Operation - Parts - Repair Protective Coating Hand-Held Paint Sprayer 3A2308C EN - For portable spray applications of protective coatings - For professional use only - Not approved for use in explosive atmospheres or hazardous locations - DO NOT SPRAY ZINC COATINGS OR MATERIALS WITH AGGREGATE. ACCELERATED PUMP WEAR WILL OCCUR 4000 psi (27.6 MPa, 276 bar) Maximum Working Pressure IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual. Save these instructions.
Table of Contents Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Charger Status Indicator Lights . . . . . . . . . . . . . . . . . . 7 Sprayer Status Indicator . . . . . . . . . . . . . . . . . . . . . . . .
Warnings Warnings The following warnings are for the setup, use, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING WARNING SKIN INJECTION HAZARD High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment. • Do not aim the sprayer at, or spray any person or animal. • Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body. • Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
Warnings WARNING WARNING CHARGER ELECTRIC SHOCK, FIRE AND EXPLOSION HAZARD Improper setup or usage can cause electric shock, fire, and explosion. • Charge only in a well-ventilated area and away from flammable or combustible materials, including paints and solvents. • Do not charge on a combustible or flammable surface. • Do not leave battery unattended while charging. • Immediately unplug charger and remove battery when charging is complete.
Component Identification Component Identification A B C R D E P F N G M H K J ti19345a Ref. 6 Description Ref.
Operation Operation Charging the Battery 2. Plug charger into an electrical outlet and slide battery into charger as shown (light will turn on in 5 seconds). Replace and charge battery only in a well-ventilated area and away from flammable or combustible materials, including paints and solvents. Batteries are initially 50% charged to provide optimum battery life and require charging before first use. It takes approximately 50 minutes to charge a dead battery to 80%, at which point it can be used.
Operation Sprayer Status Indicator Red No light Normal operation. No action required. Change battery. Solid Red Battery is too hot. Unit will shut down until battery has cooled. Yellow Liquid has contacted control board. Allow battery to cool. Allow unit to dry. Flashing Red Motor is too hot and will shut Increase tip size. down if heavy use continues. Turn down pressure. Unit will shut down until motor Let unit cool down. has cooled. Solid Yellow Battery is low or battery is too cold.
Operation Common Procedures Pressure Relief Procedure Trigger Lock Follow the Pressure Relief Procedure whenever you see this symbol. Always engage the trigger lock when you stop spraying to prevent the sprayer from being triggered accidentally by hand, or if dropped or bumped. ti14994a ti14995a ti19350a Do not operate or spray near children. Do not aim the sprayer at, or spray any person or animal. Keep hands and other body parts away from the discharge.
Operation Adjusting Pressure NOTE: Spraying water, solvents, and thin materials (low viscosity materials) at high pressure (setting “2” or higher with yellow light flashing) can result in temporary pump leaking. To avoid, read and follow instructions (Quick Guide or Manual) on how to properly adjust pressure. 4. You MUST start with dial at “1” and gradually increase by increments of “1” or less until desired spray pattern is achieved.
Operation 5. If yellow light is flashing while triggering, pressure is set too high. You MUST turn down pressure until yellow light no longer flashes, increase tip size, or do not thin material as much. 6. If pressure relief valve is vibrating, pressure is set too high. You MUST turn down pressure, increase tip size, or do not thin material as much. ti19655a ti19656a ti19654a ti19653a NOTE: Thin materials will generally require a low setting and thick materials will generally require a high setting.
Operation Setup 3. Thread lid onto cup and connect cup to sprayer. Flammable fumes (such as solvent and paint fumes) in work area can ignite or explode. See Grounding Instructions, page 3. Do not spray flammable or combustible liquids in a confined area. Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. NOTICE Your sprayer is NOT compatible with harsh cleaners such as chlorine bleach. Using these cleaners will cause damage to the sprayer.
