Graco 190ES User Manual
REPAIR
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
First choice when
quality counts.t
309063F
- 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
232906, A, B
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....................
ti7400a
232900
309365.......
309045.......
309064.....................
309065.......
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...............................
309060.......
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.
D If 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.
D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.
3309063
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
D Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. Read Technical Data in all equipment manuals.
D Use fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in
all equipment manuals. Read fluid and solvent manufacturer’s warnings.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
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.
D 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:
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.
D 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.
4 309063
Component Identification and Function
H
A
J
V
U
PR
S
T
K
F
ti7400a
B
D
ti5914a
N
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
G
E
5309063
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 sett ing.
2. Hold gun against side of grounded metal flushing
pail. Trigger gun to relieve pressure.
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 retain-
ing 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:
ti7401a
Fig. 1
3. Turn prime valve down
FLUSH
D Use needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
D Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
D 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
WARNING
Read Electric ShockWarning and
Burn Hazard Warning.
WARNING
Flammable materials spilled on hot,
bare, motor could cause fire or
explosion. T o reduce risk of burns, fire or
explosion, do not operate sprayer with
cover removed.
D Keep 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.
D If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Troubleshooting, page 9.
D 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.
D Do 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:
D Do not touch moving or electric parts
with fingers or tools while testing repair
D Unplug sprayer when power is not
required for testing
D Install all covers, gaskets, screws and
washers before you operate sprayer
CAUTION
D Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
D 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.
D 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 sprayer during storage.
D 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.
7309063
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.
Fig. 3
The sprayer requires:
1 10--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.
ti7480a
Fig. 5
Recommended extension cords for use with this
sprayer:
D 1 10--120V: 3--wire, 12 AWG (2.5 mm
300 ft. (90 m) maximum length.
D 240V: 3--wire, 16 AWG (1.0 mm
(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.
ti7482a
2
) minimum,
2
) minimum, 300 ft.
ti7481a
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.
8 309063
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
ti7483a
Relieve pressure; page 6.
gg,pg
MOTOR WON’T OPERATE
Troubleshooting
TYPE OF PROBLEM
Basic Fluid Pressure
Problems
Basic Mechanical
Problems
Basic Electrical Problems
See Wiring Diagram, pages
15 to 18.
WHAT TO CHECK
If check is OK, go to next check
1. Pressure control knob setting. Motorwill not run
if at minimum setting (fully counterclockwise).
2. Spray tip or fluid filter may be clogged. 2. Relieve pressure and clear clog or clean fil-
1. Pump (13) frozen or hardened paint. 1. Thaw sprayer if water or water-based paint
2. Displacement pump connecting rod pin (9a).
Pin mustbe completely pushed into connecting
rod (9) and retaining spring (9b) must be firmly
in groove of pump pin. See Fig. 18.
3. Motor (1). Remove drive housing assembly
(10). See page 24. Try to rotate fan by hand.
1. Motor control board.Board shuts down and displays error code on some models.
2. Electrical supply. Meter must read 100--130
VAC for 110--120 VAC models and 210--255
VAC for 240 VAC models.
WHAT TO DO
When check is not OK refer to this column
1. Slowly increase pressuresetting to see if motor starts.
ter; refer to separate gun or tip instruction
manual.
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. Push pin into place and securewith spring retainer.
3. Replace motor (1) if fan won’t turn. See page
25.
1. See Motor Control Board Diagnostics,
page 19.
2. Reset building circuit breaker; replace building fuses. Try another outlet.
3. Extension cord. Check extension cord continuity with volt meter.
4. Sprayer power supply cord. Inspect for damage
such as broken insulation or wires.
5. Fuse. Check replaceable fuseon control board. 5. Replace fuse after completing motor inspec-
6. Motor leads are securely fastened and properly
connected to control board.
7. Motor thermal switch. Yellow motor leads must
have continuity through thermal switch.
8. Brush cap missing or loose brush lead connections.
9. Brush length which must be 1/4 in. (6 mm) minimum.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
10.Motor armature commutator for burn spots,
gouges and extreme roughness.
11.Motor armature for shorts using armature tester
(growler) or perform spin test, page 12.
3. Replace extension cord.
4. Replace power supply cord.
tion.
6. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
7. Replace motor. See page 25, Motor Replacement.
8. Install brush cap or replace brushes if leads
are damaged. See page12, Motor BrushReplacement.
9. Replace brushes. See page 12, Motor Brush
Replacement.
10. Remove motor and have motor shop resurface commutator if possible. See page 25,
Motor Replacement.
11.Replace motor. See page 25, Motor Replacement.
12.Pressure control notplugged into controlboard. 12. Insert pressure control connectorinto control
board.
9309063
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