Graco 820-116 Operation manual

820–232
Rev. H
Supersedes A
and PCN F

INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
U.S. P A TENT NO. 4,323,741, 4,397,610
PATENTED 1983, CANADA
AND OTHER PATENTS PENDING
ELECTRIC, 120 VAC
ULTIMATE Plus + 1500
Airless Paint Sprayer
3000 psi (21.0 MPa, 210 bar) Maximum Working Pressure
Model 820–116, Series A (C.S.A.)
Basic sprayer on Upright cart without hose or gun
The SHERWIN-WILLIAMS COMPANY, CLEVELAND, OHIO 44115
COPYRIGHT 1997, GRACO INC.

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Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod 22. . . . . . . . . . . . .
Drive Housing 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 24. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts Drawing and List 26. . . . . .
Technical Data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty and Disclaimers 28. . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call Graco T echnical Assis -
tance at 1–800–543–0339.
D Do not alter or modify this equipment.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the T echnical Data on page 27 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warn -
ings.
D
Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82 _ C (180 _ F) or below –40 _ C (–40 _F).
D
Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING
INSTRUCTIONS

 
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex -
tremely serious injury , including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury .

Fluid injected into the skin may look like just a cut, but it is a serious injury . Get immediate medi -
cal attention.

Do not point the gun at anyone or at any part of the body .

Do not put your hand or fingers over the spray tip.
 Do not stop or deflect leaks with your hand, body , glove or rag.
 Do not “blow back” fluid; this is not an air spray system.
 Always have the tip guard and the trigger guard on the gun when spraying.
 Check the gun dif fuser operation weekly . Refer to the gun manual.
 Be sure the gun trigger safety operates before spraying.
 Lock the gun trigger safety when you stop spraying.
 Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten all fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING

 
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.

If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Electrically disconnect all equipment in the spray area.
 Extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
 Do not operate a gasoline engine in the spray area.
WARNING
WARNING
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the
equipment from starting unexpectedly .
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.A void accidental trig -
gering
of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical
T reatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable liq -
uids
in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip -
ment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga -
rettes,
arcs from connecting or disconnecting power cords or turn -
ing
light switches on and off.
Failure to follow this warning can result in death or serious injury .
NOTE: This is an example of the DANGER label on
your sprayer . This label is available in other
languages, free of charge. See page 27 to order .

 
C
Fig. 1
J
E
F
D
A
G
K
R
0137 M
N
B
H
S
U
L
TP
03656A
A Motor (Under shield shown) DC motor , 120 V ac, 18A, 1 phase
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch, Circuit Breaker Power switch that controls 120 V ac power to sprayer; with circuit
breaker
D Drive Assembly T ransfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Secondary Fluid Outlet Second hose and spray gun is connected here
G Pail Hanger Container of fluid to be sprayed may be hung here
H Displacement Pump Pressures fluid to be sprayed through spray gun
J 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
K RAC IV T ip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection inju -
ry
L Contractor Gun High pressure spray gun with gun safety latch
M RAC IV SwitchT ip RAC SwitchT ip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
N 3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray
gun to allow more flexibility when spraying
P Pressure Drain V alve Relieves fluid pressure when open
R Pressure Control Controls motor speed to maintain fluid pressure. W orks with pressure
adjusting knob.
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
T Primary Fluid Outlet Hose and spray gun is connected here
U 15/20 Amp Switch Allows sprayer to operate on 15A service with reduced performance

