Graco 16N664 User manual

3A2853A
Operation - Repair - Parts
Cordless Hand-Held Paint Sprayers
- For portable spray applications of architectural paints and coatings only -
- Not approved for use in explosive atmosphere locations -
All Models:
Maximum Working Pressure 2000 psi (14 MPa, 138 bar)
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this
manual. Save these instructions.
Model Charger
Voltag e
16N664 230V ✓
16N665 110V ✓
16N666 230V ✓
16N668 100V ✓
16N669 230V ✓
16N670 230V ✓
EN
ti19605a
WARNINGWARNINGWARNING
WARNING
Use only water-based materials. Do not use materials which state “FLAMMABLE” on the packaging. For
more information about your material, request MSDS from distributor or retailer.
Spraying certain materials may cause static build-up in the sprayer that can result in static shock to
the user. If this occurs, first ensure the material has a flash point greater than 100° F (38° C) and does not
state that it is FLAMMABLE anywhere on the package. If still feeling a static shock, the material likely con-
tains a non-mineral spirits fluid such as, but not limited to, xylene, toluene, or naphtha, which can build up
static. Switch to an alternative material.

Table of Contents
23A2853A
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charger Status Indicator Lights . . . . . . . . . . . . . . . . . . 6
Sprayer Status Indicator Light . . . . . . . . . . . . . . . . . . . 6
Common Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prime/Spray Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . 7
Reversible Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flexible Suction Tube . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sprayer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starting a New Job
(or Refilling the Material Cup) . . . . . . . . . . . . . . . . . 10
Choosing the Correct Tip . . . . . . . . . . . . . . . . . . . . . . . . 11
Understanding Tip Number . . . . . . . . . . . . . . . . . . . . 11
Selecting Tip Hole Size . . . . . . . . . . . . . . . . . . . . . . . 11
Choosing Pressure Control Knob Setting . . . . . . . . . . 11
Install Spray Tip/Guard
Assembly (if not installed) . . . . . . . . . . . . . . . . . . . . 12
Getting Started with Basic Techniques . . . . . . . . . . . . . 12
Triggering Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Aiming Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spray Pattern Quality . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unclogging Spray Tip/Guard Assembly . . . . . . . . . . . 13
Shutdown and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flushing Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning Sprayer Exterior . . . . . . . . . . . . . . . . . . . . . 16
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inlet Valve Fitting Removal/Service . . . . . . . . . . . . . . . . 20
Outlet Valve Fitting Repair . . . . . . . . . . . . . . . . . . . . . . . 21
General Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Control Knob . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting Leaks . . . . . . . . . . . . . . . . . . . . . . . . 27
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preferred Material Settings Log . . . . . . . . . . . . . . . . . . . 29
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 32
Important User Information
Before using your sprayer read this Operation manual for complete instructions on proper use and safety warnings.
Congratulations! You have purchased a high-quality sprayer made by Graco Inc. This sprayer is designed to provide superior
spray performance with water-based architectural paints and coatings. This user information is intended to help you
understand the types of materials that can be used with your sprayer.
Before using this equipment, be sure to read and follow the information on your container label and ask for a Material Safety
Data Sheet (MSDS) from your supplier. The container label and MSDS will explain the contents of the material and the
specific precautions related to it.
Paints, coatings and clean-up materials generally fit into one of the following 2 basic categories:
WATER-BASED: The container label should indicate that the material can be cleaned up with soap and water.
Your sprayer is compatible with this type of material. Your sprayer is NOT compatible with harsh cleaners such as
chlorine bleach.
FLAMMABLE: This type of material contains flammable solvents such as xylene, toluene, naphtha, MEK, lacquer
thinner, acetone, denatured alcohol, and turpentine. The container label should indicate that this material is FLAM-
MABLE. This type of material is NOT compatible with your sprayer and CANNOT be used.
DO NOT RETURN THIS SPRAYER TO THE STORE!
If you experience problems, contact Graco Product Support at www.graco.eu

Warnings
3A2853A 3
Warnings
The following warnings are for the setup, use, maintenance, and repair of this equipment. The exclamation point symbol
alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in
the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings
not covered in this section may appear throughout the body of this manual where applicable.
WARNINGWARNINGWARNING
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
• Sprayer generates sparks. Do not spray or flush with flammable liquids.
• Use only water-based materials.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area.
• Do not spray or flush with combustible materials near an open flame or sources of ignition.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk
of fire or explosion in the presence of paint or solvent fumes. Keep sprayer at least 10 in. (25 cm) away from
objects while spraying or flushing.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and
container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety
instructions.
• Fire extinguisher equipment shall be present and working.
