OWNER’S MANUAL 820–204 Rev. K Supercedes Rev. G, H & J This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE U.S. PATENT NO.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Function and Identification . . . . . . . . . . . . 5 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. D Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious injury. Get immediate medical attention. D Do not point the gun at anyone or at any part of the body.
WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. D If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem. D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
Component Function and Identification B DC A E F G H J K 04512A Fig.
Setup WARNING If you supply your own hoses and spray gun, be sure the hoses are electrically conductive, that the gun has a tip guard, and that each part is rated for at least 3000 psi (210 bar, 21 MPa) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or over– pressurization and rupture of the hose or gun. 5. Fill the wet–cup (L). Pry off the wet–cup seal. Fill the cup 1/3 full with Graco Throat Seal Liquid (TSL) (68) supplied. Install the seal. 6.
Setup 8. Flush the pump to remove the oil which was left in to protect pump parts after factory testing. See page 12. 9. Prepare the paint according to the manufacturer’s recommendations. Remove any paint skin. Stir the paint to mix pigments. Strain the paint through a fine nylon mesh bag (available at most paint dealers) to remove particles that could clog the gun filter or spray tip. This is an important step toward trouble-free paint spraying.
Setup Pressure Relief Procedure WARNING PRESSURIZED EQUIPMENT HAZARD The equipment stays pressurized until pressure is manually relieved.
Startup 1 Shown in closed, or spray position. 2 Open, or drain position + – B N M C 1 J 2 Model 820–206 Shown 03193A Fig. 7 Use this procedure each time you start the sprayer to help ensure the sprayer is ready to operate and that you start it safely. NOTE: If this is a first–time startup, flush the sprayer. See page 12. 1. Open the pressure drain valve (J). See Fig. 7. 2. Don’t install the spray tip until the pump is primed! 3. Put the suction hose or tube (M) into the paint.
Startup WARNING FIRE AND EXPLOSION HAZARD To reduce static sparking and splashing when priming, be sure the spray tip is not installed on the gun, and hold a metal part of the gun firmly to the side of a grounded metal pail. NOTE: Spray patterns will change as tips wear. Change the spray tip if adjusting the pressure will not improve the spray pattern. 1 B 7. To prime the hose, lower the pressure to reduce splashing.
Shutdown and Care WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. 8. Coil the hose when storing it, even for overnight, to help protect the hose from kinking, abrasion, coupling damage, etc. WARNING INJECTION HAZARD See the warning section INJECTION HAZARD on page 3 for information on the hazard of using damaged hoses. 1. Relieve pressure. 2. Check the packing nut/wet-cup daily.
Flushing When to flush CAUTION Determine the material you are going to pump from Column 1, then flush with the material indicated in Column 2. Depending on what you plan to do next, follow the recommendations in one of the next three columns. Column 1 Column 2 NEVER leave water or water-based fluids in the sprayer if there is a chance it could freeze. Push the water out with mineral spirits. Frozen fluid in the sprayer prevents it from starting and may cause serious damage.
Flushing WARNING FIRE AND EXPLOSION HAZARD To reduce static sparking and splashing, always remove the spray tip from the gun, and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing. 7. Lower the pressure setting. Turn on the sprayer. Maintaining metal-to-metal contact, trigger the gun into the flushing pail. Slowly increase the sprayer pressure just until the pump starts. Keep the gun triggered until the solvent flows freely from the gun.
Troubleshooting WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of serious injury, always follow the Pressure Relief Procedure on page 8 before checking or repairing any part of the sprayer. CAUTION Thaw sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm area. Do not try to start sprayer until it has thawed completely or damage to motor and/or control board may occur.
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. Check motor brushes for the following: a. Loose terminal screws. b. Broken or misaligned brush springs. 4. Refer to page 21. 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 assure free vertical brush movement.
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. Check for worn spray tip. 1. Follow Pressure Relief Procedure Warning on page 8, 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 momentarily, then release and engage safety latch.
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 7. Check motor control board (47) by substituting with a good board. 7. Replace board. See page 27. (continued) 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. Check motor armature for shorts by using an arma- 8. Replace motor.