 
Setup
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 3000 psi (21.0 MPa, 210 bar) Working
Pressure . This is to reduce the risk of serious inju -
ry caused by static sparking, fluid injection or over-
pressurization and rupture of the hose or gun.
CAUTION
T o avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
1. Always use a nylon spray hose at least 50 ft.
(15 m) long.
2.
Never use a wire braid hose as it is too rigid to
act as a pulsation dampener .
3.
Never install any shutof f device between the
filter and the hose. See Fig. 2.
1. Assemble the gun (106), 3 ft. whip hose (105)
and 50 ft. hose (104).
Don’t install the spray tip
and tip guard yet.
2. Two gun hookup. Remove the cap (12) from the
1/4 npsm(m) secondary hose outlet and attach a
minimum 50 ft. long hose. For more flexible gun
movement, install a 3/16 in. ID, 3 ft. whip hose be -
tween the main hose and the gun.
3. Fill the packing nut/wet–cup (216) 1/3 full with
Throat Seal Liquid (TSL), supplied.
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read FIRE OR
EXPLOSION HAZARD on page 4.
WARNING
4. Check the electrical service. Be sure the electri -
cal service is 120 V AC, 60 Hz, 20A. Use a properly
grounded outlet. Do not remove the grounding
prong of the power supply cord. Do not use an
adapter . Extension cords must have 3 wires of a
minimum 12 gauge size. Long extension cords
reduce sprayer performance. If 20A service is not
available, flip the 15/20 Amp switch (U) to 15 set -
ting to avoid nuisance tripping of circuit breakers.
5. With the the ON/OFF switch OFF, plug the cord
into a grounded electrical outlet
located at least
20 ft. (6 m) away from the spray area.
6. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after fac -
tory testing. See page 1 1.
Fig. 2
1
Do not install any
fluid shutof f device here
216
12
46
K104
105
1
C
B
U
50
42
106
03657

 
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in -
jected through the skin and cause
serious injury . T o reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
 are instructed to relieve the pressure,
 stop spraying/dispensing,
 check or service any of the system equipment,
 or install or clean the spray tip/nozzle.
1. Engage the gun safety latch.
2. T urn the ON/OFF switch to OFF .
3.
Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. T rugger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the pressure
drain valve open until you area ready to spray
again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
tip guard retaining nut or hose end coupling to relieve
pressure gradually , then loosen completely . Now clear
the tip or hose obstruction.

 
Operation
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
Startup (Fig. 2)
Always use this procedure to help ensure the sprayer
is ready to operate and that you start it safely .
1.
For a first time startup , flush the sprayer . See
page 1 1.
2.
Close the pressure drain valve (50).
3. Don’t install the spray tip and tip guard until
the pump is primed!
4. Put the suction tube (42) into the paint con-
tainer.
5.
Lower the pressure setting by turning the pres -
sure adjusting knob (B) fully counterclockwise.
6. Disengage the gun safety latch. See Fig 3.
Fig. 3
1
2
Gun safety latch
shown engaged
0137
12
Gun safety latch
shown disengaged
CAUTION
Do not run the sprayer dry for more than 30 sec -
onds to avoid damaging the pump packings.
7. T o prime the pump :
a.
Open the drain valve.
b. T urn the ON/OFF (C) switch to ON.
c. Slowly increase the pressure setting until the
sprayer starts.
d. When fluid is flowing from the valve, turn down
the pressure and close the valve.
e. Hold a metal part of the gun firmly against a
grounded metal waste container . See Fig. 4.
Fig. 4
1
Maintain
firm
metal to metal
contact when
flushing
0143
1
f. Trigger the gun and slowly increase the pres -
sure setting until the sprayer starts. Keep the
gun triggered until all air is forced out of the
system and the paint flows freely from the gun.
g. Release the trigger and engage the gun safety
latch. See Fig 3.
8. Check all fluid connections for leaks . If any
leaks are found, relieve pressure before tightening
the connections.

