Graco 312805C - 190ES/210ES/210ES Plus Airless Sprayer, Repair Owner's Manual
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Repair
190ES/210ES/210ES Plus
™
Electric Airless Sprayer
312805C
EN
-
For portable spray application of architectural paints and coatings. For professional use only. -
190
ES
Stand Model: 255847, 255848
210
ES
Stand Model: 255851
210 Plus Stand Model: 255849
190
ES
Plus Hi-Boy Model: 255712, 255713
210
ES
Plus Hi-Boy Model: 255714, 255715
Maximum Working Pressure: 3300 psi (22.7 MPa, 227 bar)
I mportant Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
Related Manuals
312800
312830
309250 ti11532a ti11631a
2
Warning
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 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:
• 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.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
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 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.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
312805C
312805C
Warning
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. Read Technical Data in all equipment manuals.
• 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. For complete information about your material, request MSDS from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or overbend hoses or use hoses to pull equipment.
• Comply with all applicable safety regulations.
• Keep children and animals away from work area.
• Do not operate the equipment when fatigued or under the influence of drugs or alcohol.
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.
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 MSDS’s 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
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:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
3
4
Installation
Grounding and Electric
Requirements
Installation
Do not use the sprayer if the electrical cord has a damaged ground contact. Only use an extension cord with an undamaged ground contact.
The sprayer cord includes a grounding wire with an appropriate grounding contact.
Never use an outlet that is not grounded or an adapter.
ti11559a
The sprayers require:
110-120V Units: 100-130 VAC, 50/60 Hz, 11A, 1 phase, circuit with a grounding receptacle.
240V Units: 210-255 VAC, 50/60 Hz, 7.5A, 1 phase, circuit with a grounding receptacle.
ti4297
Recommended extension cords :
• 110-120V: 3-wire, 12 AWG (2.5 mm
2
) minimum.
• 240V: 3-wire, 16 AWG (1.0 mm
2
) minimum.
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 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.
ti5573a ti11558a
312805C
Pressure Relief Procedure
3.
Turn prime valve down.
Pressure Relief Procedure
Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure, stop spraying, check or service equipment or install or clean spray tip.
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.
ti8326a
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.
ti8324a ti11543a
312805C 5
6
General Repair Information
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 electrical fittings removed during repair procedures. These parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair procedure to verify you did it correctly. See Troubleshooting
• Overspray may build up in the air passages. Remove any overspray and residue from air passages 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.
•
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.
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 freezing. Never leave water or water-base paint in sprayer when its not in use in cold weather. Freezing fluids can seriously damage sprayer. Store sprayer with Pump Armor to protect sprayer during storage.
312805C
Troubleshooting
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
Basic Mechanical
1.
Pressure control knob setting.
Motor will not run if set at minimum (fully counter-clockwise).
2.
Spray tip or fluid filter may be clogged.
Slowly increase pressure setting to see if motor starts.
Relieve pressure
clean gun filter. Refer to gun instruction manual, 312830.
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 11,
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
Displacement Pump
Replacement .
3.
Motor. Remove drive housing
Drive
Housing Replacement . Try to rotate fan by hand.
Replace motor if fan won’t turn. See page 25,
Motor Replacement .
312805C 7
8
Problem
What To Check
(If check is OK, go to next check)
What To Do
Troubleshooting
(When check is not OK, refer to this column)
Basic Electrical
See wiring diagram, page
1.
Electric supply. ON/OFF switch in
OFF position. Meter must read
100-130 Vac; 210-260 Vac.
Turn ON/OFF switch to ON position. Reset building circuit breaker, replace building fuses.
Try another outlet.
2.
Extension cord. Check extension cord continuity with volt meter.
Replace extension cord.
3.
Sprayer power supply cord.
Inspect for damage such as broken insulation or wires.
Replace power supply cord. See page 24,
Power Cord Replacement .
4.
Fuse. Check replaceable fuse on control board (next to ON/OFF switch).
Replace fuse after completing motor inspec-
Fuse Replacement .
5.
Motor leads are securely fastened and properly connected to control board.
Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
6.
Motor thermal switch. Yellow motor leads must have continuity through thermal switch.
Motor Replacement .
7.
Brush cap missing or loose brush lead connections.
Install brush cap or replace brushes if leads
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.
Motor Brush
Replacement .
9.
Motor armature commutator for burn spots, gouges and extreme roughness.
Remove motor and have motor shop resurface
commutator if possible. See page 25,
Motor
Replacement .
10. Motor armature for shorts using armature tester (growler) or per-
Motor Replacement .
11. Pressure control not plugged in to control board.
Insert pressure control connector into control board.
312805C
Problem
Low Output
What To Check
(If check is OK, go to next check)
What To Do
Troubleshooting
(When check is not OK, refer to this column)
1.
Worn spray tip.
2.
Verify pump does not continue to stroke when gun trigger is released.
Displacement
Pump Replacement .
3.
Prime valve leaking.
Relieve pressure
to gun instruction manual, 312830.
4.
Suction tube connections.
Relieve pressure
Manifold Replacement .
Tighten any loose connections. Check o-ring on suction tube.
5.
Electric supply with volt meter.
Meter must read 100-130 Vac;
210-260 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 4 , Grounding and Electric
Requirements.
7.
Leads from motor to circuit board for damaged or loose wire connectors. Inspect wiring insulation and terminals for signs of overheating.
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).
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 pressure control knob fully clockwise.
Replace pressure control assembly. See
Pressure Control Assembly
Replacement .
11. Motor armature for shorts by using an armature tester
(growler) or perform spin test,
Motor
Replacement .
312805C 9
Problem
What To Check
(If check is OK, go to next check)
What To Do
Troubleshooting
(When check is not OK, refer to this column)
Motor runs and pump strokes
1.
Prime Valve Open.
2.
Paint supply.
3.
Intake strainer clogged.
4.
Suction tube leaking air.
Close prime valve.
Refill and reprime pump.
Remove and clean, then reinstall.
Tighten nut. Check o-ring on tube.
5.
Intake valve ball and piston ball are seating properly.
See Pump Manual 309250. Strain paint before using to remove particles that could clog pump.
6.
Leaking around throat packing nut which may indicate worn or damaged packings.
7.
Pump rod damaged.
See Pump Manual 309250.
Motor runs but pump does not stroke
Motor is hot and runs intermittently
1.
Displacement pump pin damaged or missing.
See Pump Manual 309250.
Replace pump pin if missing. Be sure retaining spring is fully in groove all around connecting
Displacement Pump
Replacement .
Replace connecting rod assembly. See page
Displacement Pump Replacement .
2.
Connecting rod assembly for damage.
3.
Gears or drive housing.
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.
Inspect drive housing assembly and gears for damage and replace if necessary. See page
Drive Housing Replacement .
Move sprayer to shaded, cooler area if possible.
2.
Motor has burned windings indicated by removing positive (red) brush and seeing burned adjacent commutator bars.
Motor
Replacement .
3.
Tightness of pump packing nut.
Overtightening tightens packings on rod, restricts pump action and damages packings.
Loosen packing nut. Check for leaking around throat. Replace pump packings if necessary.
See pump manual 309250.
10 312805C
Displacement Pump Replacement
Displacement Pump Replacement
See manual 309250 for pump repair instructions.
Removal
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).
C
1.
Relieve pressure
, page 5. Unplug sprayer from outlet.
2.
Loosen two screws (11) and remove pail hanger (10).
11
10 ti9138a
3.
Loosen nut (37) and remove suction tube (39). Loosen nut (B) and remove coupled hose (42).
31 ti9040a
7.
Loosen pump jam nut (34). Unscrew and remove pump (33).
34
33 ti9141a
37
39
B 42 ti9139a
312805C 11
Installation
Displacement Pump Replacement
5.
Screw in pump until threads are flush with top of drive housing opening.
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.
NOTICE
If the pump jam nut loosens during operation, the threads of the drive housing will be damaged.
1.
