic Electrical Problems	1.	Motor control board. Board shuts down and dis-	1.	See Motor Control Board Diagnostics,
	See Wiring Diagram, pages		plays error code on some models.		page 19.
	15 to 18.
		2.	Electrical supply. Meter must read 100--130	2.	Reset building circuit breaker; replace build-
			VAC for 110--120 VAC models and 210--255		ing fuses. Try another outlet.
			VAC for 240 VAC models.
		3.	Extension cord. Check extension cord continu-	3.	Replace extension cord.
			ity with volt meter.
		4.	Sprayer power supply cord. Inspect for damage	4.	Replace power supply cord.
			such as broken insulation or wires.
		5.	Fuse. Check replaceable fuse on control board.	5.	Replace fuse after completing motor inspec-
					tion.
		6.	Motor leads are securely fastened and properly	6.	Replace loose terminals; crimp to leads. Be
			connected to control board.		sure terminals are firmly connected.
					Clean circuit board terminals. Securely re-
					connect leads.
		7.	Motor thermal switch. Yellow motor leads must	7.	Replace motor. See page 25, Motor Re-
			have continuity through thermal switch.		placement.
		8.	Brush cap missing or loose brush lead connec-	8.	Install brush cap or replace brushes if leads
			tions.		are damaged. See page 12, Motor Brush Re-
					placement.
		9.	Brush length which must be 1/4 in. (6 mm) mini-	9.	Replace brushes. See page 12, Motor Brush
			mum.		Replacement.
			NOTE: Brushes do not wear at the same rate on
			both sides of motor. Check both brushes.
		10.Motor armature commutator for burn spots,		10. Remove motor and have motor shop resur-
			gouges and extreme roughness.		face commutator if possible. See page 25,
					Motor Replacement.
		11. Motor armature for shorts using armature tester		11. Replace motor. See page 25, Motor Re-
			(growler) or perform spin test, page 12.		placement.

12.Pressure control not plugged in to control board. 12.Insert pressure control connector into control board.

309063 9