 
Operation
9. Install the spray tip and tip guard. Engage the
gun safety latch. Install the spray tip. If you are
using the RAC IV tip guard, refer to manual
307–848 for installation instructions.
10. Adjust the pressure.
a. T urn the pressure adjusting knob clockwise
just until spray from the gun is completely at -
omized. T o avoid excessive overspray and fog -
ging, and to decrease tip wear and extend the
life of the sprayer , always use the lowest pos -
sible pressure needed to get the desired re -
sults.
b.
If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. T est the spray pattern. T o adjust the direction
of the spray pattern: engage the gun safety
latch, loosen the retaining nut, position the tip
guard horizontally for a horizontal pattern or
vertically for a vertical pattern and tighten the
retaining nut.
Cleaning a Clogged Tip
To reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
WARNING
INJECTION HAZARD
1. If the spray tip does clog, release the gun trigger ,
engage the gun safety latch, relieve pressure, and
rotate the RAC IV SwitchT ip 180  . See Fig. 5.
2. Disengage the gun safety latch and trigger the gun
into a waste container . Engage the gun safety
latch again.
Fig. 5
1
2
SwitchTip shown in
spraying position
Gun safety latch
shown engaged
0137
1
2
3. Return the SwitchT ip to the original position, disen -
gage the gun safety latch, and resume spraying.
4. If the tip is still clogged, engage the gun safety
latch, shut of
f and unplug the sprayer , and open
the pressure drain valve to relieve pressure. Clean
the spray tip as shown in manual 307–848, sup -
plied with the RAC IV .
Shutdown and Care
1. Check the packing nut/wet-cup (216) daily. Re -
lieve the pressure. Keep the packing nut/wet-cup
1/3 full with TSL at all times to help prevent fluid
buildup on the piston rod and premature wear of
packings. Tighten the packing nut just enough to
stop leakage. Overtightening may cause binding
and excessive packing wear . Use a screwdriver
and light hammer to adjust the nut. See Fig. 6.
2. Clean the fluid filter (48) often and whenever the
sprayer is stored. First relieve pressure. See man -
ual 307–273 for the cleaning procedure.
3. Fill the connecting rod cavity (A) with motor oil
every 100 hours of operation. Relieve pressure
first. See Fig. 6.
Fig. 6
A
48
216
03658
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
5. Coil the hose and hang it on the hose rack
when storing it, even for overnight, to help protect
the hose from kinking, abrasion, coupling damage,
etc.

10 820-232
Flushing
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
When to Flush
1. New Sprayer . The sprayer was factory tested in
lightweight oil which was left in to protect pump
parts.
Before using water–base paint , flush with mineral
spirits, then warm, soapy water , and then clean
water.
Before using oil–base paint, flush with mineral spir -
its.
2. Changing Colors.
Flush with a compatible sol -
vent.
3. Changing water–base to oil–base paint.
Flush
with warm, soapy water , then mineral spirits.
4. Changing from oil–base to water–base paint.
Flush with mineral spirits, then warm, soapy water ,
and then clean water .
5.
Storage. Flush as indicated below , shut of f the
sprayer , open the pressure drain valve to relieve
pressure and leave it open.
W ater–base paint: flush with water , then mineral
spirits. Leave the system filled with mineral spirits.
Oil–base paint: flush with mineral spirits.
CAUTION
Never allow water to freeze in the pressure control.
Doing so prevents the sprayer from being started
and causes serious damage to the pressure control.
Push the water out with mineral spirits.
6. Startup after storage. Before using water–base
paint, flush out the mineral spirits with soapy water
and then clean water . When using oil–base paint,
flush out the mineral spirits with the paint to be
sprayed.

820-232 11
Flushing
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
How to Flush
Fig. 7
50
A
B
C
01893
1. Relieve pressure.
2. Remove the filter bowl (A), support (C) and screen
(B); see manual 307–273. Install the bowl and
support. Clean the screen separately and install
after flushing. See Fig 7.
3. Close the pressure drain valve.
4. Pour one–half gallon of compatible solvent into a
grounded metal pail. Put the suction tube in the
pail.
5.
Remove the spray tip from the gun, if it is installed.
6. T urn the pressure adjusting knob all the way coun -
terclockwise to lower the pressure setting.
7. Open the drain valve. T urn on the sprayer and
increase the pressure until until the sprayer starts.
When fluid comes from the valve, close it. Hold a
metal part of the gun firmly against a metal waste
container. T rigger the gun until all air is forced out
of the system and the solvent flows freely from the
gun. Release the trigger and engage the gun
safety latch.
T o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
WARNING
FIRE AND EXPLOSION HAZARD
8. Remove the suction tube from the pail. Disengage
the gun safety latch and trigger the gun to force
solvent from the hose. Do not run the pump dry for
more than 30 seconds to avoid damaging the
pump packings! Relieve pressure.
9. Leave the pressure drain valve open until you are
ready to use the sprayer again. If the screen was
removed, unscrew the filter bowl and reinstall the
clean screen. Reinstall the bowl, hand tight only .
10.
If you flushed with mineral spirits and are going to
use a water–base paint, flush with soapy water
and then clean water. Relieve pressure.

