Graco 16N655, 16N654, 16N656, 16N927, 16H960 User Manual
Operation - Parts - Repair
Protective Coating
Hand-Held Paint Sprayer
- 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.
Model
16H960 ✓
16N654 ✓
16N927
16N655 ✓
16N656 ✓
3A2308C
EN
-
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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 . . . . . . . . . . . . . . . . . . . . . . . . 8
Common Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starting a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install/Service Filter (if needed) . . . . . . . . . . . . . . . . . 13
Install Tip/Guard Assembly (if not installed) . . . . . . . . 14
Filling and Installing Cup . . . . . . . . . . . . . . . . . . . . . . 14
Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Setting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Getting Started with Basic Techniques . . . . . . . . . . . 17
Triggering Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Aiming Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unclogging Spray Tip/Guard Assembly . . . . . . . . . . . 18
Shutdown and Cleaning . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning Sprayer Exterior . . . . . . . . . . . . . . . . . . . . . 21
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Spray Pattern Diagnostics . . . . . . . . . . . . . . . . . . . . . 26
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Outlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure Control Knob . . . . . . . . . . . . . . . . . . . . . . . . 30
Pump Module/Drive Module . . . . . . . . . . . . . . . . . . . . 31
Pump Rebuild Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Clamshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motor/Control Board Replacement Kit . . . . . . . . . . . . 35
Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FCC Declaration for Battery Charger . . . . . . . . . . . . . . . 41
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 44
Important User Information
Before using your sprayer read this Operation Manual for complete instructions on proper use and safety warnings.
DO NOT RETURN THIS SPRAYER TO THE STORE!
If you experience problems, contact Graco Product Support at 1-888-541-9788 or visit www.graco.com.
Before using this equipment, be sure to read and follow the information on your container label and ask for a Material Safety
Data Sheet (MSDS) from your supplier. The container label and MSDS will explain the contents of the material and the
specific precautions related to it.
Paints, coatings and clean-up materials generally fit into one of the following 3 basic categories:
WATER-BASED:
Your sprayer is compatible with this type of material. Your sprayer is NOT compatible with harsh cleaners such as
chlorine bleach.
OIL-BASED:
mineral spirits or paint thinner. The MSDS must indicate that the flash point of the material is above 100° F. Your
sprayer is compatible with this type of material. Use oil-based material outdoors or in a well-ventilated indoor area
with a flow of fresh air. See the safety warnings in this manual.
FLAMMABLE:
thinner, acetone, denatured alcohol, and turpentine. The container label should indicate that this material is
FLAMMABLE. Your sprayer is compatible with this type of material. Use flammable materials outdoors or in a
well-ventilated indoor area with a flow of fresh air. See the safety warnings in this manual.
The container label should indicate that the material can be cleaned up with soap and water.
The container label should indicate that the material is COMBUSTIBLE and can be cleaned up with
This type of material contains flammable solvents such as xylene, toluene, naphtha, MEK, lacquer
2 3A2308C
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.
WARNING
FIRE AND EXPLOSION HAZARD (GROUNDING)
Some oil-based and flammable materials generate static electricity when sprayed. Static electricity creates
an explosion and fire risk. Your sprayer has a ground wire that will conduct the static electricity to earth
ground. The sprayer and all objects in spray area must be properly grounded to protect against static
discharge, sparks or shocks.
• Connect the ground wire when spraying flammable or static producing oil-based materials.
• If there is static sparking or if you feel a shock, stop spraying immediately and connect the sprayer to
earth ground with the ground wire provided.
GROUNDING INSTRUCTIONS
Clamp sprayer ground wire to earth ground.
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FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• 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.
• Paint or solvent flowing through the sprayer is able to result in static electricity. Static electricity creates
a risk of fire or explosion in the presence of paint or solvent fumes. The sprayer and all objects in spray
area shall be properly grounded to protect against static discharge, sparks, or shocks.
• Always connect the ground wire provided when spraying flammable materials or static producing
oil-based materials. See Grounding Instructions above.
• If there is static sparking or you feel a shock, stop operation immediately and connect sprayer to earth
ground with the ground wire provided.
• Do not spray flammable or combustible materials near open flame or sources of ignition such as
cigarettes, external motors, and electrical equipment.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Do not smoke in the spray area.
• Keep spray area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets
(MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents
manufacturer’s safety instructions.
• Fire extinguisher equipment shall be present and working.
3A2308C 3
Warnings
WARNING
WARNINGWARNINGWARNING
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.
• Always use the spray tip guard. Do not spray without spray tip guard in place.
• Use caution when cleaning and changing spray tips. In the case where the spray tip clogs while spraying,
follow the Pressure Relief Procedure for relieving the pressure before reversing or removing the spray tip
to clean.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, follow the
Pressure Relief Procedure and engage the trigger lock.
