Sherwin-Williams 820169 D Series User manual

OWNER’S
MANUAL
824113
Rev A
Related Manuals
Operator 824112. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308190. . . . . . . . . . . . . . . . .
FTx Spray Gun 308645. . . . . . . . . . . . . . . . . . . . .
Spray Tip 308644. . . . . . . . . . . . . . . . . . . . . . . . . . .
All models are not available in all countries
U.S. PATENT NO. 4,323,741; 4,397,610 PATENTED
1983, CANADA AND OTHER PATENTS PENDING
Model 820169
8733
Model 824175
INSTRUCTIONS-REPAIR
SUPER NOVAtSP
ELECTRIC, AIRLESS PAINT SPRAYER
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
Model 820169, Series D
Complete sprayer with hose, gun,
RAC IVrDripLesstTip Guard and SwitchTipt
Model 824175, Series A
Upright cart; complete sprayer with hose, gun,
RAC IVrDripLesstTip Guard and SwitchTipt,
tool box
Table of Contents
Component Function and Identification 2. . . . . . . . . . . .
General Repair Information 3. . . . . . . . . . . . . . . . . . . . . .
Grounding 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 10. . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 12. . . . . . . . . . . . . . . . . . . . .
Motor Replacement 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Start Board 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 15. . . . . .
Pressure Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Hose 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 820169 Sprayer Parts Drawing 19. . . . . . . . . . . .
Model 820169 Sprayer Parts List 20. . . . . . . . . . . . . . . .
Model 824175 Sprayer Parts Drawing 21. . . . . . . . . . . .
Model 824175 Sprayer Parts List 22. . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sherwin-Williams Warranty 24. . . . . . . . . . . . . . . . . . . . .
The SHERWIN-WILLIAMS COMPANY, CLEVELAND, OHIO 44115
ECOPYRIGHT 1998, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

2824113
06973
Component Identification and Function
C
Fig. 1
G
E
F
D
A
M
B
J
L
Model 820169 Shown
K
H
N

AMotor DC motor, 120 Vac, 15A, 1 phase
BDrive Assembly Transfers power from DC motor to the displacement pump
CPressure Adjusting Knob Controls fluid outlet pressure
DON/OFF Switch Power switch that controls 120 Vac power to sprayer
EFluid Outlet Hose and spray gun is connected here
FDisplacement Pump Pressurizes fluid to be sprayed through spray gun
G50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
HRAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection inju-
ry
JContractor Gun High pressure spray gun with gun safety latch
KRAC IV Switch Tip RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
LPressure Drain Valve Relieves fluid pressure when open
MPressure Control Controls motor to maintain fluid pressure. Works with pressure
adjusting knob.
NSpray Gun Safety Latch Inhibits accidental triggering of spray gun

3824113
General Repair Information
CAUTION
To reduce risk of pressure control malfunction:
Useneedlenoseplierstodisconnectawire.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
otherconnectionsofpressurecontrol.Donotpinch
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 Guide,
page 5, 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 supply 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.

4824113
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. Models 820169 and 824175 require a 120 VAC,
50/60 Hz, 15A circuit with a grounding receptacle.
See Fig. 2.
2. Do not alter ground prong or use adapter.
Fig. 2
Grounding Prong
Grounded
Outlets
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.