Intermediate Problem Solving TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check Spray Pattern Variations (continued) 4. Check pressure adjustment potentiometer (64) by replacing it with a new one. Motor Is Hot and Runs Intermittently 1. Determine if sprayer was operated at high pressure 1. Decrease pressure setting or increase tip with small tips, which causes excessive heat build size. up. Building Circuit Breaker Opens As Soon As Sprayer Switch Is Turned O On.
General Repair Information WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. 3. Route wires carefully and avoid pinching any wires between covers. CAUTION Improper wire routing can result in poor sprayer performance or damage to the pressure transducer. Tool List These service tools are required.
Motor Test Armature Short Circuit Test WARNING Remove the fan cover (B). See Fig.12. INJECTION HAZARD To reduce the risk of serious injury, always follow the Pressure Relief Procedure on page 8 before doing this procedure. Unplug the sprayer! 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 replaced. See page 26.
Motor Brushes NOTE: Replace brushes when worn to about 12.5 mm (0.5 in.) . Always check both brushes. Brush Repair Kit 236–967 is available for motors manufactured by Pacific Scientific. Consult Rev. A of this manual for repair kit and instructions if your unit has a Leeson motor. 8. Test the brushes. a. Remove the pump connecting rod pin (17). b. With the sprayer OFF, turn the pressure control knob fully counterclockwise to minimum pressure. Plug in the sprayer. c.
Displacement Pump NOTE: Packing Repair Kit 235–703 is available. Reference numbers of parts included in the kit are marked with an asterisk, i.e., (121*). 6. Use a screwdriver to push the retaining spring (18) up and push out the pin (17). 7. Loosen the screws (21). Remove the pump (20). NOTE: To minimize down time, and for the best sprayer performance, check the motor brushes (see page 21) and clean the transducer (see page 30) whenever you repack the pump. Replace these parts as needed.
Displacement Pump Disassembling the pump (See Fig. 19) 13 17 1 Torque to 50 ft–lb (68 N.m) 2 Apply pipe sealant (42e) 1. Remove the intake valve (118). 2. Loosen the packing nut (102) and plug (123). 3. Use a plastic mallet to tap the piston rod (107) down, and then pull the rod out through the bottom of the cylinder. 120 18 85 *122 4. Remove the packing nut (102) and throat packings. *121 5. Loosen the jam nut (117). Remove the cylinder (115) and the o-ring (116*).
Displacement Pump 1 CAUTION Step 8, tightening the piston valve into the rod, is critical. Follow the procedure carefully to avoid damaging the packings by overtightening. 2 Do not allow nut (110) to move relative to piston (108) when tightening piston against rod. Torque nut against rod to 30 ft–lb (40 N.m) 6. Hand tighten the valve into the piston rod just until the nut (110) contacts the rod. See Fig. 21. 123 Lips down. 2 Lips up.
Displacement Pump 107 123 102 102 101 *103 *105 1 1 104* PLASTIC LEATHER 106* *116 101 107 110 *111 2 *113 117 112* 2 PLASTIC LEATHER 116* 108 117 1 115 2 115 Torque jam nut (117) 73 ft-lb (98 N.m) 2 Torque cylinder (115) into manifold (101) to 53 ft-lb (71 N.m) 3 118 3 Torque intake valve (118) into cylinder (115) to 53 ft-lb (71 N.m) Fig. 22 1 120 *119 3 1 114* 125* 126* 01072A 118 1 Lips face down. 2 Lips face up. 3 Torque to 53 ft-lb (71 N.
Motor 9. Remove the two screws (46) and lift the motor off the cart (1). WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. NOTE: See Fig. 26 except where noted. 10. Align the new motor with the cart and reinstall the screws (46). 11. Assemble the drive housing to the motor. Follow steps 9 to 15 on page 28. Install the junction box. 12. Connect the wires to the control card. Refer to Fig. 13.
Motor Control Board 4. Remove the screw (9) from the ground wire (G) and remove the board. WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. 5. Install the new motor control board. Reconnect all wires and secure it to the junction box (59). CAUTION To reduce the risk of a malfunction: 1. Relieve pressure. 2. Remove the screws (56,75) and lower the control card (47). See Fig. 26.
