Graco 190ES 261825 Operating instructions

- For portable spray application of architectural paints and coatings -
190ES Model: 261825
210ES Model: 261830 (Hi-Cart), 24V111 (Stand)
Maximum Working Pressure: 3000 psi (20.7 MPa, 207 bar)
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Related Manuals
311988
312830
English
312831
Français
312832
Español
312015
ti23118a
ti23118a
311990J
Repair
190ES/210ES™
Electric Airless Sprayer
EN

Warning
2311990J
Warning
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 symbol refers to procedure-specific risks. Refer back to
these warnings. Additional, product-specific warnings may be found throughout the body of this manual where appli-
cable.
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:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
• 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. Read Grounding instructions.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 severe burns, do not touch hot
equipment. Wait until equipment has cooled completely.
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 equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

Warning
311990J 3
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
WARNING

Component Identification
4311990J
Component Identification
A
B
D
E
F
G
H
J
K
M
N
P
R
S
T
U
V
W
X
ti13375b
Ref Component
A Pressure Control
B ON/OFF Switch
D Power Cord
E Fluid Outlet
F Prime Valve
G Kick Stand (210ES Series A)
HPump
J Suction Tube
K Drain Hose
M Fluid Hose
NGun
PTip
R Guard
S Trigger Safety Lock
T Serial Number ID Label
U Filter Cap
V Pail Hook
W Power Flush Adapter
X Shutoff Valve

Installation
311990J 5
Installation
Grounding and Electric
Requirements
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
The sprayer requires:
100-130 Vac, 60 Hz, 11A, 1 phase, circuit with a
grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
Do not use the sprayer if the electrical cord has a dam-
aged ground contact. Only use an extension cord with
an undamaged ground contact.
Recommended extension cords:
110-120V: 3-wire, 12 AWG (2.5 mm2) minimum, 300 ft
(90 m) maximum length.
NOTE: 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 sur-
face such as concrete. Do not place the pail on a non-
conductive 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.
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Pressure Relief Procedure
6311990J
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
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.
3. Turn prime valve down.
If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure gradually,
then loosen completely. Clear hose or tip obstruction.
4. Engage trigger safety lock on gun if unit is being
shut down or left unattended.
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 Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
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General Repair Information
311990J 7
General Repair Information
• 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 Trou-
bleshooting, page 8.
• Overspray may build up in the air passages.
Remove any overspray and residue from air pas-
sages 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 overheating and
insulates the control board from accidental electric
shock.
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.
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.
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, 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
8311990J
Troubleshooting
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 Won’t Operate
Basic Fluid Pressure 1. Pressure control knob setting.
Motor will not run if set at mini-
mum (fully counter-clockwise).
Slowly increase pressure setting to see if
motor starts.
2. Spray tip or fluid filter may be
clogged.
Relieve pressure, page 6. Then clear clog
or clean gun filter. Refer to gun instruction
manual, 311979.
Basic Mechanical 1. Pump frozen or hardened paint 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
12, Displacement Pump Replacement.
2. Displacement pump connecting
rod pin. Pin must be completely
pushed into connecting rod and
retaining spring must be firmly in
groove or pump pin.
Push pin into place and secure with spring
retainer. See page 12, Displacement Pump
Replacement.
3. Motor. Remove drive housing
assembly. See page 14, Drive
Housing Replacement. Try to
rotate fan by hand.
Replace motor if fan won’t turn. See page 27,
Motor Replacement.

Troubleshooting
311990J 9
Basic Electrical
See wiring diagram, page
28
1. Electric supply. ON/OFF switch
in OFF position. Meter must read
100-130 Vac.
Turn ON/OFF switch to ON position. Reset
building circuit breaker, replace building
fuses. Try another outlet.
2. Extension cord. Check exten-
sion cord continuity with volt
meter.
Replace extension cord.
3. Sprayer power supply cord.
Inspect for damage such as bro-
ken insulation or wires.
Replace power supply cord. See page 26,
Power Cord Replacement.
4. Fuse. Check replaceable fuse on
control board (next to ON/OFF
switch).
Replace fuse after completing motor inspec-
tion. See page 21, Fuse Replacement.
5. Motor leads are securely fas-
tened and properly connected to
control board.
Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely recon-
nect leads.
6. Motor thermal switch. Yellow
motor leads must have continuity
through thermal switch.
Replace motor. See page 27, Motor
Replacement.
7. Brush cap missing or loose brush
lead connections.
Install brush cap or replace brushes if leads
are damaged. See page 17, Motor Brush
Replacement.
8. Brush length which must be
greater than 1/4 in. (6mm).
NOTE: Brushes do not wear at
the same rate on both sides of
motor. Check both brushes.
Replace brushes. See page 17, Motor Brush
Replacement.
9. Motor armature commutator for
burn spots, gouges and extreme
roughness.
Remove motor and have motor shop resur-
face commutator if possible. See page 27,
Motor Replacement.
10. Motor armature for shorts using
armature tester (growler) or per-
form spin test, page 15.
Replace motor. See page 27, Motor
Replacement.
11. Pressure control not plugged in
to control board.
Insert pressure control connector into control
board.
Problem What To Check
(If check is OK, go to next check)
What To Do
(When check is not OK, refer to this column)