5824113
Troubleshooting
Relieve pressure;page 3.
Basic Problem Solving
Check everything in the troubleshooting table before disassembling the sprayer.
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. The pump won’t
develop much pressure if it is at minimum set-
ting (fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. For clogged spray tip or fluid filter, if used. See
manual 308645 or 308664. 2. If tip is still clogged, relieve pressure; re- fer to separate gun or tip instruction man-
ual for tip cleaning. Clean or replace filter
element. See manual 308249.
Mechanical 1. For frozen or hardened paint in pump (20). Us-
ing a screwdriver, carefully try to rotate fan at
back of motor by hand. See page 9.
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 thawed completely. If paint
hardened (dried) in sprayer, replace
pump packings. See page 12
(Displacement Pump Repair).
2. Dixplacement pump connecting rod pin (17).
Pin must be completely pushed into connecting
rod (15), and retaining spring (18) must be
firmly in connecting rod groove. See Fig. 9,
page 12.
2. Push pin into place and secure with
spring retainer.
3. For motor damage. Remove drive housing as-
sembly (11). See page 15. Try to rotate motor
fan by hand.
3. Replace motor (4) if fan won’t turn. See
page 13.
Electrical 1. Electrical supply. Meter must read:
105–125 VAC for models 820169 and 824175. 1. Reset building circuit breaker; replace building fuse. Try another outlet.
2. Extension cord for visible damage. Use a volt
meter or test lamp at extension cord outlet to
check.
2. Replace extension cord.
3. Sprayer power supply cord (50) for visible dam-
age such as broken insulation or wires. 3. Replace power supply cord. See page 14.
4. Check 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.
NOTE: The 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.
long.

6824113
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) 5. Motor armature commutator for burn spots,
gouges and extreme roughness. Remove mo-
tor cover and brush inspection plates to check.
See page 10.
5. Remove motor and have motor shop
resurface commutator if possible. See
page 13.
6. Motor armature for shorts using armature tester
(growler) or perform motor test.
See page 9.
6. Replace motor. See page 13.
7. Leads from pressure control and motor to mo-
tor start board (47) to be sure they 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 start board (47) by substituting with a
good board. See page 14.
CAUTION: Do not perform this check until mo-
tor armature is determined to be good. A bad
motor armature can burn out a good board.
8. Replace board. See page 14.
9. Power supply cord (50). Disconnect black and
white power cord terminals; connect volt meter
to these leads. Plug in sprayer. Meter must
read: 105–125 VAC for models 820169 and
824175. Unplug sprayer.
9. Replace power supply cord. See page
14.
10.ON/OFF switch (52). Disconnect the motor
start board (47) and switch and connect volt
meter between exposed terminal on switch and
power cord’s white wire. Plug in sprayer and
turn ON.Meter must read: 105–125 VAC for
models 820169 and 824175.
10.Replace ON/OFF switch. See page 14.
11. Motor thermal cutout switch. Connect ohmme-
ter between motor’s red leads. Meter should
read 1 ohm maximum.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12.Remove pressure control (64) and check mi-
croswitch operation with ohmmeter:
(1) With pressure knob at lowest setting and
stem pushed into control, readings should
be: white & black = 1 ohm max.
white & red = open.
(2) With pressure knob at highest setting,read-
ings should be: white & black = open;
white & red = 1 ohm max.
12.Replace pressure control. See page 16.
13.Pressure transducer (29) for hardened paint or
damaged or worn components. See page 17. 13.Replace transducer. See page 17. Thor- ough system flushing will help extend life
of transducer.
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 then
replace tip. See your separate gun or tip
manual.
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and turn
on sprayer. Prime with paint. Trigger gun mo-
mentarily, then release and lock safety latch.
Relieve pressure, turn off and unplug sprayer.
2. Service pump. See page 12.

