Graco 824910 User manual

309069
Rev. C
TI0038B
824912
Related Manuals
Operation 309068. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308815. . . . . . . . . . . . . . . . .
Fluid Filter 308249. . . . . . . . . . . . . . . . . . . . . . . . . .
824910
TI0039
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ULTiMATE Mx 695
Airless Paint Sprayer
3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure
120 VAC
824910, A
Hi-boy sprayer
824912, B
Lo-boy sprayer
Table of Contents
Component Function and Identification 2. . . . . . . . . . . .
General Repair Information 3. . . . . . . . . . . . . . . . . . . . . .
Grounding 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brushes 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 13. . . . . . . . . . . . . . . . . . . . . . . .
Power Cord 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Adjusting Potentiometer 14. . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 15. . . . . .
Pressure Transducer 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Seal 16. . . . . . . . . . . . . . . . . . . . . .
Drain Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The SHERWIN–WILLIAMS COMPANY, CLEVELAND, OHIO 44115
COPYRIGHT 1999, GRACO INC.

2 309069
Component Function and Identification
C
Fig. 1
E
F
D
A
G
R
B
H
P
824910
R
TI0040
AMotor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled
BPressure Adjusting Knob Controls fluid outlet pressure
CON/OFF Switch Power switch that controls VAC main power to sprayer
DDrive Assembly Transfers power from DC motor to the displacement pump
EFluid Filter Filter of fluid between source and spray gun
FFluid Outlet Main hose to spray gun is connected here
GPail Hanger Container for fluid to be sprayed may be hung here
HDisplacement Pump Transfers fluid to be sprayed from source through spray gun
PPressure Drain Valve Relieves fluid outlet pressure when open; diverts fluid to drain line
RPressure Control Controls motor speed to maintain fluid outlet pressure at displacement
pump outlet. Works with pressure adjusting knob.

309069 3
General Repair Information
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect a wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. adjustable wrench
Adjustable, open-end
wrench
Torque wrench
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
Tool List
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
WARNING
ELECTRIC SHOCK HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting,
page 4, for other possible solutions.
WARNING
EXPLOSION HAZARD
Motor and drive housing are very hot
during operation and could burn skin if
touched. Flammable materials spilled on
hot, bare motor could cause fire or explosion. Have
motor shield in place during operation to reduce
risk of burns, fire or explosion.
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.

4 309069
Grounding
WARNING
Improper installation or alteration of grounding plug
results in risk of electric shock, fire or explosion
that could cause serious injury or death.
1. The 824910 and 824912 require 120 VAC, 60 HZ,
15A with a grounding receptacle. See Fig. 2.
2. Do not alter ground prong or use adapter.
Fig. 2
Grounding Plug Grounded
Outlets
120 VAC plug and outlet
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
Troubleshooting
Relieve pressure; page 3.
Basic Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Fluid Pressure 1. Pressure control knob setting. Motor will not run if at mini-
mum setting (fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. Clogged spray tip or fluid filter, if used. Refer to separate
gun, tip or fluid filter instruction manual.
2. If tip is still clogged, relieve pressure;
refer to separate gun or tip instruction
manual for tip cleaning. Clean or replace
filter element. See manual 308249.
Mechanical 1. Frozen or hardened paint in pump (18). Use a screwdriver
and carefully rotate fan at back of motor. See page 12.
1. Thaw sprayer if water or water-based
paint has frozen in sprayer. Place spray-
er in warm area to thaw. Do not start
sprayer until completely thawed. If paint
hardened (dried) in sprayer the pump
packings and/or pressure transducer
must be replaced. See page 11 (pump)
or 16 (pressure transducer).
2. Pump connecting rod pin (14). Pin must be completely
pushed into connecting rod (12), and retaining spring (15)
must be firmly in connecting rod groove. See Fig. 9, page
11.
2. Push pin into place and secure with
spring retainer.
3. For motor damage. Remove drive housing assembly (2).
See page 15. Try to rotate motor
fan by hand.
3. Replace motor (85) if fan won’t turn. See
page 12.
Electrical 1. Electrical supply with volt meter.
Meter must read 105–125 VAC.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Extension cord for damage. Check extension cord conti-
nuity with volt meter.
2. Replace extension cord.
3. Sprayer power cord (30) for damage such as broken insu-
lation or wires.
3. Replace power cord. See page 14.