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection
occurs, get immediate surgical treatment.
• Do not aim the sprayer at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of
the body.
• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying, fol-
low the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle
tip to clean.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit
and follow the Pressure Relief Procedure for turning off the unit.
• Check parts for signs of damage. Replace any damaged parts.
• This system is capable of producing 2000 psi. Use replacement parts or accessories that are rated a minimum
of 2000 psi.
• Do not carry the tool with a finger on the trigger.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.
• Do not operate or spray near children. Keep children away from equipment at all times.
• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
• Stay alert and watch what you are doing.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Use only in dry locations. Do not expose to water or rain.
• Use in well-lit areas.

Warnings
43A2853A
BATTERY HAZARD
The battery may leak, explode, cause burns, or cause an explosion if mishandled. Contents of an open battery can
cause severe irritation and/or chemical burns. If on skin, wash with soap and water. If in eyes, flush with water for at
least 15 minutes and seek immediate medical attention.
• Replace battery only in a well-ventilated area and away from flammable or combustible materials; including
paints and solvents.
• When battery is not in use, keep it away from metal objects like keys, nails, screws or other metal objects that
can short circuit the battery terminals.
• Do not throw into fire.
• Charge only with Graco-approved charger as listed in this manual.
• Do not store at temperatures below 32° or above 113° F (0° to 45° C).
• Do not use at temperatures below 40° or above 90° F (4° to 32° C).
• Do not expose battery to water or rain.
• Do not disassemble, crush, or penetrate the battery.
• Do not charge a battery that is cracked or damaged.
• Follow local ordinances and/or regulations for disposal.
CHARGER ELECTRIC SHOCK, FIRE AND EXPLOSION HAZARD
Improper setup or usage can cause electric shock, fire, and explosion.
• Charge only in a well-ventilated area and away from flammable or combustible materials, including paints and
solvents.
• Do not charge on a combustible or flammable surface.
• Do not leave battery unattended while charging.
• Immediately unplug charger and remove battery when charger is complete.
• Charge only Graco batteries listed in this manual; other batteries may burst.
• Use only in dry locations. Do not expose to water or rain.
• Do not use a charger that is cracked or damaged.
• If the supply cord is damaged, replace the charger or cord, depending on model.
• Never force the battery into the charger.
• When operating a charger outdoors, always provide a dry location and use an extension cord suitable for out-
door use.
• Disconnect the charger from the outlet before cleaning.
• Ensure that the outside surface of the battery is clean and dry before plugging into the charger.
• Do not attempt to charge non-rechargeable batteries.
• Do not disassemble the charger. Take charger to authorized service center when service or repair is required.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction
and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for
compatibility.
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.
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
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNINGWARNINGWARNING
WARNING

Component Identification
3A2853A 5
Component Identification
*NOTE: Spray Tip filter is reverse-threaded. Turn left (or counter-clockwise) to tighten, turn right (or clockwise) to
loosen.
J
D
*B
G
A
N
P
S
T
R
W
H
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F
E
K
M
C
L
A Spray Tip/Guard Assembly
*B Spray Tip Filter (Reverse Threaded)
CAirVentValve
D Flexible Suction Tube
E Pump Armor Storage/Startup Tool
F Battery Charger
G Pressure Control Knob
H Material Cup Liners (5 included)
JPrime/SprayValve
K Material Cup Cover and Seal
L Part Number = Model Number
M Sprayer Case
NBattery
P Battery Release Button
R Sprayer Status Indicator Light
S Trigger
T Trigger Lock
W Outlet Valve Fitting Access Plug

Charging the Battery
63A2853A
Charging the Battery
Batteries are initially 50% charged to provide optimum battery
life and require charging before first use. It takes approxi-
mately 45 minutes to charge a dead battery to 80%, at which
point it can be used. It will take approximately 75 minutes to
fully charge a dead battery.
1. Place charger in a dry, well-ventilated area and away from
flammable or combustible materials, including paints and
solvents.
2. Plug charger into an electrical outlet and slide battery into
charger as shown (light will turn on in 5 seconds).
3. When battery becomes fully charged, immediately unplug
the charger from the power supply and remove the battery
from the charger.
NOTE: The amount sprayed with each battery varies depend-
ing on material, spray tip size, battery charge, and battery tem-
perature. One battery fully charged will spray up to one gallon.
Amount sprayed will be less depending on spray tip size,
material sprayed, life of battery, temperature, and other envi-
ronmental factors.
Charger Status Indicator Lights
NOTE: When the charger is plugged in, the charger status indicator lights will alternate between green and red several times
before they turn off, indicating that the charger is ready to charge a battery.