7824113
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 (continued) 3. Release gun trigger. Observe resting position of
pump rod (107). 3. If pump consistently comes to rest with rod (107) fully extended, the piston pack-
ings and/or piston valve may be worn.
Service the pump. See page 12.
4. Electrical supply. Meter must read: 105–125
VAC for models 820169 and 824175. 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 gauge wire and less than 150 ft
(45 m) long.
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.
7. Motor start board (47) by substituting with a
good board.
CAUTION: Do not perform this check until mo-
tor armature is determined to be good. A bad
motor armature can burn out a good board.
7. Replace board. See page 14.
8. Motor armature for shorts by using an armature
tester (growler) or perform motor test. See page
9.
8. Replace motor. See page 13.
Drain valve leaks 1. Drain valve for correct torque and/or worn
parts. Check for debris trapped on seat. 9. Tighten to 185 in–lb (21 N.m). Clean valve and replace with new gasket (42a)
and sealant (42d). See page 18.
Transducer leaks 1. Slight leakage from transducer is normal. 1. Periodically remove residue from its cyl-
inder port. See page 17.
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. See
page 17. 3. Tighten; use thread sealant on npt threads of adapter (38).
4. To see if intake valve ball and piston ball are
seating properly. See page 12. 4. Remove intake valve and clean. Check ball and seat for nicks; replace as need-
ed. See page 12. 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 12.
5. Replace packings. See page 12. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut/wet-cup.
6. Release gun trigger. Observe resting position of
pump rod (107). 6. If pump consistently comes to rest with rod (107) fully extended, the piston pack-
ings and/or piston valve may be worn.
Service the pump. See page 12.
No output: motor runs but
pump does not stroke 1. Displacement pump connecting rod pin (17).
See Fig. 9, page 12. 1. Replace pin if missing. Be sure retainer spring (18) is fully in groove all around
connecting rod.
7. Connecting rod assembly (15) for damage.
See page 15. 7. Replace connecting rod assembly. See page 15.
8. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off
and unplug sprayer. See page 15.
8. Check drive housing assembly for
damage and replace if necessary. See
page 15.

8824113
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 1. Spray tip worn beyond sprayer pressure capa-
bility. 1. Replace spray tip.
NOTE: A smaller size tip will provide
longer life.
2. Transducer (29) for wear or damage. 2. Replace transducer. See page 17.
3. Pressure control (64) for smooth operation. 3. Replace pressure control. See page 16.
4. Low output section, page 7.
Motor Is Hot and Runs
Intermittently 1. Determine if sprayer was operated at high pres-
sure 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 13.
Building Circuit Breaker
Opens As Soon As
Sprayer Switch Is
Turned On.
1. All electrical wiring for damaged insulation, and
all terminals for loose fit or damage. Also check
wires between pressure control and motor. See
page 13.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. For missing motor brush inspection plate gas-
ket (see page 9), 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 13.
4. Motor start board (47) 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.
4. Replace board. See page 14.
Circuit breaker opens
after sprayer operates
for 5 to 10 minutes.
1. Basic Problems – Electrical on page 5.
Building circuit breaker
opens as soon as sprayer
is plugged into outlet and
sprayer is NOT turned on.
1. ON/OFF switch (52). Be sure sprayer is un-
plugged!
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 start board (47).
1. Replace ON/OFF switch. See page 14.
2. Electrical supply. Meter must read: 105–125
VAC for models 820169 and 824175. 2. If voltage is too high, do not operate sprayer until corrected.
Unit will not run on gener-
ator but does run on AC
power
Generator peak voltage. Models 820169 and
824175.willnotrunifthepeakvoltageisabove190V. Use AC power or a differentgenerator

9824113
Motor Test
Relieve pressure;page 3.
For checking armature, motor winding and brush
electrical continuity.
Setup
Remove the drive housing. See page 15. This is to
ensure that any resistance you notice in the armature
test is due to the motor and not to worn gears in the
drive housing.
Remove the motor brush inspection covers (A). See
Fig. 3.
Remove the junction box screws (56). Lower the
junction box. Disconnect the two leads (C) from the
motor to the board (47). See Fig. 4.
Armature Short Circuit Test
Remove the fan cover (B). See Fig. 3.
Spin the motor fan by hand. If there are no shorts, the
motor will coast two or three revolutions before coming
to a complete stop. If the motor does not spin freely,
the armature is shorted and the motor must be re-
placed. See page 13.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
Connect the two black motor leads together with a test
lead. Turn the motor fan by hand at about two revolu-
tions per second.
When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is irregular
turning resistance, or no turning resistance, check and
repair the following as needed: broken brush springs,
brush leads, motor leads; loose brush terminal screws
or motor lead terminals; worn brushes. See page 10.
If there is still uneven or no turning resistance, replace
the motor. See page 13.
06975
Fig. 3
A
B
Model 820169 Shown
Fig. 4
MOTOR
BLACK/
WHITE
BLACK
C
59 RED
47
04720
56