309069 5
Basic Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Electrical
(continued)
4. Motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
d. Broken leads.
e. Worn brushes.
f. Brush leads snagged on spring clip.
NOTE: Brushes do not wear at same rate on both
sides of motor. Check both brushes.
4. Refer to page 10.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
(12.5 mm) long.
f. Correctly route wires. See page 10.
5. Motor armature commutator for burn spots, gouges and
extreme roughness. Remove motor cover and brush in-
spection plates to check. See page 10.
5. Remove motor and have motor shop
resurface commutator if possible.
See page 12.
6. Motor armature for shorts using armature tester (growler)
or perform motor test. See page 9.
6. Replace motor. See page 12.
7. That leads from pressure transducer and motor to motor
control board (22a) are securely fastened and properly
mated.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate, sub-
stitute with a good board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
8. Replace board. See page 13.
9. Power cord (30).
Disconnect black and white power cord terminals; connect
volt meter to these leads.
Plug in sprayer. Meter must read 105–125 VAC.
Unplug sprayer.
9. Replace power cord.
See page 14.
10. ON/OFF switch (80).
Disconnect black wire (96) between motor control board
(22a) and switch and connect volt meter between exposed
terminal of (96) and power cord white wire. Plug in sprayer
and turn ON.
Meter must read 105–110 VAC.
Turn OFF and unplug sprayer.
10. Replace ON/OFF switch. See page 14.

6 309069
Basic Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
11. Motor thermal cutout switch. Connect ohmmeter between
motor yellow leads. Meter must read 1 ohm maximum.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12. Pressure transducer (67) by replacing it with a new one. 12. Replace pressure transducer.
See page 16.
13. Pressure adjustment potentiometer (77) by replacing it
with a new one.
13. Replace potentiometer. See page 14.
Intermediate Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low output 1. For worn spray tip. 1. Follow Pressure Relief Procedure
Warning on page 3, then replace tip.
See your separate gun or tip manual.
2. Verify pump does not continue to stroke when gun trigger
is released. Plug in and turn on sprayer. Prime with paint.
Trigger gun momentarily, then release and engage safety
latch. Relieve pressure, turn off and unplug sprayer.
2. Service pump. See page 11.
3. Release gun trigger. Observe resting position of pump rod
(222).
3. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service pump. See page 11.
4. Electrical supply with volt meter.
Meter must read 105–125 VAC.
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Extension cord size and length; must be at least 12 AWG
(1.5 mm2) and no longer than 300 ft (90 m).
5. Replace with a correct, grounded exten-
sion cord.
6. Motor brushes. See Electrical – What To Check, item 4, on
page 5.
6. See page 10.
Low output
(continued)
7. Motor control board (22a) by substituting with a good
board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
7. Replace board. See page 13.
8. Motor armature for shorts by using an armature tester
(growler) or perform motor test. See page 9.
8. Replace motor. See page 12
.