Operation 7. Reverse tip to UNCLOG position. Put prime/pressure relief valve DOWN to spray position and trigger sprayer through tip into waste area for 1- 2 seconds. Install/Service Filter (if needed) 1. Perform Pressure Relief Procedure, page 9. 2. Unthread front valve housing from sprayer. ti19370a ti19346a ti14995a ti19366a 8. Engage trigger lock and put prime/pressure relief valve UP to release pressure. ti19362a ti19347a 3. Filter should come out of pump housing with valve.
Operation Install Tip/Guard Assembly (if not installed) 2. Install liner into material cup and fill with material. NOTE: Only use Graco Tip/Guard assemblies. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. ti19348a 3.
Operation Priming Pump Setting Pressure 1. Put prime/pressure relief valve UP to priming position. NOTE: Spraying water, solvents, and thin materials (low viscosity materials) at high pressure (setting “2” or higher with yellow light flashing) can result in temporary pump leaking. To avoid, read and follow instructions (Quick Guide or Manual) on how to properly adjust pressure. 1. To reduce overspray and extend battery life, always spray at lowest pressure that produces an acceptable spray pattern.
Operation 4. If yellow light is flashing while triggering, pressure is set too high. You MUST turn down pressure until yellow light no longer flashes, increase tip size, or do not thin material as much. 5. If pressure relief valve is “popping”, pressure is set too high. You MUST turn down pressure, increase tip size, or do not thin material as much. ti19655a ti19656a ti19654a ti19653a NOTE: If not enough pressure can be achieved for an acceptable pattern, reduce tip orifice size and repeat steps.
Operation Getting Started with Basic Techniques Triggering Sprayer Use a piece of scrap cardboard to practice these basic spraying techniques before you begin spraying the surface. Pull trigger after starting stroke. Release trigger before end of stroke. Sprayer must be moving when trigger is pulled and released. Hold sprayer 10 in. (25 cm) from surface and aim straight at surface. Tilting sprayer to direct spray angle causes an uneven finish. (25 cm) 10 in.
Operation Unclogging Spray Tip/Guard Assembly 5. Disengage trigger lock, put prime/pressure relief valve DOWN to spray position, and resume spraying. Always perform the Pressure Relief Procedure (page 9) before unclogging spray tip. ti19374a 1. To unclog tip obstruction, engage trigger lock and put prime/pressure relief valve UP to relieve pressure. ti19346a 6. If tip is still clogged, it may be necessary to repeat steps 1 - 5 and rotate the tip from SPRAY to UNCLOG several times.
Operation Shutdown and Cleaning 3. Remove cup from sprayer. NOTICE Failure to properly clean sprayer after each use will result in hardened materials, damage to the sprayer, and the warranty will no longer be valid. Do not store solvents other than mineral spirits in sprayer. Flushing Sprayer ti19360a 4. Remove lid from cup. Do not spray solvents through the spray tip. Clean the tip in a bucket of compatible solvent. Keep spray area well-ventilated.
Operation 7. Disengage trigger lock, turn sprayer upside-down and trigger for approximately 15 seconds to recirculate material. 11. Remove cup and properly dispose contaminated fluid. ti19385a ti19374a ti14994a 12. Refill liner 1/2 full. Disengage trigger lock, turn sprayer upside-down and trigger sprayer for approximately 15 seconds to recirculate material. To avoid serious injury or damage to equipment, do not expose the sprayer electronics to flushing solvents. Keep sprayer at least 10 in.
Operation Cleaning Sprayer Exterior Wipe paint off outside of sprayer using a soft cloth moistened with water or flushing fluid. Do NOT submerge the sprayer or pump. 3. Disengage trigger lock, turn sprayer upside-down and trigger for approximately 10 seconds to recirculate material. ti19374a ti19358a 4. Reverse tip to UNCLOG position. Put prime/pressure relief valve DOWN to spray position and trigger sprayer through tip into waste area for 1- 2 seconds.
Parts Parts 40 59 33 57 18 11 32 60 34 58 55 41 56 53 22 31 54 49 16 51 50 52 21 35 44 20 15 7 18 17 61 19 63 39 38 25 26 27 28 30 24 3 29 42 43 4 37 2 10 47 13 36 46 65 6 45 48 62 64 ti19153a 22 3A2308C
Parts Parts List Ref.