Sprayer Status Indicator Light
*NOTE: The sprayer status indicator light is only visible when sprayer trigger is engaged. You must squeeze and hold the trigger
to see the sprayer status indicator.
Replace and charge battery only in a well-ventilated area and
away from flammable or combustible materials, including
paints and solvents. ti14990a
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Label Appearance Description
Solid green light Indicates a full charge. Battery can be used.
Flashing green light Battery is charging, indicates 80% charge.
Battery can be used.
Flashing red light Battery is charging, indicates less than 80% charge.
Do NOT use battery.
Solid red light Battery is too hot or too cold to charge. Remove battery and allow to cool or
warm up before charging.
Light* Appearance Description
No light Normal operation.
Solid red Battery is low on power and needs to be charged, or battery is too cold and
must warm up before spraying.
Flashing red Battery temperature is too high, or spray tip is clogged.
See Troubleshooting, page 23.
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Common Procedures
3A2853A 7
Common Procedures
Trigger Lock
Prime/Spray Valve
Follow the Pressure Relief Procedure
whenever you see this symbol.
Pressure Relief Procedure
1. Engage trigger lock.
2. Put prime/spray valve UP to release pressure.
Always engage the trigger lock when you stop spraying
to prevent the sprayer from being triggered accidentally
by hand, or if dropped or bumped.
Trigger Locked
Trigger Unlocked
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(red ring is visible)
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UP position
(For priming and releasing
DOWN position
(Ready to spray)
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pump pressure)
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Do not operate or spray near children. Do not aim the
sprayer at, or spray any person or animal. Keep hands
and other body parts away from the discharge. For
example, do not try to stop the paint flow with any part
of the body.
This sprayer builds up an internal pressure of 2000 psi
(14 MPa, 138 bar) during use. Follow this Pressure
Relief Procedure whenever you stop spraying and
before cleaning, checking, servicing, or transporting
equipment to prevent serious injury.
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Common Procedures
83A2853A
Reversible Spray Tip
In the event that particles or debris clog the spray tip,
this sprayer is designed with a reversible spray tip that
can be used to quickly and easily clear the particles and
resume spraying as quickly as possible.
• Always point the reversible spray tip
forward when spraying.
• When particles or debris get caught in the tip, it can
be reversed to quickly clean the tip.
•SeeUnclogging Spray/Tip Guard Assembly
(page 13) for detailed instructions.
Pressure Control Knob
• To reduce overspray, always spray at lowest pres-
sure that results in an acceptable spray pattern.
• Spray test pattern and adjust pressure to get
desired coverage.
• With some materials, if pressure is set too low, no
material may spray out. Turn pressure control knob
up.
• Thin materials sprayed at high pressure settings
may cause the sprayer to enter an operational mode
designed to protect it from overheating. This mode
is noticeable by the sprayer sounding like it is slow-
ing down and will result in a poor spray pattern.
To exit this mode, turn pressure control knob
down to lowest pressure setting that results in
an acceptable spray pattern.
• If spraying in low pressure range, there may not be
enough pressure to clear the plug. Turn pressure
control knob up to clear the plug.
Flexible Suction Tube
This sprayer comes with a flexible suction tube for
multi-directional spraying without adjustment.
To ensure proper function of flexible suction tube, orient
as shown. Make sure tab from sprayer is aligned with
groove from flexible suction tube and firmly push into
place.
NOTE: If the sprayer is angled or tilted too far, the flexi-
ble suction tube will lose contact with the material and
the sprayer will stop spraying.
Always perform Pressure Relief Procedure before
adjusting spray tip position.
Spray Tip Forward
(SPRAY position)
Spray Tip Reversed
(UNCLOG position)
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Minimum Pressure Setting Maximum Pressure Setting
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NOTICE
See Choosing Pressure Control Knob Setting on
page 11 for recommendations on the setting for your
job.
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Tab
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Sprayer Setup
3A2853A 9
Sprayer Setup
This sprayer arrives from the factory with a small
amount of test material in the system. It is important
that you flush this material from the sprayer before
using it for the first time:
1. Fill material cup with water or compatible solvent,
thread onto sprayer and hand tighten.
2. Put prime/spray valve to UP position, then hold trig-
ger in for 10 seconds.
3. Put prime/spray valve DOWN to spray position.
4. Reverse Spray Tip to UNCLOG position and trigger
sprayer into a waste area for 10 seconds.
5. Engage trigger lock and put prime/spray valve UP to
release pressure.
6. Unscrew and remove material cup.
7. Disengage trigger lock, hold sprayer slightly above
material cup, and pull trigger to discharge fluid from
pump.