309069 7
Intermediate Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Drain valve
leaks
1. Drain valve for correct torque and/or worn parts. Check for
debris trapped on seat.
1. Tighten to 185 in-lb (21 Nm). Clean
valve and replace with new gasket (55)
and sealant 110–110. See page 18.
No output:
motor runs
and pump
strokes
1. Paint supply. 1. Refill and reprime pump.
2. For clogged intake strainer. 2. Remove and clean, then reinstall.
3. For loose suction tube or fittings. 3. Tighten; use thread sealant on
npt threads of adapter fitting (43).
4. To see if intake valve ball and piston ball are seating
properly. See page 11.
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as need-
ed. See page 11. Strain paint before us-
ing to remove particles that could clog
pump.
5. For leaking around throat packing nut which may indicate
worn or damaged packings. See page 11.
5. Replace packings. See page 11. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut.
6. Release gun trigger. Observe resting position of pump rod
(222).
6. If pump consistently comes to rest
with rod (222) fully extended, piston
packings and/or piston valve may be
worn. Service pump. See page 11.
No output:
motor runs but
pump does not
stroke
1. Displacement pump connecting rod pin (14).
See Fig. 9, page 11.
1. Replace pin if missing. Be sure retainer
spring (15) is fully in groove all around
connecting rod.
2. Connecting rod assembly (12) for damage. See page 15. 2. Replace connecting rod assembly. See
page 15.
3. Be sure crank in drive housing rotates; plug in sprayer and
turn on briefly to check. Turn off and unplug sprayer.
See page 15.
3. Check drive housing assembly for dam-
age and replace if necessary. See
page 15.
Spray pattern
variations
1. Spray tip worn beyond sprayer pressure capability. 1. Replace spray tip.
NOTE: Smaller size tip provides
longer life.
2. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate, sub-
stitute with a good board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
2. Replace board. See page 13.

8 309069
Intermediate Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Spray pattern
variations
3. Pressure adjustment potentiometer (77) by replacing
with a new one.
3. Replace potentiometer. See page 14..
(continued) 4. Low Output section, page 6.
Motor is hot and
runs intermit-
tently
1. Determine if sprayer was operated at high pressure with
small tips, which causes excessive heat build up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer is located is
no more than 90F (32C) and sprayer is not located in
direct sun.
2. Move sprayer to shaded, cooler area if
possible.
3. Motor. 3. Replace motor. See page 12.
Building circuit
breaker opens
as soon as
sprayer switch is
1. All electrical wiring for damaged insulation,
and all terminals for loose fit or damage.
Also check wires between pressure transducer
and motor. See page 12.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
turned on. 2. For missing motor brush inspection plate gasket (see
page 10), bent terminal forks or other metal to metal
contact points which could cause a short.
2. Correct faulty conditions.
3. Motor armature for shorts. Use an
armature tester (growler) or perform motor test.
See page 9. Inspect windings for burns.
3. Replace motor. See page 12.
4. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate,
substitute with a good board.
CAUTION: Do not perform this check until motor arma-
ture is determined to be good. A bad motor armature
can burn out a good board
4. Replace board. See page 13.
Circuit breaker
opens after
sprayer oper-
ates for 5 to 10
minutes.
1. Basic Problems – Electrical’ on page 4.
Building circuit
breaker opens
as soon as
sprayer is
plugged into
outlet and
sprayer is not
turned on.
1. ON/OFF switch (80). Be sure sprayer is unplugged!
Disconnect wires from switch. Check switch with
ohmmeter. The reading should be infinity with ON/OFF
switch OFF, and zero with switch ON.
CAUTION: A short in motor circuit can damage switch
and or motor control board (22a).
1. Replace ON/OFF switch. See page 14.
2. For damaged or pinched wires in junction box (20). 2. Replace damaged parts.
Unit will not run
on generator but
does run on AC
power
1. Generator “peak” voltage.
Sprayer will not run if peak voltage is above 190V or
below 100V.
1. Use AC power or a different generator.