10 824113
Motor Brush Replacement
NOTE: Replace brushes when worn to about 0.5 in.
(12.5 mm). Always check both brushes. Brush Repair
Kit 236–967, which includes spring clip 112–766, is
available for motors manufactured by Pacific Scientific.
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).
Relieve pressure;page 3.
1. Remove both inspection covers (A) and their
gaskets. See Fig 5.
Fig. 5
A
02831A
2. Push in the spring clip (F) and release its hook (G)
from the brush holder (B). Pull out the spring clip.
See Fig 6.
3. Slide off the brush lead terminal (E) off the blade
connector. Remove the old brush (C). See Fig 6.
Fig. 6
F
G
E
D
C
B
H


Motorlead; do not disconnect
Minimum0.5”(12.5mm)

Includedin BrushRepair
Kit236–967


4. Inspect the commutator for excessive pitting,
burning or gouging. A black color on the commuta-
tor is normal. Have the commutator resurfaced by
a qualified motor repair shop if the brushes seem
to wear too fast or arc excessively. See Step 9.d.,
also.
5. Repeat for the other side.
NOTE: The motor brushes on the other side are
upside down.
6. Place a new brush (C) in the holder (B) so the
ramp (H) faces the spring. See Fig. 16.
Fig. 7 

G
C
E
F
7. Holding the spring clip (F) at a slight angle, slide
the spring clip into the brush holder and hook it
over the end of the holder. See Fig. 7. Pull on the
spring clip to be sure it stays in place. Connect the
brush lead to the blade connector (E).
8. Repeat for the other side.

11824113
Motor Brush Replacement
9. Test the brushes.
a. Remove the pump connecting rod pin (17).
See Fig. 9, page 12.
b. With the sprayer OFF, turn the pressure con-
trol knob fully counterclockwise to minimum
pressure. Plug in the sprayer.
c. Turn the sprayer ON. Slowly increase the
pressure until the motor is at full speed.
d. Inspect the brush and commutator contact area
for excessive arcing. Arcs should not trail or
circle around the commutator surface.
WARNING
MOVING PARTS 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 injury.
10. Install the brush inspection covers and gaskets.
11. Break in the brushes. Operate the sprayer for at
least one hour with no load. Install the pump
connecting rod pin. See Fig. 9, page 12.

12 824113
Displacement Pump Repair
Relieve pressure;page 3.
NOTE: Packing Repair Kit 235703 is available. Refer-
ence numbers of parts included in the kit are marked
with an asterisk, i.e., (121*). For the best results, use
all the new parts in the kit, even if the old ones still look
good.
NOTE: To minimize down time, and for the best sprayer
performance, check the motor brushes (see page 10)
and clean the transducer (see page 17) whenever you
repack the pump. Replace these parts as needed.
Removing the pump (See Fig. 8.)
1. Flush the pump, if possible. Relieve pressure. Stop
the pump with the piston rod (107) in its lowest
position, if possible. To lower the piston rod manu-
ally, rotate the motor fan blades.
2. Remove the filter (85).
3. Remove suction hose or tube (32).(For suction
hose, refer to page 17.
4. Use a screwdriver to push the retaining spring (18)
up and push out the pin (17).
5. Loosen the screws (21). Remove the pump (20).
Repairing the pump
See manual 308190 for pump repair instructions.
Installing the pump (See Fig. 8 and 9.)
1. Mount the pump on the drive housing. Tap it into
the alignment pins with a soft hammer. Tighten the
screws (21) to 50 ft-lb (68 N.m).
WARNING
MOVING PARTS HAZARD
Be sure the retaining spring (18) is firmly
in the groove all the way around, to pre-
vent the pin (17) from working loose due
to vibration. See Fig. 9.
If the pin works loose, it or other parts could break
off due to the force of the pump action. These parts
could be projected into the air and result in serious
injury or property damage, including the pump
connecting rod or drive housing.
2. Align the hole in the rod (107) with the connecting
rod assembly (15). Use a screwdriver to push the
retaining spring (18) up and push in the pin (17).
Push the retaining spring (18) into place around
the connecting rod.
3. Replace the o-ring (27) if it is worn or damaged.
Reconnect the suction and drain hoses (32,33).
Install the front cover (13).
4. Tighten the packing nut (102) just enough to stop
leakage, but no tighter. Fill the packing nut/wet-cup
1/3 full with Graco TSL. Push the plug (123) into
the wet-cup.
02832B
Fig. 8