Extend pump piston rod fully. Apply grease to top of pump rod (D). Install jam nut (34) on pump threads.
6.
Align pump outlet (E) to back.
34
E ti6111a
30
D
34 ti9143a
2.
Install pump rod (D) into connecting rod (30).
3.
Install pump pin (31). Verify retainer spring (30a) is in groove over pump pin.
ti ti9145a
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).
30a
31
30
33 ti9144a
4.
Push pump (33) up until pump threads engage.
B 42
37
39 ti9139a
9.
Fill packing nut with Graco TSL until fluid flows onto top of seal. Install pail hanger (10 ) with screws (11).
11
10 ti9040a
12 312805C
Drive Housing Replacement
Drive Housing Replacement
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.
Removal
1.
Relieve pressure
2.
Remove pump (33).
Displacement Pump Replacement
3.
Disconnect power cord from outlet.
27
Needle
Bearing Surfaces
28
32
4
13
29
28
27
26
26 ti9147a
2.
Push drive housing (29) into motor front endbell.
Insert gear crank (27) through hole in connecting rod
(30).
11 ti9148a
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 bearing
(28) from drive housing.
NOTICE
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.
30
13
32
11
27
4 ti9149a
3.
Install four screws (4) and screw (13).
4.
Install cover (32) with two screws (11).
5.
Install pump (33).
Displacement Pump Replacement
312805C 13
Spin Test
Spin Test
To check armature, motor winding and brush electrical continuity:
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
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 16.
3.
If still uneven or no resistance, replace motor, page 25.
D
32
13
29
12
D
11
4.
Remove screw (13) and shroud (12).
5.
Remove drive housing (29), page 13.
ti9150a
6.
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 25.
4.
Connect motor connector (D).
5.
Install drive housing, page 13.
6.
Install shroud (12) with screw (13).
7.
Install front cover (32) with two screws (11).
8.
Install the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
ti9135a b.
Install kick stand (66).
14 312805C
Fan Replacement
Fan Replacement
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
4.
Remove screw (13) and shroud (12).
5.
Remove retaining ring (57b) on back of motor.
6.
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 the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
11
13
32
57b
57a
12 ti11550a
312805C 15
Motor Brush Replacement
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 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
4.
Remove screw (13) and shroud (12) (see illustration
5.
Disconnect motor connector (D) from control board (18).
6.
Cut tie wrap (F).
7.
Locate two yellow wires (C). Cut each yellow wire at the center.
8.
Pry off two brush caps (A). Remove brushes (B) from motor.
9.
Discard old brush assembly.
10. 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.
Motor Brush Replacement
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.
Wrap new tie wrap around motor and wires only. Trim off excess. Be sure pressure hose is not caught in tie wrap.
7.
Connect motor connector (D) to control board (18).
30
A
A
29
33
D
+
B
Red
D
C
Black ti5637b
E ti9133a
8.
Install shroud (12) with screw (13) (see illustration,
9.
Install front cover (32) with two screws (11).
10. Install the following on 210
ES
Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
16 312805C
Control Board Replacement
Control Board Replacement
18
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
Remove screw (13) and shroud (12) (see illustration,
4.
Disconnect pressure control assembly connector (A) from control board (18).
18
D
A
18 D
11
.
ti11554a
7.
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.
8.
Remove grommet and wires from strain relief.
NOTE: Ground wire remains attached to sprayer with grounding screw.
Strain
Relief
A
240V 120V ti6143b
5.
Disconnect motor connector (D) from control board (18).
6.
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).
18
Grommet ti6122a
9.
Remove two power cord (C) connectors from control board.
18
D
D
A
18
240V
C
120V
A
C ti6143b
312805C 17
Installation
1.
Push grommet and power cord wires into strain relief in control board (18).
Control Board Replacement
3.
Slide control board into place on side of motor front endbell.
18
D
A
18
Strain
Relief
Grommet ti6122a
2.
Connect power cord connectors to terminals indicated on control board (18).
18
D
11 ti11553a
4.
Replace three screws (11). Torque to 30-35 in-lb
(3.4-3.9 N.m).