12 820-232
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Before servicing this equipment always make sure to
Relieve the Pressure .
Check all possible problems and solutions before
disassembling the unit.
TYPE OF PROBLEM WHA T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK refer to this column
Building circuit breaker opens Check all electrical wiring for damaged
insulation.
Replace any damaged wiring.
Check for other electrical appliances on
circuit.
Shutdown other electrical appliances on
circuit.
Check position of 15–20 (Lo-High) amp
switch.
Put switch in 15 amp (LO) position.
Sprayer circuit breaker opens Check for locked motor rotor . Unplug cord
and try to turn fan blades with a screwdriver .
Repair gear train or pump, if damaged. Thaw
the sprayer , if frozen; See NOTE 1. Replace
the pressure control, if damaged.
Check for shorted motor . Use ohmmeter to
check for shorts between motor leads or
between motor leads and motor frame.
Inspect for damage to motor brush leads.
Replace motor , if necessary.
Check electrical supply with voltmeter . Meter
should read 105–125 V
AC.
Connect to outlet of correct voltage.
Sprayer will not run Check pressure control knob setting. Motor
will not run if it is at minimum setting (fully
counterclockwise).
Slowly increase pressure setting to see if
motor starts.
Check for a clogged spray tip. Refer to
separate gun or tip instruction manual.
Relieve pressure. Refer to separate gun or
tip instruction manual for tip cleaning.
Check extension cord for visible damage.
Use a volt meter or test lamp at extension
cord outlet to check.
Replace extension cord.
Check sprayer power supply cord for visible
damage such as broken insulation or wires.
Replace power supply cord.
Check electrical supply with volt meter . Meter
should read 105–125 V
AC.
Reset building circuit breaker; replace
building fuse. T ry another outlet.
Check for motor damage. Remove drive
housing assembly . See page 23. T ry to rotate
fan by hand.
Replace motor (1) if fan won’t turn.
Poor spray pattern Check for worn spray tip. Relieve pressure and then replace the tip.
See the separate gun or tip manual.

820-232 13
Troubleshooting
TYPE OF PROBLEM WHA T T O CHECK
If check is OK, go to next check
WHA T T O DO
When check is not OK refer to this column
Motor runs and pump strokes,
but output is low or there is no
output.
Check extension cord size and length. Replace cord with a larger size, grounding
type extension cord.
Check paint supply . Refill and reprime pump.
Check for clogged intake strainer . Remove and clean strainer and reinstall.
Check for loose suction tube or loose fittings. T ighten; use thread sealant or sealing tape
on threads, if necessary .
Check for worn spray tip. Follow Pressure Relief Procedure
Warning , then replace tip. See your
separate gun or tip manual.
Check motor brushes; check for loose leads
and terminals, minimum 1/2” brush length,
broken or misaligned springs, or brushes
binding in holders. See page 14.
Replace parts as needed. See page 14.
Check motor armature for shorts by using an
armature tester (growler).
Replace motor . See page 21.
Check to see if pump continues to stroke
when gun trigger is released. With pump on
and primed, trigger gun momentarily , then
release and engage safety latch. Relieve
pressure, turn of f and unplug sprayer .
Service pump. See page 15.
Check to see if intake valve ball and piston
ball are seating properly .
Remove intake valve and clean. Check balls
and seats for nicks; replace if necessary.
See page 16. Strain paint before using to
remove particles that could clog the pump.
Check for leaking around throat packing nut
which may indicated worn or damaged
packings.
Replace packings. See page 15. Also check
piston valve seat for hardened paint or nicks
and replace if necessary . T ighten the
packing nut/wetcup.
Motor runs but pump does not
stroke.
Check displacement pump connecting rod
pin (20). See page 19.
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. See Fig. 38, page 19.
Check for frozen or hardened paint in the
pump (39).
Thaw . See NOTE 1. Plug in sprayer and turn
on. Slowly increase pressure setting to see if
motor starts.
Be sure crank in drive housing rotates; plug
in sprayer and turn on briefly to check. T urn
of
f and unplug sprayer .
Check drive housing assembly for damage
and replace if necessary . See page 23.
Motor is hot and runs
intermittently.
Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
Decrease pressure setting or increase tip
size.
Be sure ambient temperature where sprayer
is located is no more than 90  F and sprayer
is not located in direct sun.
Move sprayer to shaded, cooler area, if
possible.
Determine in sprayer was turned on,
pressurized, but not operating for long
periods of time.
T urn of f sprayer whenever you stop spraying
for a while and relieve fluid pressure.
NOTE 1: Thaw the sprayer if water or water-based paint has frozen in it, by placing it in a warm area. Do not try to
start the sprayer until it has thawed completely . If paint hardened (dried) in the sprayer , replace the pump packings.
See page 15.