Troubleshooting Troubleshooting Check everything in this Troubleshooting Table before you bring the sprayer to an authorized service center. Problem Sprayer makes no sound when trigger is pulled Cause Trigger is locked. Solution Disengage trigger lock. See page 9. Status Indicator Light is solid YELLOW Replace with charged battery and when triggering, indicating that the bat- place old battery in charger, or allow tery charge is low, or the battery is too battery to warm up. cold.
Troubleshooting Problem Sprayer sprays with poor results Cause Solution Tip is partially clogged See Unclogging Tip/Guard Assembly, page 18. Tip filter is partially clogged or damaged. Clean or replace filter. See page 13. Material being sprayed is aerated because it was shaken. Do NOT shake material. Stir the material or check the manufacturer’s recommendation for the material being sprayed. Material being sprayed is too cold to spray. Warm material. Pressure adjustment is not set correctly.
Troubleshooting Problem Cause Paint leaks from bottom of pump module. Solution Piston seal failure. Replace pump module. See Repair manual. Replace piston seals. See Repair manual. Water or thin cleaning fluids drip from bottom of pump module. Thin fluids commonly drip while spraying at high pressure. After storage, the piston seals need to be energized prior to next use to prevent leakage. To energize, follow steps below: a. Prime system with flushing fluid. b.
Troubleshooting Problem Cause Spray pattern has dripping: Spray pattern is too narrow: ti15523a ti15523a Spray pattern is too wide: Solution Sprayer is moving too slow for material. Move sprayer faster while spraying. Sprayer is too close to target surface. Move sprayer away from surface 10 in. (25 cm) Holding trigger while changing spray direction. Release trigger when changing directions. Incorrect tip for application of material. Replace tip. Pressure control is too high.
Repair Repair Inlet Valve Installation 1. Insert ball guide (25) with smaller diameter inserted first. Removal 25 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19615a ti19347a ti19350a 2. Use a thin wire to assemble spring into inlet cavity. 2. Remove material cup and battery. ti19612a ti19360a ti19617a 3. Hold sprayer upside-down and use wrench or socket to loosen fitting. Remove inlet fitting (29), inlet ball (27), spring, and ball guide (25).
Repair Outlet Valve 5. Clean as much excess material from outlet valve cavity as possible. Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19614a ti19347a ti19350a Installation 2. Remove material cup and battery. NOTE: Inlet valve must be fully installed before outlet valve can be installed. 1. Make sure prime/pressure relief valve is in UP position. Use a thin screwdriver or allen wrench and turn outlet valve (31) counter-clockwise to install.
Repair Pressure Control Knob Installation NOTE: Inlet valve must be fully installed before outlet valve can be installed. Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19350a 1. Make sure prime/pressure relief valve is in UP position. Use a thin screwdriver or allen wrench to turn outlet valve counter-clockwise until it touches inlet ball. DO NOT TIGHTEN. Outlet valve should only be threaded until inlet ball does not move when touched.
Repair Pump Module/Drive Module 5. Remove pump module (35) from drive module (11). 11 35 Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19625a Installation 1. Engage trigger lock and remove battery from unit. ti19347a ti19350a 2. Remove material cup and battery. ti19350a ti19617a ti19617a ti19360a 3. Unscrew swivel bolt (22) by pressing down and turning it counter-clockwise. Use tool if needed. 2.
Repair Pump Rebuild Kit Installation 1. Hold rebuild kit (15) and insert wobble drive into piston pocket and connect together. Removal 1. Remove pump module from drive module. See Pump Module/Drive Module, page 31. 15 2. Remove outlet valve from pump module and set aside. See Outlet Valve, page 29. 3. Remove inlet valve from pump module and set aside. See Inlet Valve, page 7. 4. Remove accumulator (16), front valve (18), and prime valve (17) from pump module and set aside. 16 ti19642a 2.