18
D
A
18 D
A
240V 120V
C
C ti6143b
NOTE: Route power cord (19) between coupled hose
(42) to filter manifold and sprayer frame.
42
A
240V
C
120V
C ti6143b
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 14).
7.
Install the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
19
Bottom View of Sprayer ti11555a
18 312805C
Fuse Replacement
If the fuse is blown, check for:
• Pinched or shorted wires
• A defective motor (see Spin Test, page 15)
• A locked or frozen pump
Correct defective condition before replacing fuse.
Fuse Replacement
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
Remove screw (13) and shroud (12) (see illustration,
4.
Remove fuse from control board.
Installation
1.
Install Fuse 119277 on control board.
2.
Install shroud (12) with screw (13). Install front cover
(32) with two screws (11). (see illustration, page 14).
3.
Install the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
Replaceable Fuse
ti9134b
312805C 19
Pressure Control Assembly Replacement
Pressure Control Assembly Replacement
6.
Pull wires through hole (K).
7.
Turn pressure control knob (17) counter clockwise as far as you can to access flats on either side of pressure control.
8.
Loosen and unscrew pressure control.
17
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove two screws (11) and front cover (32).
4.
Remove screw (13) and shroud (12).
12
32
13 ti9128a ti9130a
11
5.
Disconnect pressure switch connector (A) from control board (18). Pull bushing (23) from hole (K).
NOTICE
If you plan to reuse pressure control, be careful not to damage or tangle wires when unscrewing pressure control.
9.
Remove pressure control.
A
18 ti9129a
K 23
20 312805C
Pressure Control Assembly Replacement
Installation
A
18 ti9129a
K 23 B 21 o-ring
1.
Inspect pressure control before installation to verify o-ring is installed.
2.
Align pressure control wire cap (21) on fluid manifold so opening faces toward motor.
3.
Apply loctite to pressure control knob (B) threads.
4.
Screw pressure control threads (B) into manifold and torque to 150 in-lb (17.0 N.m).
NOTICE
Be careful when tightening pressure control knob that wires are not pinched between pressure control and fluid manifold.
5.
Tuck wires into pressure control wire cap (21) and route wires toward cap opening. Feed wires through housing hole (K).
6.
Insert bushing (23) in hole (K).
7.
Connect pressure switch connector (A) to control board (18).
8.
Install shroud (12) with screw (13). Install front cover
(32) with two screws (11). (see illustration, page 14).
9.
Install the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
312805C 21
Drain Valve Replacement
Drain Valve Replacement
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove pin (47) from drain valve handle (46).
3.
Pull drain valve handle and valve base (45) from drain valve (44).
4.
Unscrew drain valve from filter manifold (43).
5.
Remove valve seat (44b) and seat gasket (44a) from inside of filter manifold or end of drain valve.
Installation
1.
Install new seat gasket (44a) and valve seat (44b) on end of drain valve.
2.
Screw drain valve (44) into filter manifold (43). Torque to 120 to 130 in-lb.
3.
Push valve base (45) over drain valve (44) and then valve drain handle (46) over valve base.
4.
Install pin (47) in drain valve handle. If necessary, use a hammer to tap pin in place completely.
46
47
45
44
44a
44b
43 ti11549a
22 312805C
Drain Line Replacement
Drain Line Replacement
Removal
1.
Cut drain line (49) from barbed fitting (51).
2.
Unscrew barbed fitting from filter manifold (43).
NOTE: To reuse existing barbed fitting (51) and drain line
(49), cut and remove remaining drain line material from end of barbed fitting.
Installation
1.
Screw barbed fitting (51) into filter manifold (43).
2.
Push drain line (49) onto barbed fitting.
NOTE: To make drain line more pliable and easier to install over barbed fitting, heat end of drain line (49) with a hair dryer or place end in hot water a few seconds.
51
43 ti9156a
49
312805C 23
Power Cord Replacement
Power Cord Replacement
Removal
1.
Remove control board, Control Board Replacement, Removal
2.
Remove green ground screw (20) and disconnect green ground wire (G) from frame.