14 820-232
Motor Brush
NOTE: Replace the brushes when they have worn to
about 0.4 in (10 mm). Always check both brushes and
replace them together . A Brush Repair Kit, 820–536,
and the spring clip, 820–594, are available. Order sep -
arately.
NOTE: Replacement brushes may last only half as
long as the original ones. To maximize brush life, break
in new brushes by operating the sprayer for at least
one hour with no load (remove the pump connecting
rod pin).
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
1. Remove the motor cover (14) and both inspection
covers (A). See Fig 8.
2. Push in the spring clip (D) to unhook it, and then
pull it out. See Fig 9.
3. Loosen the terminal screw (F). Pull the brush lead
(G) away , leaving the motor lead in place. Remove
the brush (C) and spring (B). See Fig 10.
4. Inspect the commutator for excessive pitting, burn -
ing or gouging. A black color on the commutator is
normal. Have the commutator resurfaced by a
qualified motor repair shop if the brushes seem to
wear too fast.
5. Install the new brush (C) so its lead is in the long
slot (K) of the holder (H). Slide the terminal (E)
under the terminal screw (F) washer . Make sure
the motor lead terminal (G) is still connected at the
screw. T ighten the screw . See Fig 1 1.
6.
Place the spring (B) on the brush (C) as shown in
Fig 1 1.
7.
Push in and hook the spring clip (D). See Fig 1 1.
8.
Repeat for the other side.
CAUTION
Do not run the sprayer dry for more than 30 sec -
onds while checking the brushes to avoid damag -
ing the displacement pump.
9. Reinstall the remaining parts.
Fig. 8
A
14
03659
Fig. 9
1
B
C
D1
Part No.
110–816
01227
Fig. 10
BD
C
E
F
G01227
Fig. 11 01227
D
C
HJ
K
Note: Spring must coil
in this direction
1
1
2
2
Minimum brush length:
0.4 in. (10 mm)
B