309069 9
Motor Test
Relieve pressure; page 3.
For checking armature, motor winding and brush
electrical continuity.
Setup
1. Unplug sprayer.
2. Remove drive housing. See page 15. This ensures
that any resistance noticed in armature test is due
to motor and not to worn gears in drive housing.
3. Fig. 3. Remove brush inspection covers (A).
4. Fig.4. Remove screws (25, 26). Lower control
board (22a). Disconnect two leads (C) from motor
to board.
A
B
Fig. 3 02991
Armature Short Circuit Test
1. Remove fan cover (B). See Fig.3.
2. Spin motor fan by hand. If there are no shorts,
motor coasts two or three revolutions before
coming to complete stop. If motor does not spin
freely, armature is shorted and motor must be
replaced. See page 12.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Fig. 4 Connect red and black motor leads (C)
together with a test lead. Turn motor fan by hand
at about two revolutions per second.
Fig. 4
77
67
30
78
C
22a
96
D
E
black
green
white black red
yellow
107
108
8385A
80
brown
2. If uneven or no resistance, check for: broken brush
springs, brush leads, motor leads; loose brush
terminal screws or motor lead terminals; worn
brushes. See page 10.
3. If still uneven or no resistance, replace motor;
page 12.

10 309069
Motor Brushes
NOTE: Replace brushes worn to less than13 mm
(0.5 in.). Check both brushes. Use Brush Repair Kit
236967 for motor brush repair.
Relieve pressure; page 3.
1. Unplug sprayer.
2. Remove both inspection covers (A) and their
gaskets. See Fig.5.
Fig. 5
A
TI0041
3. Push in spring clip (F) and release hooks (G) from
brush holder (B). Pull out spring clip. See Fig. 6.
4. Inspect commutator for excessive pitting, burning or
gouging. A black color on commutator is normal.
Have commutator resurfaced by a qualified motor
repair shop if brushes seem to wear too fast or arc
excessively. See Step 9.d., also.
5. Repeat for other side.
6. Place a new brush (C) in holder (B) so ramp (H)
faces spring. See Fig. 6.
7. Holding spring clip (F) at a slight angle, slide spring
clip into brush holder and hook it over end of
holder. See Fig. 7. Pull on spring clip to be sure it
stays in place. Connect brush lead to blade con-
nector (E).
8. Repeat for other side.
9. Test brushes.
a. Remove pump connecting rod pin (14).
WARNING
ELECTRIC SHOCK HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious bodily injury.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
d. Inspect brush and commutator contact area for
excessive arcing. Arcs must not trail or circle
around commutator surface.
10. Install brush inspection covers and gaskets.
11. Install pump connecting rod pin (14).
Fig. 6
F
G
E
D
C
B
H
1
1
Motor lead; do not disconnect
2Minimum 13 mm (.5 in.)
2
03881
03881
Fig. 7
1
G
C
E
F

309069 11
Displacement Pump
NOTE: Packing Repair Kit 239939 is available. Refer-
ence numbers of parts included in the kit are marked
with an asterisk, i.e., (223*).
Removing pump (See Fig.8)
*227
*214
215
222
15
14
17
18
50
36
43
11
Fig. 8
1
2Apply pipe
sealant (110110)
2
1
48
Torque to
50 ft-lb (68 Nm)
824912
12
213
213
47
TI0042
1. Relieve pressure; page 3.
2. Flush pump, if possible. Relieve pressure. Stop
pump with piston rod (222) in its lowest position, if
possible. To lower piston rod manually, rotate
motor fan blades.
3. Remove filter (48).
4. 824912. Unscrew drain hose from inlet adapter
(43). Remove drain hose by unscrewing displace-
ment pump nipple (36).
5. 824910. Remove suction tube. Remove drain hose
by unscrewing from displacement pump
nipple (36).
6. Use a screwdriver to push retaining spring (15) up
and push out pin (14).
7. Loosen screws (17). Remove pump (18).
Repairing pump
See manual 308815 for displacement pump repair
instructions and parts.
Installing pump (See Fig. 8 and 9)
14
201
15
Fig. 9
202
7840A
1. Lightly grease or oil transducer (67). See Fig. 15.
Guide pump over alignment pins and pressure
transducer. Tap it into position with a soft hammer.
Tighten screws (17) to 50 ft-lb (68 Nm).
2. Align hole in rod (222) with connecting rod assem-
bly (12). Use screwdriver to push retaining spring
(15) up and push in pin (14). Push retaining spring
into place around connecting rod.
WARNING
MOVING PARTS HAZARD
Be sure retaining spring (18) is firmly in
groove all around, to prevent pin (14)
from working loose. See Fig. 9.
If pin works loose, parts (including pump connect-
ing rod or bearing housing) could project into the air
and cause serious injury or property damage.
3. Reconnect suction and drain hoses (47, 50). Install
front cover (11).
4. Tighten packing nut (202) enough to stop leakage,
but no tighter. Fill packing nut full with Graco TSL.
Push plug (201) into packing nut.