Installation
1.
Connect green ground wire (G) to frame with green ground screw (20). Be sure green ground wire terminal faces up or wires could get caught in shroud.
2.
Install control board, Control Board Replacement,
Installation
G
20 ti11552a
24 312805C
Motor Replacement
Motor Replacement
NOTICE
Do not drop gear cluster (27) and (26) when removing drive housing (29). Gear cluster may stay engaged in motor frontend bell or drive housing.
Removal
1.
Relieve pressure
, page 5. Disconnect power cord
from outlet.
2.
Remove the following from 210 ES Hi-boy models: a.
Remove kick stand (66) .
b.
Remove two screws (5) and toolbox (3).
3.
Remove pump, Displacement Pump Replacement ,
4.
Remove drive housing, Drive Housing
Replacement
5.
Remove control board, Control Board
Replacement
6.
Remove two screws (4) and filter manifold (43).
57
7.
Remove green ground screw (20) and ground wire
(G) from motor endbell.
8.
Remove cover (14). Remove four screws (4) and motor
(57) from frame (1).
Installation
1.
Install cover (14) on motor (57). Install motor on frame (1) with four screws (4).
2.
Connect green ground wire (G) to frame with green ground screw (20). Be sure green ground wire terminal faces up or wires could get caught in shroud. (See illustration, page 25.)
3.
Install manifold (43) with two screws (4).
4.
Install control board, Control Board Replacement ,
5.
Install drive housing.
Drive Housing Replacement ,
6.
Install pump.
Displacement Pump Replacement ,
7.
Install the following on 210 ES Hi-Boy models: a.
Install toolbox (3) with two screws (5).
b.
Install kick stand (66).
14
5
66
1
3
1
43
20 G 4 11 18
11
4
1 Liberally apply grease ti11551a
312805C 25
Wiring Diagrams
120V
240V
Pr essu r e
C on t ro l
Asse m bl y from Mo t or
2 x Y ell ow
Red (+)
Black (-)
Replaceable Fuse
ON/O FF
Sw itc h
Pow
P
Capacit or ti56 4 3a lu g e r
2 x from
Y ell
Wh ite
Mo ow t or
Black
Capacit or
Gr ee n ti5643a1
Pr essu r e C on t ro l
Asse m bl y
Red (+)
Black (-)
Replaceable Fuse
ON/O FF
Sw itc h
Wiring Diagrams ti5857a
Pow e r
P lu g
B rown
Blue
Gr ee n ti5857a
26 312805C
Notes
Wiring Diagrams
312805C 27
Parts
12
13
29
28
27
26
69
11
32
11
10
41
40
39
38
37
4
31
30a
34
33
30
14
35
4
36
16
15
68
1
5
57b
57
57a
2
70
63
64
Parts ti11556b
28 312805C
Parts List
Parts List
Ref Part Description Qty
4
5
1
2
288216 FRAME, cart, hi
287489 HANDLE, cart
117493 SCREW, mach, hex washer hd
109032 SCREW, mach, pnh
10 15J812 HANGER, pail
11 117501 SCREW, mach, slot hex wash hd
12 255165 SHIELD; includes 13, 71, 72
13 114531 SCREW, mach, hex washer hd
14 15J651 COVER, 210 / 190ES
15 240794 HOSE, cpld, 1/4 in. x 50 ft
16 289843 GUN, spray, SG3-E, (packaged)
Manual 312830
26 249194 GEAR, assembly, combination
27 249195 GEAR, crankshaft; includes 28
28 180131 BEARING, thrust
29 255168 HOUSING, drive; includes 4, 10, 11 1
30 287053 ROD, connecting; includes 30a, 31 1
30a 196750 SPRING, retaining
31 196762 PIN, straight
1
1
32 15E630 COVER, front
33 255198 PUMP, displacement; includes 35
1
1
1
1
1
Manual 309250
34 195150 NUT, jam, pump