Troubleshooting
10 311990J
Low Output 1. Worn spray tip. Relieve pressure, page 6. Replace tip. Refer
to gun instruction manual, 311979.
2. Verify pump does not continue to
stroke when gun trigger is
released.
Service pump. See page 12, Displacement
Pump Replacement.
3. Prime valve leaking. Relieve pressure, page 6. Then repair prime
valve. See page 24, Manifold Replacement.
4. Suction tube connections. Tighten any loose connections. Check o-ring
on suction tube.
5. Electric supply with volt meter.
Meter must read 100-130 Vac.
Low voltages reduce sprayer
performance.
Reset building circuit breaker; replace building
fuse. Repair electrical outlet or try another
outlet.
6. Extension cord size and length. Replace with a correct, grounded extension
cord. See page 5, Grounding and Electric
Requirements.
7. Leads from motor to circuit board
for damaged or loose wire con-
nectors. Inspect wiring insulation
and terminals for signs of over-
heating.
Be sure male terminal pins are centered and
firmly connected to female terminals. Replace
any loose terminals or damaged wiring.
Securely reconnect terminals.
8. Worn motor brushes which must
be greater than 1/4 in. (6 mm).
Replace brushes. See page 17. Motor Brush
Replacement.
9. Motor brushes binding in brush
holders.
Clean brush holders. Remove carbon dust by
using compressed air to blow out brush dust.
10. Low stall pressure. Turn pres-
sure control knob fully clockwise. Replace pressure control assembly. See
page 22, Pressure Control Assembly
Replacement.
11. Motor armature for shorts by
using an armature tester
(growler) or perform spin test,
page 15.
Replace motor. See page 27, Motor
Replacement.
Problem What To Check
(If check is OK, go to next check)
What To Do
(When check is not OK, refer to this column)

Troubleshooting
311990J 11
Motor runs and pump
strokes
1. Prime Valve Open. Close prime valve.
2. Paint supply. Refill and reprime pump.
3. Intake strainer clogged. Remove and clean, then reinstall.
4. Suction tube leaking air. Tighten nut. Check o-ring on tube.
5. Intake valve ball and piston ball
are seating properly.
See Pump Manual 312015. Strain paint before
using to remove particles that could clog pump.
6. Leaking around throat packing
nut which may indicate worn or
damaged packings.
See Pump Manual 312015.
7. Pump rod damaged. See Pump Manual 312015.
Motor runs but pump does
not stroke
1. Displacement pump pin dam-
aged or missing.
Replace pump pin if missing. Be sure retaining
spring is fully in groove all around connecting
rod. See page 12, Displacement Pump
Replacement.
2. Connecting rod assembly for
damage.
Replace connecting rod assembly. See page
12, Displacement Pump Replacement.
3. Gears or drive housing. Inspect drive housing assembly and gears for
damage and replace if necessary. See page
14, Drive Housing Replacement.
Motor is hot and runs
intermittently
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.
Move sprayer to shaded, cooler area if
possible.
2. Motor has burned windings indi-
cated by removing positive (red)
brush and seeing burned adja-
cent commutator bars.
Replace motor. See page 27, Motor
Replacement.
3. Tightness of pump packing nut.
Overtightening tightens pack-
ings on rod, restricts pump action
and damages packings.
Loosen packing nut. Check for leaking around
throat. Replace pump packings if necessary.
See pump manual 312015.
Problem What To Check
(If check is OK, go to next check)
What To Do
(When check is not OK, refer to this column)