TI0043
Fig. 12
1
16
4
11
34
20
25
5
13
2
32
4
3
75
Torque to 80 in-lb (9 Nm)
A26
22
23
1
1
22a
70
12 309069
Motor
NOTE: See Fig. 12 except where noted.
1. Try to stop pump with piston rod (222) in lowest
position. To lower piston rod manually, remove
shroud (32) and rotate motor fan blades. Use a
screwdriver to push retaining spring (15) up and
push out pin (14). See Fig. 10.
2. Relieve pressure; page 3.
3. Remove motor shield (32).
4. Lift connecting rod. Remove screws (25, 26) and
lower heat sink (22) and motor control board (22a).
Disconnect motor wires and pressure transducer
wire (A) from motor control board. Remove heat
sink (22) and motor control board (22a), screws
(23), and junction box (20). Refer to Fig. 12 and 4.
5. Remove drive housing cover (11).
6. Turn displacement pump rod (222) so pin hole
aligns with bottom drive housing screw (16). See
Fig. 11. Remove three drive housing screws and
lockwashers (16, 4). See Fig. 11 and 12.
7. Remove two motor screws and lockwashers (3, 4).
8. Tap lower rear of drive housing (2) with a plastic
mallet to loosen motor. Pull drive housing straight
off motor while guiding pressure transducer wire
(A) from motor. Do not allow gear (13) to fall. Read
CAUTION on page 15.
9. Remove four screws (75) and lift motor off cart
(70).
10. Align new motor with cart and reinstall screws (75).
11. Assemble drive housing to motor. Follow steps 9
to 15 on page 15. Install junction box.
12. Connect wires to motor control board (22a). Refer
to Fig. 4. Install motor control board.
13. Connect piston rod (222) to drive housing; see
page 11, Installing Pump , Step 2 and WARNING
following it.
14. Install shroud (32) and drive housing cover (11).
15
14
Fig. 10 7840A
16
7840A
222
Fig. 11
4
12
trolls
t

309069 13
Pressure Control Repair
Motor control board removal/installation
1. Relieve pressure; page 3.
2. Remove screws (25, 26) and lower heat sink (22)
and motor control board (22a). See Fig. 12.
3. Disconnect wires (C), (D), (96), (E) and 108 from
motor control board (22a). See Fig. 4.
4. Disconnect potentiometer (77) and transducer (67)
from motor control board (22a).
5. Remove four screws and motor control board
(22a).
6. Install new motor control board (22a) with four
screws. Reconnect all wires and secure heat sink
(22) to junction box (20).
CAUTION
To reduce the risk of a malfunction:
 Be sure the flat blade of the insulated male
connector is centered in the wrap–around blade of
the female connector when the connections are
made.
 Route all wires carefully to avoid interference with
the motor control board or junction box.
Motor control board diagnostics
1. Relieve pressure; page 3.
2. Remove screws (25, 26) and lower heat sink (22)
and motor control board (22a). See Fig. 12.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
LED
BLINKS
SPRAYER OPERATION INDICATES WHAT TO DO
Once Sprayer runs Normal operation Do nothing
Twice Sprayer runs Normal operation Do nothing
Two times
repeatedly
Sprayer shuts down and LED continues
to blink two times repeatedly
Run away pressure.
Pressure greater than
4500 psi.
Replace motor control board.
See preceding Motor control
board removal procedure.
Three times
repeatedly
Sprayer shuts down and LED continues
to blink three times repeatedly
Pressure transducer
is faulty or missing
Replace pressure transducer
Four times
repeatedly
Sprayer shuts down and LED continues
to blink four times repeatedly
Line voltage is too
high
Lower line voltage to 120 VAC
Five times
repeatedly
Sprayer shuts down and LED continues
to blink five times repeatedly
Locked rotor. Motor
can not turn because
of some mechanical
condition.
Clear obstruction and replace
broken parts preventing motor
from turning