820-232 15
Displacement Pump
Removing the Pump
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
1. Flush the pump, if possible, and relieve pressure
again. Stop the pump with the piston rod in its
lowest position, if possible.
2. Remove the hose (47), clips and drain tube (101).
Remove the suction tube (42); hold the wrench
on the pump intake valve (223) to keep the pump
from loosening. See Fig. 12.
3. Push the retaining spring (35) up. See Fig. 13.
4. Push out the pin (20). See Fig. 14.
5. Loosen the locknut (38) and unscrew the pump
from the bearing housing (27). See Fig. 15.
Tools Needed for Pump Repair
Repair Kit, 820–672
Sleeve Removal T ool, 224–788
Heavy duty vise
1-1/16’ ’ open end wrench for Pump 220–872
2-1/4’ ’ adjustable, open-end wrench
Plastic mallet
Small screwdriver
Throat Seal Liquid
Thread Sealant
NOTE: Soak leather packings in oil before installing.
Cleaning and Inspecting Parts
Clean and inspect the parts. Pay particular attention to
the ball seat in the intake valve, which should have no
nicks or wear , and to the inside of the sleeve and the
outside of the piston rod, which should not be worn or
scratched. Replace worn or damaged parts.
Remove and clean the sleeve when you are repacking
the pump. A special sleeve removal tool is available.
See the chart, above, for the tool number for your
pump.
WARNING
INJECTION HAZARD
Always use the special sleeve removal
tool to remove the sleeve. Other removal
methods could cause the pump to rup
-
ture, resulting in serious bodily injury . If the sleeve
cannot be removed easily using the tool, return the
sleeve and cylinder to your Graco distributor for
removal.
Fig. 12
101
47
42
04585
223
Fig. 13 04586
35
Fig. 14 04587
20
Fig. 15 04588 04589
38 27

16 820-232
Displacement Pump
Disassembly
NOTE: Parts included in the Packing Repair Kit,
820–672, are marked with an asterisk (*) in the text
and drawings. Use all the new parts in the kit.
1. Loosen the packing nut (216) and remove plug
(205). Unscrew the cylinder from the intake valve.
See Fig. 16.
2. Disassemble the intake valve. Use a pick to
remove the old gasket (202). Clean and inspect
the parts. See Fig. 17.
3. Reassemble the intake valve using a new gasket
(202*), ball (204*) and pin (221*). See Fig. 17.
4. T ap the piston rod (224) out of the cylinder . See
Fig. 18.
5. Screw the sleeve removal tool’ s large nut (A) into
the top of the cylinder . Screw down the rod to push
the sleeve out. See Fig. 19. Remove the tool.
Clean and inspect the parts.
6. Clamp the piston rod (224) in a vise. Loosen the
retaining nut (21 1). Unscrew the piston valve
(222). See Fig. 20.
7. Disassemble the piston and discard the packings
and glands. See Fig. 21.
8. Remove and discard the throat packings and
glands from pump cylinder . See Fig. 22.
Fig. 16 02558A
216
205
Fig. 17 02559
*204
*202 221*
Fig. 18 02561
224
Fig. 19 02562
A
Fig. 20 02563
211
224
222
Fig. 21 02564
Fig. 22 02565

820-232 17
Displacement Pump
Pump Reassembly
1. Clean the piston valve threads. One at a time,
stack the backup washer (203*), seal (215*) (with
lips facing down), and female gland (214*) on the
piston. Alternately stack the polyethylene (212*)
and leather (206*) packings (lips facing up) on the
piston. Then install the male gland (210*). See Fig.
23.
2.
Place the flats of the piston valve in a vise. T ighten
the packing retaining nut against the piston valve
to 4 in-lb (0.35 N.m). See Fig. 24.
Note the alignment of the piston to the packing re -
tainer nut. Maintain this alignment through Steps 4 and
5.
3.
Apply one drop of Locktite to the threads. Place
the ball (225*) on the piston valve. See Fig. 25.
4. While maintaining the alignment, thread the piston
valve assembly into the piston rod just until the
piston valve nut contacts the rod. See Fig. 26.
5. Place the flats of the rod in a vise. Carefully tighten
the piston valve nut (21 1) against the piston rod to
19 ft-lb (27 N.m). Use two wrenches to maintain
the alignment. See Fig. 27.
6. Place the male gland (208*) in the cylinder . Alter -
nately stack the polyethylene (213*) and leather
packings (207*) (lips facing down). Then place the
female gland (209*) in the top of the cylinder . Seat
the packings. See Fig. 28.
Fig. 23 02566
203*
206*
215*
*212
*210
*214
Fig. 24 02567
Torque to 4 in-lb
(0.35 N.m)
Fig. 25
02568
225*
Fig. 26 02569
Fig. 27 02570A
Torque to 19 ft-lb
(27 N.m)
Fig. 28
02571
*207
209*
213*
208*