35 162453 FITTING, (1/4 npsm x 1/4 npt)
1
2
1
1
1
7
10
4
1
1
1
'1
1
Ref Part Description
36 235004 STRAINER, 3/4-16 unf
37 15E813 NUT, jam
38 15B652 WASHER, suction
39 15J801 TUBE, suction, intake
40 103413 O-RING
41 115099 WASHER, garden hose
57 ❖ MOTOR, electric, includes 57a, 57b
255157 190ES; UK 120V
249040 210ES; UK 120V
249041 190/210ES; Europe 240V
57a 249043 FAN, motor
57b 119653 RING, retaining
63 119451 WHEEL, semi pneumatic
64 119452 CAP, hub
68 15C871 CAP, leg
69 LABEL, front, brand
15K360 190ES
70
15K362 210ES
LABEL, side, brand
15K361 190ES
15K363 210ES
78 206994 FLUID, TSL, 8 oz (not shown)
Qty
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
1
1
1
1
Warning labels are available free of charge
❖ 249042 KIT, brush, motor
312805C 29
Parts Drawing
72
20
3
71 98
19
25
24
66
Parts Drawing
22
23
17
21
11
4 11
18
42
96
19
44a
95
56
55
54
51
49
67
50
53
52
43 35
48
44b
4
44
45
47
46 ti11557a
30 312805C
Parts List
Parts List
Ref Part Description
3
4
288503 TOOL BOX, assembly
117493 SCREW, mach, hex washer hd
11 117501 SCREW, mach, slot hex wash hd
17 CONTROL, pressure; includes 21,
18
22, 23
249005 190/210ES UK 120V
249053 190/210ES Europe 240V
CONTROL, board
249052‡ 190/210ES UK 120V
249053 190/210ES Europe 240V
CORD 19
253368 190/210ES UK 120V
253370 190/210ES Europe 240V, jumper
20 115498 SCREW, mach, slot hex wash hd
21 15E794 CAP, wire, control, pressure
22 15F399 LABEL, pressure control knob
23 115756 BUSHING, universal
24 195551 RETAINER, plug, adapter
25 CORD SET
242001 190/210ES Europe adapter, 240V
287121 190/210ES Italy, Denmark, Switzerland adapter, 240V
42 287003 HOSE, cpld
43 15J745 MANIFOLD, Filter, 190/210ES
44 235014 VALVE, drain; includes 44a, 44b
44a GASKET, seat
Qty
1
10
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref Part Description Qty
44b SEAT, valve
45 224807 BASE, valve
46 187625 HANDLE, valve, drain
47 111600 PIN, grooved
48 195811 LABEL, instruction
49 15K092 TUBE, drain
50 244035 DEFLECTOR, barbed
51 M70809 FITTING, barbed, hose
52 104361 O-RING
53 243080 FILTER, fluid
54 15E288 INSERT, manifold
55 15E289 CAP, filter
56 195707 LABEL, identification
66 ROD, kickstand
190ES 0
15J117 210ES 1
67 195400 CLIP, spring 1
71
▲
195813 LABEL, 190-210 261825 261830 war 1
72 ▲ 195793 LABEL, warning
95 115523 GUAGE, pressure, fluid
1
1
96 119783 TEE, swivel 1
98 108795 SCREW, mach, pnh 2
1
1
1
1
1
1
1
1
1
1
1
1
1
▲
Warning labels are available free of charge
‡ 119277 Fuse replacement
312805C 31
Parts Drawing
Parts Drawing
9
35
45
4
46
47
44
12
18
56
55
22
17
8
21
25
76
15
68
24
11
54
53
23
35
52
43
14
51
16
71,72
57
27
19
28
100
29
4
13
4
32
67
11 26
19
30
30a
35
65
10
34
31
11
33
41
40
38
37
49
50
36
39 ti11632a
32 312805C
Ref Part Description Qty
4
8
9
117493 SCREW, mach, hex washer hd
119783 FITTING, tee, swivel
115523 GAUGE, pressure, fluid
10 15B589 COVER, pump rod
11 117501 SCREW, mach, slot hex wash hd
12 255165 SHIELD, motor
13 114531 SCREW, mach, hex washer hd
14 15J651 COVER, 210/190ES
15 240794 HOSE, cpld, 1/4 in. x 50 ft
16 289843 GUN, spray, SG3-E (packaged)