8. Discard material in cup.
Use only water-based materials. Do not use materi-
als which state “FLAMMABLE” on the packaging. For
more information about your material, request MSDS
from distributor or retailer.
Spraying certain materials may cause static
build-up in the sprayer that can result in static
shock to the user. If this occurs, first ensure the mate-
rial has a flash point greater than 100° F (38° C) and
does not state that it is FLAMMABLE anywhere on the
package. If still feeling a static shock, the material likely
contains a non-mineral spirits fluid such as, but not lim-
ited to, xylene, toluene, or naphtha, which can build up
static. Switch to an alternative material.
Keep spray area well-ventilated. Keep a good supply
of fresh air moving through the area.
NOTICE
Your sprayer is NOT compatible with harsh cleaners
such as chlorine bleach. Using these cleaners will
cause damage to the sprayer.
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i15491
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Starting a New Job (or Refilling the Material Cup)
10 3A2853A
Starting a New Job
(or Refilling the Material Cup)
1. Engage trigger lock and put prime/spray valve UP to
release pressure.
2. Install material cup liner, fill with material, and
thread onto sprayer.
3. To fill sprayer with fluid, disengage trigger lock and
trigger sprayer for 10 seconds. Then release trigger
and put prime/spray valve DOWN to spray position.
4. Reverse spray tip to UNCLOG position, pull trigger
and release.
5. Put prime/spray valve UP to release pressure. Then
rotate spray tip back to spray position.
NOTE: Failure to perform this operation could result
in poor spray pattern.
If sprayer fails to prime, try one of the steps
below:
1. Use the Pump Armor storage/startup tool to clean
the inlet valve fitting. See Storage, page 16.
2. Clean air vent holes or the air vent valve,
depending on model. See Shutdown and Clean-
ing, page 14. Remove air vent valve, clean, and
reinstall.
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Choosing the Correct Tip
3A2853A 11
Choosing the Correct Tip
Understanding Tip Number
The last three digits of tip number (i.e.: XXX517) con-
tains information about hole size and fan width on sur-
face when gun is held 12 in. (30.5 cm) from surface
being sprayed.
Example: For a 10-12 in. (254-305 mm) fan width and a
0.017 in (0.43 mm) hole size, order part number
PST517, depending on your sprayer model number.
Selecting Tip Hole Size
• Tips come in a variety of hole sizes for spraying a
range of fluids. The sprayer includes a 0.017 in.
(0.43 mm) tip for use in most spraying applications.
Use the table below to determine the range of rec-
ommended tip hole sizes for each fluid type.
• Consider coating and surface to be sprayed. Make
sure to use the best tip hole size for the coating and
best fan width for that surface.
• Tip hole size controls flow rate - the amount of paint
that comes out of the gun.
HINTS:
• As you spray, the tip wears and enlarges. Starting
with a tip hole size smaller than the maximum will
allow you to spray within the rated flow capacity of
the sprayer.
• Tips wear with use and abrasive paint and need
periodic replacement.
• Do not spray with worn spray tips. Poor spray
pattern quality will result.
Choosing Pressure Control Knob Setting
Recommendations of a starting point for determining the best set point for your sprayer and particular coating are
shown in the table below.
First digit when doubled = approximate fan width
517 tip has
10 - 12 in.
fan width
517 tip has
a 0.017 in.
hole size
Last two digits = tip hole size in thousands of an inch
ti19498a
Tip Hole Size
Stains Enamels Primers Interior Paints Exterior Paints
.011 in. (0.28 mm) ✓
.013 in. (0.33 mm) ✓✓✓ ✓
.015 in. (0.38 mm) ✓✓ ✓ ✓
.017 in. (0.43 mm) ✓✓ ✓
Pressure Control Knob
Setting Number
0 - 2 3 - 7 4 - 10 4 - 10 4 - 10
CoatingsThinner Thicker
10

Install Spray Tip/Guard Assembly (if not installed)
12 3A2853A
Install Spray Tip/Guard
Assembly (if not installed)
1. Engage trigger lock and put prime/spray valve UP to
release pressure.
2. Install filter to spray/tip guard assembly.
NOTE: Spray tip filter is reverse-threaded. Turn left (or
counter-clockwise) to install. Turn right (or clockwise)
to remove.
3. Screw spray/tip guard assembly onto sprayer. Tighten
retaining nut until completely engaged with sprayer. Do
not overtighten nut.
Getting Started with Basic
Techniques
Use a piece of scrap cardboard to practice these basic
spraying techniques before you begin spraying the surface.
• Hold sprayer 10 in. (25 cm) from surface and aim
straight at surface. Tilting sprayer to direct spray angle
causes an uneven finish.