14 309069
Power Cord
1. Relieve pressure; page 3.
2. Remove screws (25, 26) and lower heat sink (22).
See Fig. 12.
3. Disconnect power cord leads (30), including green
wire to grounding screw (78). See Fig. 4.
4. Loosen strain relief bushing (29). Remove power
cord (30).
5. Install new cord (30) in reverse order of disassem-
bly.
6. Install heat sink (22). Be sure no leads are pinched
between heat sink and junction box (20).
On/Off Switch
1. Relieve pressure; page 3.
2. Remove screws (25, 26 ) and lower heat sink (22).
See Fig. 14.
3. Remove rubber boot (82). See page 20.
4. Disconnect black and brown wires from ON/OFF
switch (80) and remove switch. See Fig. 4.
5. Install switch so internal tab of anti–rotation ring
(81) engages with vertical groove in threads of
switch, and external tab engages with slot of
junction box. See page 20.
6. Powder inside of rubber boot (82) with talcum,
then shake excess out of boot. Install nut and
rubber boot and tighten.
7. Reconnect black and brown wires to ON/OFF
switch (80).
8. Install heat sink (22) with screws (25, 26 ).
See Fig. 14. Be sure no leads are pinched be-
tween motor control board or other components.
Pressure Adjusting Potentiometer
1. Relieve pressure; page 3.
2. Remove screws (25, 26 ) and lower heat sink (22).
See Fig. 14.
3. Remove potentiometer knob (27).
4. Remove shaft sealing nut (76).
5. Disconnect and remove potentiometer (77).
6. Install and connect new potentiometer (77).
7. Install shaft sealing nut (76).
8. Install potentiometer knob (27).
9. Install heat sink (22) with screws (25, 26 ).
See Fig. 14. Be sure no leads are pinched be-
tween motor control board or other components.

12
2
4, 3
6
5
7
22
2a
A
13
22a
Fig. 14
Note: Filter &
Displacement Pump
not shown
16
C
B
26
1Torque to 80 in-lb (9 Nm)
1
1
41
25
TI0044
309069 15
Drive Housing, Connecting Rod, Crankshaft
NOTE: Inspect parts as they are removed. Replace
parts that are worn or damaged.
1. Relieve pressure; page 3.
2. Remove displacement pump. See page 11.
3. Remove shroud (32).
4. Lower heat sink (22) and remove pressure trans-
ducer (67). See page 16.
Fig. 13 7840A
16
5. Remove three drive housing screws (16). Also see
Fig. 14.
6. Remove two motor screws and lockwashers (3, 4).
See Fig. 14.
CAUTION
Do not allow gear (13) to fall; gear may stay attached
to the drive housing or to the motor.
Do not lose the thrust balls (2a or 41) or let them fall
between the gears, which will damage the drive
housing if not removed. The balls, which are heavily
covered with grease, usually stay in the gear re-
cesses, but could be dislodged. If the balls are not in
place, the bearings will wear prematurely.
7. Tap lower rear of drive housing (2) with a plastic
mallet to loosen motor. Pull drive housing straight
off motor.
8. Remove and inspect crankshaft (5) and connecting
rod (12). Replace all damaged or worn parts.
9. Install connecting rod.
10. Lubricate inside of connecting rod bearing with
SAE non-detergent oil. Pack roller bearing and
gears with grease supplied.
NOTE: The gears and bearings between the drive
housing (2) and motor front end bell (C) should contain
a total of 3 fl oz (89 cc) of grease.
11. Place large washer (6) and then small washer (7)
on crankshaft (5).
12. Rotate crank to top of stroke and insert crankshaft
(5). Align gears and push drive housing (2) straight
onto motor and locating pins. Install screws (16, 3)
and their lockwashers (4). Torque to 80 in-lb (9
Nm).
13. Plug in pressure transducer. See page 16.
14. Install displacement pump. See page 11.
15. Install front cover (11).
16. Replace shroud (32).
17. Replace heat sink (22).