Displacement Pump Replacement
12 311990J
Displacement Pump Replacement
See manual 312015 for pump repair instructions.
Removal
1. Relieve pressure , page 6. Unplug sprayer from out-
let.
2. Loosen two screws (11) and remove pail hanger (10).
3. Loosen nut (37) and remove suction tube (39).
Loosen nut (B) and remove coupled hose (42).
4. Cycle pump until pin (31) is in position to be
removed.
5. Disconnect power cord from outlet.
6. Push up retaining spring (C). Push out pump pin (31).
7. Loosen pump jam nut (34). Unscrew and remove
pump (33).
11
10
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37
39 ti9139a
C
31
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34
33
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Displacement Pump Replacement
311990J 13
Installation
1. Extend pump piston rod fully. Apply grease to top of
pump rod (D). Install jam nut (34) on pump threads.
2. Install pump rod (D) into connecting rod (30).
3. Install pump pin (31). Verify retainer spring (30a) is
in groove over pump pin.
4. Push pump (33) up until pump threads engage.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet (E) to back.
7. Screw jam nut (34) 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 approximately
75 ft-lb (102 N•m).
8. Install suction tube (39) and coupled hose (42).
Tighten nuts (37) and (B).
.
9. Fill packing nut with Graco TSL until fluid flows onto
top of seal. Install pail hanger (10) with screws (11).
If pump pin works loose, parts could break off due to
force of pumping action. Parts could project through
air and result in serious injury or property damage.
CAUTION
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
D
34
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30
30
30a
31
33
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ti
E
34
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42B
37
39 ti9139a
10
11
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Drive Housing Replacement
14 311990J
Drive Housing Replacement
Removal
1. Relieve pressure, page 6.
2. Remove pump (33). Displacement Pump
Replacement, page 12.
3. Disconnect power cord from outlet.
4. Remove two screws (11) and cover (32).
5. Remove screw (13) and four screws (4).
6. Pull drive housing (29) out of motor front endbell.
7. Remove gear cluster (27) and (26) and thrust bear-
ing (28) from drive housing.
Installation
1. Apply a liberal coat of grease to gears and needle
bearing surfaces. Install thrust bearing (28) and
gears (26) and (27) in motor front endbell.
2. Push drive housing (29) into motor front endbell.
Insert gear crank (27) through hole in connecting
rod (30).
3. Install four screws (4) and screw (13).
4. Install cover (32) with two screws (11).
5. Install pump (33). Displacement Pump Replace-
ment, page 12.
CAUTION
Do not drop gear cluster (27) and (26) when removing
drive housing (29). Gear cluster may stay engaged in
motor front endbell or drive housing.
13
32
26
11
27
28
4
29
2
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Needle
Bearing Surfaces
27
26
28
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13
11
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32
4
30
27

Spin Test
311990J 15
Spin Test
See Wiring Diagram, page 29.
To check armature, motor winding and brush electrical
continuity:
1. Relieve pressure, page 6. Disconnect power cord
from outlet.
2. Remove kick stand (66) on (210ES Series A).
3. Remove two screws (5) and toolbox (3) (190ES,
210ES Series A).
4. Remove two screws (11) and front cover (32).
5. Remove screw (13) and shroud (12).
6. Remove drive housing (29), page 14.
7. Disconnect motor connector (D).
Armature Short Circuit Test
Quickly turn motor fan by hand. If motor coasts two or
three revolutions before complete stop, there are no
electrical shorts. If motor does not spin freely, armature
is shorted. Replace motor, page 27.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Connect red and black motor leads with test lead.
Turn motor fan by hand at about two revolutions per
second.
2. If uneven or no resistance, check for missing brush
caps, broken brush springs, brush leads, and worn
brushes. Repair as needed, page 17.
3. If still uneven or no resistance, replace motor, page 27.
4. Connect motor connector (D).
5. Install drive housing, page 14.
6. Install shroud (12) with screw (13).
7. Install front cover (32) with two screws (11).
8. Install toolbox (3) with two screws (5) (190ES, 210ES
Series A).
9. Install kick stand (66) on (210ES Series A).
11
32
13
29
12
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D

Fan Replacement (Hi-Cart)
16 311990J
Fan Replacement (Hi-Cart)
Removal
1. Relieve pressure, page 6. Disconnect power cord
from outlet.
2. Remove kick stand (66) (210ES Series A).
3. Remove two screws (5) and toolbox (3) (190ES,
210ES Series A).
4. Remove two screws (11) and front cover (32).
5. Remove screw (13) and shroud (12).
6. Remove retaining ring (57b) on back of motor.
7. Pull off fan (57a).
Installation
1. Slide new fan (57a) on back of motor. Be sure fan
blades face motor.
2. Install spring clip (57b).
3. Install shroud (12) with screw (13).
4. Install front cover (32) with two screws (11).
5. Install toolbox (3) with two screws (5) (190ES, 210ES
Series A).
6. Install kick stand (66) (210ES Series A).
57b
57a
11
12
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13 32