Drive Housing, Connecting Rod, Crankshaft WARNING CAUTION INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. NOTE: Inspect parts as they are removed. Replace parts that are worn or damaged. 1. Relieve pressure. 2. Remove the displacement pump. See page 22. Do not allow the gear (16) to fall; it may stay attached to the drive housing or to the motor.
Drive Housing, Connecting Rod, Crankshaft 12 1 6,5 12a 19 12b 6 16 B C 11a Note: Filter not shown 15 47 A 29 11 1 Torque to 80 in–lb (9 N.m) 1 75 56 02995 Fig.
Pressure Transducer NOTE: See Fig. 28 and 29 for this procedure. NOTE: The pressure transducer (29) cannot be repaired or adjusted. If it malfunctions, replace it. 3. Guide the harness up through the leg and notch of the drive housing (11). Secure the guide wire over the connector. 4. While pulling the guide wire out through the bottom of the motor, guide the harness through the drive housing and motor castings.
Pressure Transducer Seal NOTE: The PTFE seal is unaffected by most solvents and materials. Replacement of the seal is recommended only when leakage has occurred. Installation 1. Lightly coat the cleaned packing recess in the manifold with a light grease or oil. 2. Heat the packing (7) in hot water for several minutes. Removal CAUTION WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. 1.
Suction Hose (Model 820–206) WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. CAUTION Misalignment or cross-threading will damage the parts and/or create shavings which can cause the o-ring (27) to leak. 1. Relieve pressure. 2. Remove the drain hose (33) from the clip. 3. Pull upward on the suction hose (32) while unscrewing it from the inlet tube (38).
Drain Valve Repair WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 8. 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. 1. Relieve pressure. 2. Turn the handle (45) to the closed position. Drive out the pin (44). Remove the handle. 3.
Complete Sprayer Parts Model 820–206, Series B 1 Ref 3 Ref 63 58 62 3 Ref 53 39 30 6 5 2c 2a 2b 9 2 4 12b 4a 3 86 60 33 12 32 1 11 70 6 22 11a 16 19 77 12a 59 46 71 57 15 34 72 35 76 29 7 40 73 75 47 13 17 18 85 42 20a 10 20 21 36 56 25 45 43 44 27 38 04390A 28 65 69 64 Pressure Control Box (Bottom View) 48 52 54 50 34 820-204 51 49 55 03020
Complete Sprayer Parts Model 820–206, Series B Ref. No. Part No. 1 2 2aY 2bY 2cY 3 4 4a 4b 4c 4eY 4fY 4gY 5 6 7 8 9 10 11 11a 12 12a 12b 13 15 16 17 18 19 20 20a 21 22 25 27H 28 29 30 32 33 34 35 36 38 39 236–367 236–510 187–791 187–975 187–784 189–934 238–682 100–069 107–265 Description Qty.
Complete Sprayer Parts Model 820–208, Series B 3 5 4 6 2c 2a 2b 9 58 86 12b 62 12 78 63 4a 11 60 53 6 11a 16 19 15 77 34 13 12a 72 35 76 29 7 59 46 71 73 75 1 47 85 56 17 18 20a 80 22 42 10 40 57 81 79 36 45 21 20 33 30 25 43 44 32 28 04513A 39 65 69 64 Pressure Control Box (Bottom View) 48 52 54 50 36 820-204 51 49 55 03020
Complete Sprayer Parts Model 820–208, Series B Ref. No. Part No.
Displacement Pump Parts Model 237–662 Series A 123 Ref. No. Part No. Description 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 MANIFOLD, pump PACKING NUT GLAND, female, throat V–PACKING, plastic, throat V–PACKING, leather, throat GLAND, male.
Technical Data Power Requirements . . . . . . . . . . . . . . 120 VAC, 60 Hz, 1 phase, 15A minimum Generator . . . . . . . . . . . . . . . . . . . . . . . 3000W minimum Working Pressure Range . . . . . . . . . . . . . . . . 0–3000 psi (0–210 bar, 21 MPa) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 HP Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . 530 (140) Delivery . . . . . . . . . . . . . . . . . . . . . . . . 0.55 gpm (2.1 lpm) Tip Size . . . . . .
Sherwin-Williams Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor 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.