16 309069
Pressure Transducer
NOTE: See Fig. 14 and 15 for this procedure.
NOTE: The pressure transducer (67) cannot be re-
paired or adjusted. If it malfunctions, replace it.
Removal
1. Relieve pressure; page 3.
2. Remove displacement pump (18). See page 11.
3. Remove front cover (11). Remove screws (25, 26).
Lower heat sink (22).
4. Disconnect harness connector from motor control
board (22a). Remove grommet (65).
5. Remove retaining ring (66). Pull pressure trans-
ducer down and out past drive housing (2).
6. Guide harness (A) through motor and drive hous-
ing and remove pressure transducer.
7. Inspect spacer (68) and seal (69) for damage.
Replace seal (69) only if it is cut, nicked, or if
leakage occurred. See page 16.
Installation
1. Using a small piece of solid copper or mild steel
wire (approximately 12 in.), form a small hook and
place it in the passage of bottom of the motor.
Guide it up and out the hole in the drive housing.
2. Pass a spacer (68) over harness connector (A)
and down into position at bottom of transducer
(67).
3. Guide harness up through leg and notch of drive
housing (2). Secure guide wire over connector.
4. While pulling guide wire out through bottom of
motor, guide harness through drive housing and
motor castings.
5. Place grommet (65) over harness and push into
position in drive housing hole.
6. Feed excess harness cable through grommet and
fully seat transducer body into hole in drive
housing leg. Secure it with retaining ring (66).
7. Attach connector to motor control board (22a).
Replace cover (11) and heat sink (22). Ensure no
wires are pinched between components.
02996A
Fig. 15
67
65
66
A
68
69
Pressure Transducer Seal
NOTE: PTFE seal is unaffected by most solvents and
materials. Replace seal only when leakage occurs.
Removal
1. Relieve pressure; page 3.
2. Remove displacement pump (18). See page 11.
3. Remove seal (69) from recess in manifold (229).
4. Clean manifold recess with solvent and cloth or
cotton swabs. Inspect for nicks or scratches.

309069 17
Pressure Transducer Seal
Installation
1. Lightly coat cleaned packing recess in manifold
with a light grease or oil.
2. Heat seal (69) in hot water for several minutes.
CAUTION
Excess pressure from the probes or fingernails will
damage the packing and cause subsequent leakage.
3. Use a blunt wooden or plastic probe and install
seal (69) into recess in manifold (229). Be careful
not to cause kinks or bends in packing during
installation.
4. Lightly grease or oil transducer (67) and install
pump (18). See page 11.
229
Fig. 16
69
TI0045

18 309069
Drain Valve
1. Relieve pressure; page 3.
2. Turn handle (54) to closed position. Drive out pin
(53). Remove handle.
3. Remove base (52).
4. Unscrew drain valve assembly (51). gasket (55)
and seat (56) will stay in valve.
53
56
52
54
Apply thread sealant
Handle shown in closed position
Apply grease to face of base
Torque into pump manifold to
140 in-lb (16 Nm)
51
55
Fig. 17 7839A
1
3
4
2
1
2
3
4
Repair
1. Unscrew spring retainer from valve body. Remove
spring, washers and stem/ball. Clean any debris
from ball or seat area.
2. If replacing gasket (55) or seat (56), pry out gas-
ket.
NOTE: Whenever gasket (55) is removed, replace it
with a new one.
3. Place seat (56) in drain valve assembly (51) so
lapped side is toward ball. Apply a small amount of
grease to new gasket (55) and install it in drain
valve assembly.
NOTE: The gasket will protrude from the end of the
valve until the valve is tightened into pump, which
correctly seats the gasket.
Replacement
1. Apply a small amount of thread sealant (110110)
onto drain valve assembly (51) threads. Tighten
the valve into the pump manifold (229) to 185 in-lb
(21 Nm).
2. Lightly grease face of base (52) and install base.
Turn stem so pin hole is vertical.
3. Securely install handle (54) and drive pin (53).