• Check parts for signs of damage. Replace any damaged parts with genuine Graco parts.
• This system is capable of producing 4000 psi. Use replacement parts or accessories that are rated a minimum of 4000 psi.
• Do not carry the sprayer with a finger on the trigger.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Disconnect the battery before servicing.
• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.
• Do not operate or spray near children. Keep children away from equipment at all times.
• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
• Stay alert and watch what you are doing.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Use only in dry locations. Do not expose to water or rain.
• Use in well-lit areas.
• Always replace cracked, broken or missing parts immediately with genuine Graco parts. See Parts List,
page 23.
BATTERY HAZARD
The battery may leak, explode, cause burns, or cause an explosion if mishandled. Contents of an open battery
can cause severe irritation and/or chemical burns. If on skin, wash with soap and water. If in eyes, flush with
water for at least 15 minutes and seek immediate medical attention.
• Replace battery only in a well-ventilated area and away from flammable or combustible materials; including paints and solvents.
• When battery is not in use, keep it away from metal objects like keys, nails, screws or other metal objects
that can short circuit the battery terminals.
• Do not throw into fire.
• Charge only with Graco-approved charger as listed in this manual.
• Do not store at temperatures below 32° or above 113° F (0° to 45° C).
• Do not use at temperatures below 40° or above 90° F (4° to 32° C).
• Do not expose battery to water or rain.
• Do not disassemble, crush, or penetrate the battery.
• Do not charge a battery that is cracked or damaged.
• Follow local ordinances and/or regulations for disposal.
4 3A2308C
Warnings
WARNING
WARNINGWARNINGWARNING
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.
• Charge only Graco batteries listed in this manual; other batteries may burst.
• Use only in dry locations. Do not expose to water or rain.
• Do not use a charger that is cracked or damaged.
• If the supply cord is damaged, replace the charger or cord, depending on model.
• Never force the battery into the charger.
• When operating a charger outdoors, always provide a dry location and use an extension cord suitable for
outdoor use.
• Disconnect the charger from the outlet before cleaning.
• Ensure that the outside surface of the battery is clean and dry before plugging into the charger.
• Do not attempt to charge non-rechargeable batteries.
• Do not disassemble the charger. Take charger to authorized service center when service or repair is
required.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for
compatibility.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye
injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited
to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A2308C 5
Component Identification
Component Identification
M
A
R
P
N
K
B
C
D
E
F
G
H
J
Ref. Description
A Accumulator
B Pressure Control Knob
C Sprayer Status Indicator
D Trigger Lock
E Trigger
F Static Wick
G Ground Wire Assembly with Clamp
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Ref. Description
H Battery
J Pressure Relief Valve / Prime Valve
KCheck Valve
M Material Cup
N Spray Tip Assembly
P Front Shut-Off Valve
R Material Filter
6 3A2308C
Operation
Operation
Charging the Battery
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. It will take approximately 75 minutes to fully charge a dead battery.
1. Place charger in a dry, well-ventilated area and
away from flammable or combustible materials,
including paints and solvents.
2. Plug charger into an electrical outlet and slide battery into charger as shown (light will turn on in 5
seconds).
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3. When battery becomes fully charged, immediately
unplug the charger from the power supply and
remove the battery from the charger.
NOTE: The amount sprayed with each battery varies
depending on material, spray tip size, battery charge,
and battery temperature. One battery fully charged will
spray up to one gallon. Amount sprayed will be less
depending on spray tip size, material sprayed, life of
battery, temperature, and other environmental factors.
Charger Status Indicator Lights
Label Appearance Description
Solid green light Indicates a full charge. Battery can be used.
Flashing green light
Flashing red light
Solid red light
Both lights Battery has internal fault or has experienced damage. Do not use.
Battery is charging, indicates 80% charge.
Battery can be used.
Battery is charging, indicates less than 80% charge.
Do NOT use battery.
Battery is too hot or too cold to charge. Remove battery and allow to cool or
warm up before charging. Battery temperature must be between
50° F - 113° F (10° C - 45° C) to charge.
3A2308C 7
Sprayer Status Indicator
Operation
Red
Yellow
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No light Normal operation. No action required.
Battery is too hot. Unit will
shut down until battery has
Solid Red
Flashing Red
Solid Yellow
Flashing Yellow
Solid red and solid yellow Locked motor.
cooled.
Liquid has contacted control
board.
Motor is too hot and will shut
down if heavy use continues.
Unit will shut down until motor
has cooled.
Battery is low or
battery is too cold.
High pressure signal. Gun will
shut down after 1.5 seconds.
Change battery.
Allow battery to cool.
Allow unit to dry.
Increase tip size.
Turn down pressure.
Let unit cool down.
Charge battery.
Warm up battery.