Fan Replacement (Stand)
311990J 17
Fan Replacement (Stand)
Removal
1. Relieve pressure, page 6. Disconnect power cord
from outlet.
2. Remove screws (11) and front cover (32).
3. Remove screws (11) and shroud (12).
4. Remove retaining ring (57b) on back of motor.
5. Pull off fan (57a).
Installation
1. Slide new fan (57a) on back of motor. Be sure fan
blades face motor.
2. Install spring clip (57b).
3. Install shroud (12) with screw (11).
4. Install front cover (32) with two screws (11).
12
11
57b
57a
32
11
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Motor Brush Replacement
18 311990J
Motor Brush Replacement
See Wiring Diagram, page 29.
Removal
Replace brushes worn to less than 1/4 in. (6 mm).
Brushes wear differently on each side of motor, check
both sides.
1. Relieve pressure, page 6. Disconnect power cord
from outlet.
2. Remove kick stand (66) (210ES Series A).
3. Remove two screws (5) and toolbox (3) (190ES,
210ES, Series A).
4. Remove two screws (11) and front cover (32)
(190ES, 210ES Series A).
5. Remove screw (13) and shroud (12) (see illustration
on page 15).
6. Disconnect motor connector (D) from control board (18).
7. Cut tie wrap (F).
8. Locate two yellow wires (C). Cut each yellow wire at
the center.
9. Pry off two brush caps (A). Remove brushes (B)
from motor.
10. Discard old brush assembly.
11. Rotate fan by hand and blow compressed air into
top brush holder to remove brush dust.
NOTE: Place end of a shop vacuum hose over lower
brush holder. Turn on shop vacuum when you blow
compressed air into top brush holder.
Installation
NOTE: Use all new parts included in brush kit. Do not
reuse old parts if new replacement parts are provided.
\
1. Install new brushes (B) in motor with wires facing
toward front of motor. Install positive (red) brush
lead in top of motor and negative (black) brush lead
in side of motor.
2. Push each cap (A) into place over brush. Orient
each cap with the two projections on either side of
the brush lead. You will hear a snap when cap is
securely in place.
3. Strip approximately 1/4 inch (6 mm) of insulation
from end of each yellow wire (C) from motor.
4. Insert stripped end into end of a butt splice (E) on
new brush assembly.
5. Crimp ends of butt splice (E) around each wire. Pull
gently on each wire to be sure wire does not pull out
of butt splice.
6. Connect motor connector (D) to control board (18).
7. Install shroud (12) with screw (13) (see illustration,
page 15).
8. Install front cover (32) with two screws (11).
9. Install toolbox (3) with two screws (5) (190ES, 210ES
Series A).
10. Install kick stand (66) (210ES Series A).
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30
29
33
A
B
+
-
C
D
E
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D
A
Red
Black

Control Board Replacement
311990J 19
Control Board Replacement
See Wiring Diagram, page 29.
Removal
1. Relieve pressure, page 6. Disconnect power cord
from outlet.
2. Remove kick stand (66) (210ES Series A).
3. Remove two screws (5) and toolbox (3) (190ES,
210ES Series A).
4. Remove two screws (11) and front cover (32).
Remove screw (13) and shroud (12) (see illustra-
tion, page15).
5. Disconnect pressure control assembly connector
(A) from control board (18).
6. Disconnect motor connector (D) from control board (18).
7. Remove three screws (11) securing control board to
housing (two are located on the front and one on the
back next to the power cord).
8. Pull control board out slightly and then slide control
board back and off of frame.
NOTE: Make sure power cord is free and not wrapped
around cord wrap.
9. Remove grommet and wires from strain relief.
NOTE: Ground wire remains attached to sprayer with
grounding screw.
.
10. Remove two power cord (C) connectors from con-
trol board.
120V
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18
D
A
11
18
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18
Grommet
Strain
Relief
120V C
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18

Control Board Replacement
20 311990J
Installation
1. Push grommet and power cord wires into strain
relief in control board (18).
2. Connect power cord connectors to terminals indi-
cated on control board (18).
NOTE: Route power cord (19) between coupled hose
(42) to filter manifold and sprayer frame.
3. Slide control board into place on side of motor front
endbell.
4. Replace three screws (11). Torque to 30-35 in-lb
(3.4-3.9 N.m).
5. Connect motor connector (D) and pressure control
assembly connector (A).
6. Install shroud (12) with screw (13). Install front cover
(32) with two screws (11). (see illustration, page 15).
7. Install toolbox (3) with two screws (5) (190ES, 210ES
Series A).
8. Install kick stand (66) (210ES Series A).
ti6122a
18
Grommet
Strain
Relief
120V
ti9132a
18
C
Bottom View of Sprayer ti9153a
42
19
11
18
ti9154a
120V
ti9132a
18
D
A