Torqueto
50 ft–lb (68 N.m)
Applyanaerobic
polycrystalpipe
sealant
118 *119
*121
*122
120
17
18
20

33
32
38
21

13
107
36
Model 820169 Shown
27
85
Fig. 9
17
18
123
15
102
Torqueto
50 ft–lb (68 N.m)


21

13824113
Motor Replacement
Relieve pressure;page 3.
NOTE: See Fig. 12 except where noted.
1. Relieve pressure.
2. Try to stop the pump with the piston rod (107) in its
lowest position. To lower the piston rod manually,
rotate the motor fan blades. Use a screwdriver to
push the retaining spring (18) up and push out the
pin (17). See Fig. 10.
3. Remove the screws (56) and lower the junction
box (59). Disconnect the motor wires and the
pressure control wire (A) from the motor start
board. Refer to Fig. 13 on page 14.
4. Remove the front cover (13).
5. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 11. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 12.
6. Remove the two motor screws (5) and the lock
washers (6).
7. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
housing straight off the motor while guiding the
harness (A) from the motor. Do not allow the gear
(16) to fall. Read the CAUTION on page 15.
8. Remove the two screws (46) and lift the motor off
the base (66).
9. Align the new motor with the base and reinstall the
screws (46).
10. Assemble the drive housing to the motor. Follow
steps 8 to 10 on page 15.
11. Connect the wires in the junction box. Refer to Fig.
13 on page 14. Install the junction box.
12. Connect the piston rod (107) to the drive housing;
see page 12, Installing the Pump, Step 2 and the
WARNING following it.
17
18
15
Fig. 10 01068
107
19,6
Fig. 11 01074
Torqueto 2.4 N.m (21 in–lb)
05119
Fig. 12


Quantityof three
Quantityof one
19
6
13
34
31
59
56
12 16
11
4
5
6
46
BC
A





14 824113
Motor Start Board
Relieve pressure;page 3.
NOTE: See Fig. 13 for this procedure.
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Disconnect the motor wires (B) and the 3-wire
connector (A) from the motor start board (47).
Observe where connections are made.
4. Remove the screws (58) and motor start board
(47). Transfer the white thermal paste from the old
board to the new board.
5. Install the new motor start board. Reconnect all
wires. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
CAUTION
Be sure the flat blade of the insulated male connec-
tor 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 start board or junction box.
These precautions are essential to reduce the risk of
a malfunction.
Power Supply Cord
NOTE: See Fig. 13 for this procedure.
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Disconnect the power supply cord leads, including
the green wire to the grounding screw (49).
4. Loosen the strain relief bushing (51). Remove the
power supply cord (50).
5. Install the new cord (50) in the reverse order of
disassembly.
6. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
On/Off Switch
NOTE: See Fig. 13 for this procedure.
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Remove the nut and rubber boot (55).
4. Disconnect the black wires from the ON/OFF
switch (52) and remove the switch.
5. Place the ring terminal of the ground wire (53) over
the barrel of the new switch. Install the switch so
the internal tab of the anti-rotation ring (54) en-
gages with the vertical groove in the threads of the
switch, and the external tab engages with the blind
hole (C) of the junction box.
6. Powder the inside of the rubber boot (55) with
talcum, then shake the excess out of the boot.
Install the nut and rubber boot and tighten.
7. Reconnect the ON/OFF switch black wires.
8. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
52