• Flex wrist to keep sprayer pointed straight. Fanning
sprayer to direct spray at angle causes uneven
finish.
NOTE: How fast you move the sprayer will affect spray
application. If material is pulsating, you are moving too fast.
If material drips, you are moving too slow. See Trouble-
shooting, page 23.
Triggering Sprayer
Pull trigger after starting stroke. Release trigger before end
of stroke. Sprayer must be moving when trigger is pulled
and released.
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.
NOTICE
Make sure spray tip filter is completely screwed into the
spray/tip guard assembly to avoid damage to the filter.
Do not use a damaged filter or poor sprayer performance
may result.
Do NOT place hands in front of tip.
NOTICE
The spray tip is permanently attached to the spray/tip
guard assembly. Removal will result in damage.
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10 in.
(25 cm)
even
finish
thick
thin
uneven
finish
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even finish thin thick thin
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Start Moving Pull Trigger Release Trigger
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Getting Started with Basic Techniques
3A2853A 13
Aiming Sprayer
Aim sprayer at bottom edge of previous stroke, overlapping
each stroke by half.
Spray Pattern Quality
A good spray pattern is evenly distributed as it hits the sur-
face. Adjust pressure control knob so pressure is just high
enough to spray without “tails”. If tails persist at highest
pressure setting, a smaller tip is needed to spray the mate-
rial or material may need to be thinned.
Unclogging Spray Tip/Guard
Assembly
1. To unclog spray tip clog, engage trigger lock and put
prime/spray valve UP to release pressure.
2. Reverse spray tip to UNCLOG position. Turn pressure
control knob to maximum pressure setting.
3. Aim sprayer at waste area, disengage trigger lock, and
put prime/spray valve DOWN to spray position. Pull
trigger to clear clog.
4. Engage trigger lock. Put prime/spray valve UP to
release pressure and rotate spray tip back to SPRAY
position.
5. Disengage trigger lock, put prime/spray valve DOWN
to spray position, and resume spraying.
6. If spray tip is still clogged, you may have to repeat
steps 1 - 5 and rotate the spray tip from SPRAY to
UNCLOG several times. Repeat step 1 to release pres-
sure, remove and clean spray tip filter, or replace with
new spray tip/guard assembly.
NOTE: Spray tip filter assembly is reverse-threaded:
Turn left (or counter-clockwise) to install.
Turn right (or clockwise) to remove.
7. When obstruction is cleared, engage trigger lock and
rotate spray tip back to SPRAY position.
Do not operate or spray near children. Do not aim the
sprayer at, or spray any person or animal. Keep hands
and other body parts away from discharge. For
example, do not try to stop leaks with any part of the
body.
ti14782a
ti18882a
ti18888a
ti18867a
ti19466a ti19502a
BAD PATTERN GOOD PATTERN
ti16700ati18866a
ti14991a ti16704a
NOTICE
Make sure spray tip filter is completely screwed into the
spray/tip guard assembly to avoid damage to the filter.
Do not use a damaged filter or poor sprayer performance
may result.
ti14995a
ti16701a
ti18874a
ti14994a
ti14999a
ti16700a ti16992a
ti14995a
ti16701a
ti18874a
ti14989a
ti16992a
ti18866a

Shutdown and Cleaning
14 3A2853A
Shutdown and Cleaning
Flushing Sprayer
1. Engage trigger lock and pull prime/spray valve UP to
release pressure.
2. Remove material cup and return excess material to
proper container. If used, properly dispose the material
cup liner.
3. Remove flexible suction tube as shown below.
4. Use screwdriver to pry suction tube strainer from flexi-
ble suction tube.
5. Clean flexible suction tube and suction tube strainer
with water (or flushing fluid) and a brush every time
you flush the sprayer. Reconnect flexible suction tube
and suction tube strainer and orient as shown.
6. Clean material cup if not using a liner, and fill with
water or appropriate flushing fluid.
NOTICE
Failure to properly clean sprayer after each use will result
in hardened materials, damage to the sprayer, and the
warranty will no longer be valid.
Use only water-based materials. Do not use materials
which state “FLAMMABLE” on the packaging. For more
information about your material, request MSDS from dis-
tributor or retailer.
Spraying certain materials may cause static build-up
in the sprayer that can result in static shock to the
user. If this occurs, first ensure the material has a flash
point greater than 100° F (38° C) and does not state that it
is FLAMMABLE anywhere on the package. If still feeling a
static shock, the material likely contains a non-mineral
spirits fluid such as, but not limited to, xylene, toluene, or
naphtha, which can build up static. Switch to an alterna-
tive material.