18 820-232
Displacement Pump
7. Loosely install the packing nut (216) and plug
(205). See Fig. 29.
8. Place a o-ring (217*) in the cylinder . Slide the
sleeve in to the cylinder to seat the o-ring. See Fig.
30. Remove the sleeve.
9. Grease the piston packings and the top edge of
the sleeve. See Fig. 31.
10. Carefully slide the piston assembly into the top of
the sleeve. See Fig. 32.
11. Slide the sleeve/piston rod assembly into the
bottom of the cylinder . See Fig. 33.
12. Grease the intake valve o-ring with non-silicon
grease. Screw the pump cylinder into the intake
valve. T orque to 70 ft-lb (95 N.m). See Fig. 34.
13. T ighten the packing nut (216) hand tight. Screw
the cylinder locknut (A) down to the bottom of the
external cylinder threads. See Fig. 35.
Fig. 29 02572
216
205
Fig. 30 02573A
217*
Fig. 31 02574A
Fig. 32
02575
Fig. 33
02576
Fig. 34
02577A
Fig. 35 02578
216
A

820-232 19
Displacement Pump
Installing the Pump
1. Screw the displacement pump into the bearing
housing (27) until the pin holes align. See Fig. 36.
2. Install the pin (221*). See Fig. 37.
3. Continue to screw the pump into the bearing hous -
ing until the top threads of the pump cylinder are
flush with the face of the bearing housing and the
outlet nipple is straight back. Push the retaining
spring (35) into the groove all the way around the
connecting rod to prevent it from working loose
due to vibration. See Fig. 38.
WARNING
MOVING P ARTS HAZARD
If the pin works loose, it or other parts
could break of f due to the force of the
pumping action. These parts could be
projected through the air and result in serious bodi -
ly injury or property damage, including damage to
the pump, connecting rod or bearing housing.
4. T ighten the locknut (38) to 70 ft-lb (97 N.m). See
Fig. 39.
CAUTION
If the locknut (38) loosens during operation, the
threads of the bearing housing (29) will be dam
-
aged. Be sure to tighten the locknut firmly .
5. T
ighten the packing nut/ wet-cup just enough to
stop leakage, but no tighter . Fill the wet-cup/pack -
ing nut 1/3 full with Graco TSL. See Fig. 40.
Fig. 36 04589
Fig. 37
221*
04590
Fig. 38
35
03043
Fig. 39
Torque to
70 ft-lb
(97 N.m)
04591
Fig. 40
04592

 
Pressure Control
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
NOTE: Refer to Fig. 41 except where noted.
1. Disconnect the hose (47).
2. Disconnect the drain tube (101) from the drain
valve.
3. Loosen the outside filter bracket nut (28).
Unscrew the fitting (8) and remove the filter .
4. Remove the pressure control cover (36). Discon -
nect the four motor leads. See Fig. 42.
5. Unscrew the connector (54). Pull the wires out of
the pressure control.
6. Remove the pressure control mounting screws
(37). Remove the pressure control. Install the con -
nector (54) on the new pressure control.
7. Install the new pressure control. Place the seal
(103) around the motor leads and push the seal
into the connector (54).
Fig. 41
8
22
16
84
28
13
40
41
37
54
47
28
101
36
03660
Power Supply Cord
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 7.
NOTE: Refer to Fig. 41 except where noted.
1. Relieve pressure.
2. Remove the back pressure control plate (16).
3. Remove the pressure control cover . Disconnect
the power supply cord leads. See Fig. 42.
4. Loosen the strain relief bushing (B). Remove the
power supply cord (23).
5. Install the new cord.
Fig. 42
Red
Black (–)
Black/
white (+)
FRONT VIEW OF PRESSURE CONTROL
01897
BACK VIEW OF PRESSURE CON -
TROL
B
23
01898
Black
Green
White