56
BLACK
47
5455
53
50
51
49
GREEN
MOTOR
BLACK/
WHITE
59
58 RED
A
B
GREEN/
YELLOW
C
Fig. 13
89

15824113
Drive Housing, Connecting Rod, Crankshaft
Relieve pressure;page 3.
Removal
NOTE: Inspect parts as they are removed. Replace
parts that are worn or damaged.
1. Remove the displacement pump. See page 12.
2. Remove the pressure control (64). See page 16.
3. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 14. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 15
on page 16.
107
19,6
Fig. 14 01074
4. Remove the two motor screws (5) and lock wash-
ers (6). See Fig. 15 on page 16.
5. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
housing straight off the motor.
CAUTION
Do not allow the gear (16) to fall; it may stay at-
tached to the drive housing or to the motor.
Do not lose the thrust balls (11a or 4a) or let them fall
between the gears, which will damage the drive hous-
ingifnotremoved.Theballs,whichareheavilycovered
with grease, usually stay in the gear recesses, but
could be dislodged. If the balls are not in place, the
bearings will wear prematurely.
6. Remove and inspect the crankshaft (12) and the
connecting rod (15).
Installation
7. Install the connecting rod.
8. Lubricate the inside of the drive housing bearing
with SAE non-detergent oil. Pack the roller bearing
and gears with the grease supplied.
NOTE: The gears and bearings between the drive
housing (11) and motor front end bell (C) should con-
tain a total of 3 fl. oz. (29 cc) of grease.
9. Place the large washer (12a) and then the small
washer (12b) on the crankshaft (12).
10. Lift the crank to the top of the stroke and insert
crankshaft (12). Align the gears and push the drive
housing (11) straight onto the motor and the locat-
ing pins. Install the screws (19, 5) and their lock-
washers (6). Torque to 80 in–lb (9 N.m).
11. Install the displacement pump. See page 12.
12. Install the pressure control (64). See page 16.
Install the front cover (13).

16 824113
Drive Housing, Connecting Rod, Crankshaft
Torqueto 2.4 N.m (21 in–lb)
Fig. 15


Quantityof three
Quantityof one
Apply a total of 3 fl. oz.(29 cc)
of grease to gears.

56
6
19
15
13
64
11
5,6
12a 12
12b
59
11a
4a
A
34
31
REF A 16
47
Note: Filter
not shown
02815





C
Pressure Control
Relieve pressure;page 3.
NOTE: See Fig. 16 for this procedure.
NOTE: The pressure control (64) cannot be repaired
or adjusted. If it has malfunctioned, replace it.
1. Remove the front cover (13). Remove the screws
(56). Lower the junction box (59).
2. Disconnect the harness connector (A) from the
motor start board (47).
3. Remove the screws (63). Pull forward on the
pressure adjusting knob and tip the pressure
control (64) forward and up to detach it from the
drive housing (11).
4. Guide the harness (A) through the motor and drive
housing and remove the pressure control.
5. Guide the harness of the new pressure control
through the drive housing and motor passages.
6. Install the new pressure control. Tip the pressure
control down and back into the drive housing (11).
Do not pinch or damage the harness (A).
7. Loosely install the screws (63) and then torque
them to 21 in–lb (2.4 N.m).
8. Install the front cover (13). Connect the harness
(A) to the motor start board (47).
9. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board.
64 63
59
56
A
13
11
Torqueto
21in–lb (2.4N.m)
Fig. 16