Keep spray area well-ventilated. Keep a good supply of
fresh air moving through the area.
NOTICE
Protect the internal parts of this sprayer from water.
Do not submerge the sprayer in cleaning fluid. Openings
in shroud allow cooling of mechanical parts and electron-
ics inside. If water or cleaning fluid gets into these open-
ings, the sprayer could malfunction or become
permanently damaged.
ti14999a
ti16700a
ti18866a
NOTICE
When removing flexible suction tube from sprayer, make
sure to pull directly on top fitting of flexible suction tube.
Flexible suction tube will become damaged if pulled from
bottom or on flexible portion.
ti19033a
ti18952a
ti15002a
ti18859a ti19467a
ti19463a
ti15001a

Shutdown and Cleaning
3A2853A 15
7. Reconnect material cup and shake sprayer to move
clean water around and clean all areas inside of mate-
rial cup.
8. Disengage trigger lock and trigger sprayer for approxi-
mately 15 seconds. Engage trigger lock.
9. Discard contaminated fluid and refill with appropriate
flushing fluid.
10. Disengage trigger lock, reverse Spray Tip to UNCLOG
position, and pull trigger for 5 seconds to prime
sprayer.
11. Put prime/spray valve DOWN to spray position. Trigger
sprayer into waste area until no paint appears in water
or flushing fluid.
12. Engage trigger lock and put prime/spray valve UP to
release pressure.
NOTE: Air vent holes or the air vent valve (as your
model is equipped) allow air to flow into the material
cup while spraying to prevent loss of fluid flow.
13. Remove material cup and discard used fluid. Remove
air vent valve, clean, and reinstall.
14. Remove spray/tip guard assembly and clean with
water or flushing fluid. A soft brush can be used to
loosen and remove dried material if needed.
To avoid serious injury or damage to equipment, do not
expose the sprayer electronics to flushing solvents. Keep
sprayer at least 10 in. (25 cm) above the rim of the con-
tainer when flushing.
Keep spray area well-ventilated. Keep a good supply of
fresh air moving through the area. When flushing with sol-
vents, always ground the sprayer and waste container.
ti15441a
ti18874a ti16716a ti18866a
ti14991a
ti18874a
ti15425a
ti16701a ti16713a
ti15529a
ti19009a
NOTICE
The spray tip is permanently attached to the guard.
Removing the spray tip from the guard will result in dam-
age to the spray tip assembly. Do not store spray/tip
guard assembly or flexible suction tube in solvent other
than mineral spirits. Damage to parts may occur.
ti14994a
ti16700a
ti18866a
ti18876a
ti15703a
ti15547a
ti15705a

Storage
16 3A2853A
Cleaning Sprayer Exterior
Wipe paint off outside of sprayer using a soft cloth moist-
ened with water or flushing fluid. Do NOT submerge the
sprayer.
Storage
1. Lift prime/spray valve UP to the prime position.
Remove material cup and flexible suction tube.
2. Remove child-resistent cap. Thread nozzle onto Pump
Armor bottle. NOTE: For best results, make sure bottle
is full.
3. Hold sprayer upside-down over a waste container.
4. Insert Pump Armor nozzle over material inlet and push
firmly until it stops. Squeeze cleaning bottle until Pump
Armor flows out drain tube.
5. Remove Pump Armor nozzle and replace
child-resistent cap and tighten securely for storage.
6. Attach flexible suction tube and material cup. Push
valve DOWN to spray position.
7. Recharge battery to full charge before storage. See
Charging the Battery, page 6.
8. Store sprayer indoors in a cool, dry place. Store in
an upright position only. Never store sprayer with
material in the cup.
NOTICE
Failure to store sprayer with Pump Armor will result in
operational problems the next time you spray. Always
circulate Pump Armor through the sprayer after cleaning.
Water left in the sprayer will corrode and damage the
pump.
ti18879a
ti16700a
ti18870a
ti18869a
ti18067a
ti18862a
ti18066a ti18177a
ti18069a
ti16701a
ti18871a
ti18872a
ti18885a

Replacement Parts
3A2853A 17
Replacement Parts
Models 16N664, 16N665, 16N666, 16N668, 16N669, 16N670
51
52
53
1
2
40
41
59
3
4
23
22
21
20
57
56
38
11
13
15
1717
12
14
16
36
34 35
39
42
43
45
44
46
31
33
37
27
25
26
31
30
29
28
24
9
10
32
32
5
7
8
7
6
60
ti19608a

Replacement Parts
18 3A2853A
Parts List - Models 16N664, 16N665, 16N666, 16N668, 16N669, 16N670
Ref.