Repair Clamshell 6. Remove nut from ground stud. Remove ring terminal and unscrew second nut from ground stud. Remove ground stud from clamshell. Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19638a 7. Carefully remove motor, motor housing, switch, control board, indicator lights, trigger lock, and static wick from clamshell. ti19347a ti19350a 2. Remove material cup and battery. ti19639a ti19617a ti19360a 3.
Repair 3. Set motor housing into right half of clamshell and loosely install two bolts (42) to motor housing as shown below. 7. Press ground stud into left half of clamshell. Tighten nut onto stud. Install ground terminal to stud and tighten second nut onto stud. Install wire up along handle. 42 ti19629a ti19633a 4. Route wires from motor down the handle. 8. Insert static wick into right half of clamshell and install left clamshell to right clamshell. ti19630a 5. Install trigger over top of wires.
Repair Motor/Control Board Replacement Kit 6. Unscrew nut from ground stud and remove ring terminal. Leave other nut secured to ground stud. Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19640a 7. Remove motor, motor housing, switch, control board, indicator lights, trigger lock, and static wick from clamshell. ti19347a ti19350a 2. Remove material cup and battery. ti19617a ti19360a ti19639a 3. Remove pump module from drive module.
Repair 3. Set motor housing into right half of clamshell and loosely install two bolts (42) to motor housing as shown below. 7. Install ground terminal to stud and tighten second nut onto stud. Install wire up along handle. 42 ti19629a ti19641a 8. Insert static wick into right half of clamshell and install left clamshell to right clamshell. 4. Route wires from motor down the handle. ti19634a ti19630a NOTICE 5. Assemble trigger over top of wires. Route trigger wires behind trigger.
Repair Switch Assembly 5. Remove eight screws (43) from clamshell. 43 Removal 1. Engage trigger lock and put prime/pressure relief valve in UP position to relieve pressure. ti19347a ti19637a ti19350a 6. Remove trigger lock from assembly. 2. Remove material cup and battery. ti19649a ti19617a ti19360a 3. Remove pump module from drive module. See Pump Module/Drive Module, page 31. 7. Remove trigger switch from clamshell and loosen screws connecting wires to switch. 4.
Repair Installation 1. Insert wires and tighten screws to connect wires into slots 1 and 2 of trigger switch. 3. Install trigger lock over trigger with o-ring facing out. ti19648a 2. Install trigger over top of wires. Route trigger wires behind trigger. ti19632a 4. Install bolts (42) into motor housing and install screws (43) to connect the clamshell halves. Make sure LED lights and static wick are properly in place. Tighten all four bolts (42) to 50 in-lb (5.6 N•m) and screws (43) to 9 in-lb (1 N•m).
Repair Gear Replacement 4. Remove four screws holding clamshells together and two bolts connecting drive to clamshell. Removal 1. Remove pump module from drive module. See Pump Module/Drive Module, page 31. ti19861a ti19877a 5. Pull the clamshell up and unscrew retaining bolt until gear (48) is no longer retained. Remove gear from drive. Proceed to Installation. ti19625a 2. If unit has accessible retaining bolt shown below, proceed to step 3.
Repair 2. If unit has accessible retaining bolt shown below, proceed to step 3. If unit does not have accessible retaining bolt, proceed to step 5. 5. Install new gear into drive housing. Pull the clamshell up and screw in retaining bolt to retain gear. Torque to 30 in-lb (3.4 N•m). ti19860a ti19858a 3. Install new gear into drive housing. Screw retaining bolt into drive housing to retain gear. Torque to 30 in-lb (3.4 N•m). ti19879a 6. Install two bolts connecting drive to clamshell.
Technical Data Technical Data Models 16H960, 16N654, 16N927, 16N655, 16N656 U.S. Metric Sprayer: Adjustable Pressure Range 1000 to 4000 psi 69 to 276 bar, 6.9 to 27.6 MPa Maximum Working Pressure 4000 psi 276 bar, 26.7 MPa Weight 8.6 lb 3.9 kg Length 14.5 in. 36.8 cm Width 5.6 in. 14.2 cm Height 12.8 in. 32.
Notes Notes 42 3A2308C
Notes Notes 3A2308C 43
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