02816A

17824113
Pressure Transducer
Relieve pressure;page 3.
NOTE: See Fig. 17 for this procedure.
1. Remove the displacement pump. See page 12.
2. Use a pull–twist motion to remove the transducer
(29) from the pump manifold (101).
3. Clean paint residue from the hole in the manifold;
do not scratch the surface of the hole.
4. Lightly apply oil to the o-ring of the new transducer.
5. Install the transducer in the pump manifold, while
guiding the o-ring and backup ring into place.
6. Align the holes in the transducer as shown by the
arrows in Fig. 17.
7. Install the displacement pump. See page 12. Fig. 17 02817A
101
29
Suction Hose
Model 820169
Relieve pressure;page 3.
1. Remove the drain hose (33) from the clip. Remove
the front cover (13).
2. Pull upward on the hose (32) while unscrewing it
from the inlet tube (38). The hose coupling (A)
threads will engage and the hose will separate
from the tube.
3. Replace the o–ring (27) if it is worn or damaged.
4. Lubricate the o–ring (27) and the inlet tube (38)
threads with light grease.
5. Align the suction hose coupling with the threads of
the inlet tube (38). Tighten the hose onto the tube at
least 4 turns to ensure that the threads have disen-
gaged and can function as a swivel joint.
CAUTION
Misalignment or cross-threading will damage the
parts and/or create shavings which can cause the
o–ring (27) to leak.
06978
33
32
36
38
27
13
A
Fig. 18
Lubricate

Note:Filter
notshown
Model 820169 Shown

18 824113
Drain Valve
Relieve pressure;page 3.
44
42a42b
43
45
Applythread sealant
Handleshown
inclosedposition
Applygrease
to face of base
42
Torque intopump
manifoldto 185in–lb
(21N.m)
42c
42d
Fig. 19 02819








1. Turn the handle (45) to the closed position. Drive
out the pin (44). Remove the handle.
2. Remove the base (43).
3. Unscrew the drain valve (42). The gasket (42a)
and seat (42b) will stay in the valve.
Repair
1. Unscrew the spring retainer from the valve body.
Remove the spring, washers and stem/ball. Clean
any debris from the ball or seat area.
2. If replacing the gasket (42a) or seat (42b), pry out
the gasket.
NOTE: Whenever the gasket (42a) is removed, re-
place it with a new one.
3. Coat the o-ring (42d) with grease. Press the stem
into the valve body. Install the spring, washers and
spring retainer into the valve body.
4. Place the seat (42b) in the valve body so the
lapped side is toward the ball. Apply a small
amount of grease to the new gasket (42a) and
install it in the valve body.
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 (42e) onto
the valve (42) threads. Tighten the valve into the
pump manifold to 185 in–lb (21 N.m).
2. Lightly grease the face of the base (43) and install
the base. Turn the stem so the pin hole is vertical.
3. Securely install the handle (45) and drive pin (44).

19824113
Sprayer Parts Drawing
OUT-
SIDE
LABEL
42a
42b 42c
42d
Model 820169, Series D
33
20
4a
12
18
15
16
45
37
29
32
25
12b
12a
64
30
5
19 6
17
31
34 21
38
36
46
4
39
28
56
43
42
4e
44
REF 32
REF 33
11
23
63
67
74
11b
14
4g
INSIDE
LABEL
35
4f
Seedetail
onpage 20 24