If you have this model sprayer
(model number is the same as the part number,
which is between the battery and the sprayer)
Order Part
Number: Description
Model 16N670 262843 Sprayer Replacement Kit: includes parts 2, 7-20, 24-45, 56, 57, 59, 60
Models 16N664, 16N665 262845 Sprayer Replacement Kit: includes parts 2, 7-20, 24-45, 56, 57, 59, 60
Model 16N666 262846 Sprayer Replacement Kit: includes parts 2, 7-20, 24-45, 56, 57, 59, 60
Models 16N668, 16N669 262847 Sprayer Replacement Kit: includes parts 2, 7-20, 24-45, 56, 57, 59, 60
1 All models 243103 Pump Armor (32 oz)
2Non-Euro Models 16N668,16N669,16N670 16M816 Startup/Storage Kit
Euro Models 16N664, 16N665, 16N666 16P358 Startup/Storage Kit
3Blue Case Models 16N668,16N669,16N670 16P458 Storage Case
Black Case Models 16N664, 16N665, 16N666 16P457 Storage Case
4 100-120V Models: 16N668 16D559 Battery Charger
230V Models: 16N664, 16N665, 16N666 16D799 Battery Charger
230V Models: 16N669, 16N670 16G615 Battery Charger
5 All models PST211 211 Spray Tip/Guard Assembly
All models PST213 213 Spray Tip/Guard Assembly
All models PST315 315 Spray Tip/Guard Assembly
All models PST411 411 Spray Tip/Guard Assembly
All models PST413 413 Spray Tip/Guard Assembly
All models PST515 515 Spray Tip/Guard Assembly
All models PST517 515 Spray Tip/Guard Assembly
Models 16N664, 16N665, 16N666 PST309 309 Spray Tip/Guard Assembly
6 All models 24E376 1 pack Spray Tip Filter
All models 24F039 3 pack Spray Tip Filter
7 All models 108195 Needle Assembly O-ring
8 All models 262437 Needle Assembly Kit: includes parts 7 (qty. 2), 8
9 All models 115478 Screw
10 All models 16M865 Complete Pump Assembly w/Adjustable Prime/Spray Valve:
includes parts 10, 11-17, 24-28, 44
All models 16M868 Pump Housing Only: includes parts 10, 26, 27, 44
11 All models 262602 Inlet valve Repair Kit; includes 11, 12, 13
12 All models 262602 Inlet valve Repair Kit; includes 11, 12, 13
13 All models 262602 Inlet valve Repair Kit; includes 11, 12, 13
14 All models 109576 O-ring
15 All models 119790 O-ring
16 All models 16P151 Inlet/Outlet Valve Repair Kit: includes parts 11-17, 24
17 All models 106553 Suction Tube O-ring
20 All models 16J731 Sprayer Cup Seal
21 All models 16P121 Flexible Suction Tube Kit: includes parts 17 (qty. 2), 21, 22
22 All models 16N522 Flexible Suction Tube Strainer
23 All models 16D560 32 oz Material Cup: includes parts 23, 51, 52
16D561 48 oz Material Cup: includes parts 23, 51, 52
24 All models 16P151 Inlet/Outlet Valve Repair Kit: includes parts 11-17, 24
25 All models 16M873 Adjustable Prime/Spray Valve Repair Kit: includes 25, 42-45
26 All models 16M865 Complete Pump Assembly w/Adjustable Prime/Spray Valve:
includes parts 10, 11-17, 24-28, 44
All models 16M868 Pump Housing Only: includes parts 10, 26, 27, 44
27 All models 16M865 Complete Pump Assembly w/Adjustable Prime/Spray Valve:
includes parts 10, 11-17, 24-28, 44
All models 16M868 Pump Housing Only: includes parts 10, 26, 27, 44
(Parts List continues on next page)

Replacement Parts
3A2853A 19
Parts List - Models 16N664, 16N665, 16N666, 16N668, 16N669, 16N670 (Continued)
Ref.