Turn pressure control
counter-clockwise to reduce
pressure.
Increase tip size.
Material is too thin--do not thin
as much.
Bring sprayer in to service center for diagnostics.
*NOTE: The sprayer status indicator light is visible for 10 seconds after the trigger is released.
8 3A2308C
Operation
Common Procedures
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.
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Trigger Locked
Pressure Relief Procedure
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. For
example, do not try to stop the paint flow with any part
of the body.
This sprayer builds up an internal pressure of 4000 psi
during use. 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.
1. Engage trigger lock.
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Trigger Unlocked
(red ring is visible)
Prime/Pressure Relief Valve Position
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(For priming and releasing
UP position
pump pressure)
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DOWN position
(Ready to spray)
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2. Put prime/pressure relief valve UP to release pressure.
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Spray Tip Position
Always perform Pressure Relief Procedure before
adjusting spray tip position.
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Tip Forward
(SPRAY position)
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Tip Reversed
(UNCLOG position)
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3A2308C 9
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.
NOTE: To reduce overspray and extend battery life,
always spray at lowest pressure that results in an
acceptable spray pattern.
Operation
4. You MUST start with dial at “1” and gradually
increase by increments of “1” or less until desired
spray pattern is achieved. Put pressure relief handle
in UP position to turn pressure control knob, then
return handle to DOWN position to spray.
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1. Put the pressure relief valve UP to relieve pressure.
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2. Turn pressure control knob:
Clockwise to INCREASE pressure, or
Counter-clockwise to DECREASE pressure.
THIN
MATERIAL
THICK
MATERIAL
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0 1 2 3 4 5 6 7 8 9 10 11
3. Dial in pressure by spraying material on a scrap
material.
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10 3A2308C
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.
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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.
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NOTE: Thin materials will generally require a low
setting and thick materials will generally require a
high setting.
IMPORTANT!
After storage, the piston seals need to be energized
prior to next use to prevent leakage. To energize, follow
steps below:
1. Prime system with flushing fluid.
2. Spray at low pressure setting “1” for 10 seconds.
3. Drain fluid. You are now ready to spray.
3A2308C 11
Setup
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.
Starting a New Job
NOTICE
Always flush any cleaning material from the previous
use before starting a new job. If the new spraying
material is not compatible with leftover material in the
pump, adverse reactions could ruin new material.
Operation
3. Thread lid onto cup and connect cup to sprayer.
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4. Put prime/pressure relief valve in UP position.
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NOTE: 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. Spray at low pressure setting “1” for 10 sec-
onds.
c. Drain fluid. You are now ready to spray.
NOTICE
Do NOT spray zinc coatings or materials with
aggregate. Accelerated pump wear will occur.
1. Engage trigger lock.
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2. Install liner into cup and fill liner 1/2 full with appropriate cleaning fluid for material about to be
sprayed.
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5. You MUST set pressure control to setting “1”.
6. Disengage trigger lock, turn sprayer upside-down
and trigger for approximately 5 seconds to recirculate material.
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12 3A2308C
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.
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8. Engage trigger lock and put prime/pressure relief
valve UP to release pressure.
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9. Remove material cup.
10. Disengage trigger lock, put prime/pressure relief
valve DOWN to spray position, hold sprayer slightly
above material cup and pull trigger to discharge fluid
from pump.
Install/Service Filter (if needed)
1. Perform Pressure Relief Procedure, page 9.
2. Unthread front valve housing from sprayer.
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3. Filter should come out of pump housing with valve.
If filter remains in housing, remove it by hand or with
pliers if necessary.
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4. Install properly-sized filter (if needed).
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11. Put prime/pressure relief valve UP and pull trigger to
finish flushing material.
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12. Properly discard any material in cup.
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5. Reassemble valve housing to pump.
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3A2308C 13
Operation
Install Tip/Guard Assembly (if not installed)
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.
1. Engage trigger lock and put prime/pressure relief
valve UP to relieve pressure.
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2. Install liner into material cup and fill with material.
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3. Thread lid onto material cup and connect cup to
sprayer. NOTE: Do not squeeze sides of cup while
threading lid onto cup.
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NOTE: Check valve can be oriented in three locations when attached to cup. If squeezing liner with
left hand, position check valve on left side. If
squeezing liner with right hand, position check valve
on right side.
Do NOT place hands in front of tip.
2. Screw Tip/Guard Assembly onto sprayer. Tighten
retaining nut until completely engaged with sprayer.
Do not overtighten nut.
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Filling and Installing Cup
1. Engage trigger lock and put prime/pressure relief
valve UP to relieve pressure.
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4. Squeeze liner to purge air through check valve until
material is present at check valve.
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NOTE: To purge the maximum amount of air out of
the liner, slightly tilt the sprayer so the check valve is
the highest point.
14 3A2308C
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