309069 19
Technical Data
Power Requirements 120 VAC, 60 Hz,. . . . . . . . . . . . .
1 phase, 15A minimum
Generator 3000W minimum. . . . . . . . . . . . . . . . . . . . . . .
Working Pressure Range 0–3000 psi. . . . . . . . . . . . . . .
(0–207 bar, 0–20.7 MPa)
Motor 0.9 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with latex at 2000 psi (138 bar, 13.8 MPa)
Cycles/Gallon (liter) 566 (150). . . . . . . . . . . . . . . . . . . . .
Maximum Delivery Rating 0.6 gpm (2.3 lpm). . . . . . . .
Tip Size one gun to 0.026 new tip. . . . . . . . . . . . . . . . . .
with latex at 2000 psi (138 bar, 13.8 MPa)
Power Cord 14 AWG, 3 wire, 15 ft (4.5 m). . . . . . . . . . .
Inlet Paint Strainer 16 mesh (975 micron). . . . . . . . . . . .
Stainless Steel Screen, reusable
Outlet Filter 60 mesh (238 micron). . . . . . . . . . . . . . . . . .
Pump Inlet Size 3/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Outlet Size 1/4 npsm. . . . . . . . . . . . . . . . . . . . . . . .
Sound Data:
Sound Pressure Level 82dB(A)*. . . . . . . . . . . . . . . . . .
Sound Power Level 91dB(A)*. . . . . . . . . . . . . . . . . . . .
*Measured while spraying with a .017 tip per ISO–3744
Wetted Parts: Zinc-plated carbon steel,. . . . . . . . . . . . .
Aluminum, Stainless steel,
Polyethylene, Delrin, Leather
Tungsten carbide, Chrome plating, Polyurethane
NOTE:  and Delrin are trademarks of the Company.
Dimensions
824912 824910
Weight (dry w/o packaging) 69 lb (31 kg). . . . . . . . . . . .
Length (handle collapsed) 27 in. (686 mm). . . . . . . . . .
Width 19.5 in. (495 mm). . . . . . . . . . . . . . . . . . . . . . . . . .
Height (handle collapsed) 22 in. (559 mm). . . . . . . . . . .
Weight (dry w/o packaging) 73 lb (33.1 kg). . . . . . . . . .
Length 21 in. (533 mm). . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 20.5 in. (521 mm). . . . . . . . . . . . . . . . . . . . . . . . . .
Height (Handle Down) 28.5 in. (711 mm). . . . . . . . . . . .
Accessories
DANGER LABELS
An English language DANGER label is on your sprayer.
If you have painters who do not read English, order one
of the following labels to apply to your sprayer . The
drawing below shows the best placement of these
labels for good visibility.
Order the labels directly from Graco, free of charge:
1–800–328–0211
French 187784
Spanish 185956
German 185961
Greek 186041
Korean 186045
English 187791
Apply other
language here
TI0038
PTFE

20 309069
Sprayer Parts
49 44
911
48
47 50
53
52
18
36
54
51
46
6
5
2a 13
741
2
12
14
15
25
39
38
40
70
37
31
32
57
42
26
22
16
65
75
85
3
4
960
23
24
20
21
68
67
69
66
74
71
72
19
73
824912, B
Pressure Control Box
(Bottom View)
76
77
27
78
82
81
80
17
55 56
28
22a
33
103
64
99
95
97
67 Ref
30 Ref
78
22a
96
107
108
77 Ref
80 Ref
71
47 Ref 50 Ref
109
43
TI0047