If you have this model sprayer
(model number is the same as the part number,
which is between the battery and the sprayer)
Order Part
Number: Description
28 All models 16M863 Reciprocator Assembly Kit: includes parts 28, 44
29 All models 108326 Motor Mount Screw
30 All models 16M924 Drive Housing Assembly Kit:
includes parts 9 (qty. 4), 29 (qty. 2), 30, 44
31 All models 16M861 Motor/Control Board Kit: includes parts 29, 31, 33, 34, 44
32 Models 16N668, 16N669, 16N670 16P461 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
Models 16N664, 16N665, 16N666 16P462 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
33 All models 16N928 Switch Kit: includes parts 33, 34
34 Models 16N668, 16N669, 16N670 16P461 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
Models 16N664, 16N665, 16N666 16P462 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
35 Models 16N668, 16N669, 16N670 16E859 Made in USA Label
Models 16N664, 16N665, 16N666 16F636 Made in USA Label
36 All models 16C936 Outlet Valve Access Plug
37 Models 16N668, 16N669, 16N670 16P461 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
Models 16N664, 16N665, 16N666 16P462 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
38 All models 119236 Enclosure Screw
39 Models 16N668, 16N669, 16N670 16P461 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
Models 16N664, 16N665, 16N666 16P462 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
40 Model 16N670 16N556 Side Brand Label
Models 16N664, 16N665 16P157 Side Brand Label
Models 16N668, 16N669 16P159 Side Brand Label
41 All models 16R890 Front Brand Label
42 All models 16M873 Adjustable Prime/Spray Valve Repair Kit: includes parts 25, 42-45
43 All models 16M873 Adjustable Prime/Spray Valve Repair Kit: includes parts 25, 42-45
44 All models 119956 Pin
45 All models 262604 Prime Valve Handle: includes parts 44, 45
46 All models 16D558 Battery
51 All models 24D425 Material Cup Cover: includes parts 51, 52
52 All models 16C650 Seal for Material Cup
53 All models 16D562 Cup Liner Replacement (10 pack)
56 Models 16N668, 16N669, 16N670 16P461 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
Models 16N664, 16N665, 16N666 16P462 Enclosure Replacement Kit:
includes parts 32, 34-37, 38 (qty. 10), 39, 44, 56, 57
57 All models 16M890 Air Vent Valve
59 Models 16N664, 16N665, 16N668, 16N669, 16N670 16R891 Cup Lip Brand Label
60 All models 16R889 Pressure Control Label
Not
Shown
All Models ▲16P459 Warning Labels Replacement Kits ENG/FRE/SPA
All Models ▲16P002 Warning Labels Replacement Kits CHI/JAP/KOR
All Models ▲16P003 Warning Labels Replacement Kits SPA/POR/ITA
Not
Shown
Models 16N664, 16N665, 16N666 ▲16P207 Sprayer Enclosure Warning Label Kit
Models 16N664, 16N665, 16N666 ▲24E552 Battery Warning Label Kit
Models 16N664, 16N665, 16N666 ▲24E553 Charger Warning Label Kit
▲Replacement Danger and Warning labels, tags, and cards (Not Shown) are available at no cost.

Inlet Valve Fitting Removal/Service
20 3A2853A
Inlet Valve Fitting
Removal/Service
1. Engage trigger lock and pull prime/spray valve UP to
release pressure.
2. Remove material cup, flexible suction tube, and bat-
tery.
3. Hold sprayer upside-down and use wrench to loosen
and remove inlet valve fitting, inlet valve, and spring.
NOTE: Make sure the spring also comes out. Use nee-
dle-nose pliers to remove if needed. Inlet cavity should
be completely empty (as shown below).
4. Clean as much excess material from inlet cavity as
possible. Make sure you also clean spring (a), inlet
valve (b), o-ring (c), and top of inlet valve fitting (d).
5. Use a thin wire less than 1/16 in. (such as a paper clip)
to check that the outlet valve fitting moves freely. If
valve does not move freely, perform Outlet Valve Fit-
ting Repair, page 21.
Installation
NOTE: Before installing, make sure o-ring (c) is installed on
poppet valve (b). A needle-nose pliers can also be used to
install parts (a - c).
1. Place poppet valve (b) with spring (a) on top of inlet
valve fitting (d). Push inlet fitting up into pump cavity.
2. Hold inlet in place and turn sprayer upside-down.
Remove inlet valve fitting and visually check to see that
inlet valve has seated correctly.
3. Replace inlet fitting and use wrench or socket to
tighten to 10 ft-lb (14 N•m).
4. Use a pencil or thin rod to lightly push on inlet valve to
make sure it moves up and down freely. Perform Start-
ing New Job procedure, page 10.
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.
Move sprayer to a non-hazardous area before servicing.
NOTICE
When removing flexible suction tube from sprayer, make
sure to pull directly on top fitting of flexible suction tube.
Flexible suction tube will become damaged if pulled from
bottom or on flexible portion.
ti16700a
ti18866a
ti18895a ti18896a
ti18897a
NOTICE
Do NOT over-tighten inlet valve fitting. Damage to the
equipment will occur.
ti18898a
ti15502a
c
b
a
d
ti18899a
ti18900a
ti15509a
ti18883a