Label



89
50
13 66

11a
36
23
27
26
06974

20 824113
Sprayer Parts List
Model 820169, Series D
Ref.
No. Part No. Description Qty. Ref.
No. Part No. Description Qty.
3 111700 GRIP, handle 1
4{237458 MOTOR KIT
Includes items 4a to 4f 1
4a 100069 . BALL, sst, 1/4” dia. 1
4b 111616 . TERMINAL, flat, 1/4” (f), 18 awg 2
4c 107503 . TERMINAL, 3/16” (m), 16 awg 2
4dY187784 . LABEL, DANGER, French 1
4eY187791 . LABEL, DANGER, English 1
4fY187975 . LABEL, WARNING, electric shock 1
5 100643 SCREW, socket head, 1/4–20 x 1” 2
6 105510 LOCKWASHER, 1/4” 5
11 224965 DRIVE HOUSING KIT 1
Includes item 11a, 11b
11a 100069 . BALL, stainless steel, 1/4” dia. 1
11b 111726 . PLUG 1
12 224803 CRANKSHAFT 1
Includes items 12a, 12b
12a 180131 . BEARING, thrust 1
12b 107434 . BEARING 1
13 187789 COVER, front 1
14Y177762 LABEL, WARNING 1
15 218359 CONNECTING ROD 1
16 218364 GEAR REDUCER 1
17 176818 PIN, headless, 3/8” dia. x 1” 1
18 176817 SPRING, retaining 1
19 103345 SCREW, socket head, 5
1/4–20 x 1–1/4”
20 235699 PUMP KIT 1
See manual 308190 for parts
21 111706 CAPSCREW, 7/16–14 x 1–3/4” 2
23 111715 SCREW, 5/16–18 x 1–1/4” 6
24 192166 HANDLE, sprayer 1
25 112759 CAP, tubing 4
26 239276 LEG, with gusset 1
27H104938 O–RING 1
28 162453 NIPPLE, hex, 1/4 npsm x 1
1/4 npt, 1–3/16”
29 235009 PRESSURE TRANSDUCER 1
30 114026 CLIP, spring 1
31 108850 SCREW, filh, 8–32 x 1–1/4” 1
32 187624 SUCTION HOSE & TUBE 1
33 187652 DRAIN HOSE 1
34 111705 SCREW, filh, 8–32 x 2–1/2” 3
35 824172 LABEL, identification 1
36 111612 ADAPTER, tube, 9/16–18 1
37 187895 LEG, sprayer 2
38 192167 INLET TUBE 1
39 235004 STRAINER 1
42 235014 DRAIN VALVE KIT 1
Includes items 42a to 42e
42a 111699 . GASKET, valve seat 1
42b 187615 . SEAT, drain valve 1
42c 224968 . STEM, drain valve 1
42dH168110 . O–RING, stem 1
42e 110110 . SEALANT, pipe (not shown) 1
43 224807 BASE, valve 1
44 111600 PIN, grooved, 3/32 x 1” 1
45 187625 HANDLE, drain valve 1
46 110997 SCREW, washer/hex hd, 5/16” 2
47 235707 MOTOR START BOARD 1
48Y186620 LABEL, ground terminal 1
49 110037 SCREW, mach, pnhd, 10–24 x 5/8” 1
50 235010 POWER CORD SET 1
51 111617 STRAIN RELIEF BUSHING, 1
3/8–18 npt
52 105679 SWITCH, ON/OFF 1
53 235035 GROUND HARNESS 1
54 105658 LOCKING RING 1
55 105659 BOOT, switch 1
56 111703 SCREW, filh, 10–24 x 3” 4
58 100035 SCREW, pan hd, 8–32 x 5/16” 2
59 187795 JUNCTION BOX 1
63 111704 SCREW, filh, 10–24 x 1–5/8” 2
64 239515 PRESSURE CONTROL KIT 1
66 189932 BASE, motor 1
67 238350 CONTRACTOR FTx GUN 1
See manual 308645 for parts
68 206994 TSL, 8 oz. (not shown) 1
74 238361 HOSE, grounded, nylon; 1/4” ID; 1
cpld 1/4 npsm(f); 50 ft (15 m);’
spring guards both ends
89 187963 GASKET 1
Y
Extra warning labels available free of charge.
{ Motor Brush and Spring Replacement Kit,
236967 is available. Purchase separately.
H Replace Ref. No. 27 with 114048 and Ref. No. 42d with
112319 if using severe solvents such as lacquer thinner and
acetone.

52
47
5455
53
50
51
49
GREEN
MOTOR
BLACK/
WHITE
BLACK
59
58 RED
4b
GREEN/
YELLOW
4c
4c
48
89