17 CONTROL, pressure, includes 21,
18
22, 23
249005 190/210ES UK 120V
248929 190ES/210 Plus Europe 240V
CONTROL, board
249052‡ 190/210ES UK 120V
249053 190ES/210 Plus Europe 240V
CORD
1
1
19
253368 190/210ES UK 120V 1
253370 190ES/210 Plus Europe 240V, jumper 1
20 115498 SCREW, mach, slot hex wash hd
21 15E794 CAP, wire, control, pressure
1
1
1
1
22 15F399 LABEL, pressure control knob
23 115756 BUSHING, universal
24 195551 RETAINER, plug, adapter
25 189930 LABEL, caution
26 249194 GEAR, assembly, combination
27 249195 GEAR, crankshaft
28 180131 BEARING, thrust
29 255168 HOUSING, drive
1
1
1
1
1
1
1
1
30 287053 ROD, connecting; includes 30a, 31 1
30a 196750 SPRING, retaining 1
31 196762 PIN, straight
32 15E630 COVER
1
1
33 246428 PUMP, displacement, ST
34 195150 NUT, jam, pump
35 162453 FITTING, (1/4 npsm x 1/4 npt)
36 187651 STRAINER, 3/4-16 unf
3
1
1
1
37 15E813 NUT, jam
38 15B652 WASHER, suction
39 15J801 TUBE, suction, intake
40 103413 O-RING
1
1
1
1
10
1
1
1
1
1
7
1
1
1
Parts Drawing
Ref Part Description
41 115099 WASHER, garden hose
43 15J745 MANIFOLD, filter, 190/210ES
44 224806 VALVE, drain
45 224807 BASE, valvE
46 187625 HANDLE, valve, drain
47 111600 PIN, grooved
48 195811 LABEL, instruction
49 15K092 TUBE, drain
50 244035 DEFLECTOR, barbed
51 M70809 FITTING, barbed, hose
52 104361 O-RING
53 243080 FILTER, fluid
54 15E288 INSERT, manifold
55 15E289 CAP, filter
56 195707 LABEL, identification
57 MOTOR, electric, includes 57a, 57b
255157 190ES; UK 120V
249040 210ES; UK 120V
249041 190ES/210 Plus; Europe 240V
65 195400 CLIP, spring
67 LABEL, front, 190ES, brand
15K360 190ES
68
15K362 210ES
15T426 210 Plus
LABEL, side, brand
15K361 190ES
15K363 210ES
15T427 210 Plus
69 195813 LABEL, danger, 190ES
70 195793 LABEL, warning
71 15E968 LABEL, transparent
72 290340 ARTWORK, label, artwork
76 238049 FLUID, TSL, 4 oz
87 222385 TAG, warning
88 111733 TOOL, wrench, adjustable
89 197193 TOOL, hammer
100 CORD SET
242001 190/210ES Europe adapter, 240V
287121 190/210ES Italy, Denmark, Switzerland adapter 240V
102 243308 LABEL, set,ES int'l
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
312805C 33
Parts List
Parts List
63
64
1
Ref Part Description
4
7
1
2
258027 FRAME, stand
15R792 LEG, cart
117493 SCREW, mach, hex washer hd
289119 LEVER, handle, cam, includes 3, 5,
7a
7b
6, 7
PIN, pivot, handle, cart
SCREW, cap, socket head
7c NUT, lock, hex
63 120595 CLIP, tool
64 RIVET, blind, 1/8 x 1/4 in.
66 120151 RETAINER, caplug
110 15T783 ISOLATOR, foot
111 115723 SCREW, drill, hex washer
Qty
10
4
1
2
4
8
4
4
4
2
4
4
7c
66
2
110
111
7
7a
7b ti11633a
34 312805C
Notes
Parts List
312805C 35
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO
WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY
GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of
Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 312805
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2006, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised 01/2012
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