Graco 25T804 Guide

3A8179C
EN
Operation, Parts
Cordless Electric Airless
Sprayers
For portable airless spraying of architectural paints and coatings (390 PC). For the
application of line striping materials (ES 500 Stencil). Not approved for use in
explosive atmospheres or hazardous (classified) locations. For professional use only.
390 PC Cordless Models: 25T804, 826280, 25T863, 25T943, 25T882, 25T805
ES 500 Stencil Models: 25U513, 25U514
3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this manual and related
manuals before using the equipment. Be familiar with the controls
and the proper usage of the equipment. Save these instructions.
Manual Description
311861 Gun (Contractor/FTX)
334599 Pump
3A6285 Gun (Contractor PC)
311254 Silver/Flex Plus
Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.

Contents
2 3A8179C
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Grounding Information . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stand Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hi-Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Installation and Removal . . . . . . . . . . . . . . . . . . . . . 17
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spray Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clear Tip Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cleaning Fluid Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Gun, Hose and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Models
3A8179C 3
Models
NOTE: See Gun, Hose and Labels, page 38 for spray gun information.
The 390 PC Cordless Sprayer is compatible with the following DEWALT® FLEXVOLT® 54V and
60V batteries:
•DCB606 - 60V/2ah (20V/6ah)
•DCB546 - 54V/2ah (18V/6ah)
•DCB609 - 60V/3ah (20V/9ah)
•DCB547 - 54V/3ah (18V/9ah)
•DCB548 - 54V/3ah (18V/12ah)
•DCB612 - 60V/4ah (20V/12ah)
Related DEWALT Manuals
Battery
Voltage VDC
Charger
Voltage VAC Model
Stand
Hi-Boy
60 USA/CA 120 USA/CA
390 PC Cordless 25T804 25T805
ES 500 Stencil 25U513
NOVA 390 PC
Cordless 826280
54 EMEA/UK 230 EMEA
ES 500 Stencil 25U514
390 PC Classic
Cordless 25T863
54 EMEA/UK 230 EMEA 390 PC Classic
Cordless 25T943
54 ANZ/AP 230 ANZ/AP 390 PC Cordless 25T882
Manual Description Region
N463494 DEWALT DCB118 Fast Charger Manual USA/CA
N463510
N463511
DEWALT DCB118-QW Fast Charger Manual
(Part 1 and 2)
EMEA
N501136 DEWALT DCB118-XE Fast Charger Manual ANZ/AP

Important Grounding Information
4 3A8179C
Important Grounding Information
Before using your sprayer read this Owners Manual for complete instructions on proper use and safety
warnings.
The following information is intended to help you understand when to use the grounding wire and clamp
provided with your sprayer.
Please read the information on the material container label to determine if it is oil-based or flammable. Ask
for a Safety Data Sheet (SDS) from your supplier. The container label and SDS 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 types:
Grounding
Wire and
Clamp
Required?
Type of Material
WATER-BASED: The container label should indicate that the material
can be cleaned up with soap and water.
OIL-BASED: The container label should indicate that the material is
COMBUSTIBILE and can be cleaned up with mineral spirits or
non-flammable paint thinner. 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. Follow Grounding Instructions, page 10, when
using this type of material.
FLAMMABLE: This type of material contains flammable solvents such
as xylene, toluene, naphtha, MEK, lacquer thinner, acetone, denatured
alcohol, and turpentine. The container label should indicate that this
material is FLAMMABLE. Use flammable materials outdoors or in a
well-ventilated area with a flow of fresh air. Follow Grounding
Instructions, page 10, when using this type of material.
No
Yes
Yes

Warnings
3A8179C 5
Warnings
The following warnings are for the setup, use, grounding, 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.
FIRE AND EXPLOSION HAZARD (GROUNDING)
Oil-based and flammable materials can generate static electricity when sprayed or flushed.
Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes. To
help prevent fire and explosion when using oil-based or flammable materials:
•Connect the grounding wire and clamp to a true earth ground.
•If there is static sparking or if you feel a shock, stop operation immediately. Do not use
sprayer until you identify and correct the problem.
•All parts of the spray system, including the pump, hose assembly, spray gun, and objects
in and around the spray area shall be properly grounded to protect against static discharge
and sparks. Use Graco conductive or grounded high-pressure airless paint sprayer hoses.
Follow Grounding Instructions, page 10.
•Verify that all containers and collection systems are grounded to prevent static discharge.
Do not use pail liners unless they are anti-static or conductive.
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 materials near an open flame or sources of ignition
such as cigarettes, motors, and electrical equipment.
•Do not use a paint or a solvent containing halogenated hydrocarbons.
•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.
•Keep pump assembly in a well-ventilated area at least 20 feet (6.1 m) from the spray area
when spraying, flushing, cleaning, or servicing. Do not spray pump assembly.
•Do not smoke in the spray area or spray where sparks or flame is present.
•Do not operate light switches, engines, or similar spark producing products in the spray
area.
•Keep 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 Safety Data Sheets
(SDSs) and container labels provided with the paints and solvents. Follow the paint and
solvent manufacturer’s safety instructions.
•Keep a working fire extinguisher in the work area.

Warnings
6 3A8179C
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious injury that can
result in amputation. In the event that injection occurs, get immediate surgical treatment.
•Do not aim the gun 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 use the spray tip guard. Do not spray without spray tip guard in place.
•Use Graco spray tips.
•Use caution when cleaning and changing spray tips. In the case where the spray tip clogs
while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving
the pressure before removing the spray tip to clean.
•Equipment maintains pressure after power is shut off. Do not leave the equipment
energized or under pressure while unattended. Follow the Pressure Relief Procedure
when the equipment is unattended or not in use, and before servicing, cleaning, or
removing parts.
•Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
•This system is capable of producing 3300 psi (228 bar, 22.8 MPa). Use Graco parts or
accessories that are rated a minimum of 3300 psi (228 bar, 22.8 MPa).
•Always engage the trigger lock when not spraying. Verify the trigger lock is functioning
properly.
•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.
•Always wear appropriate gloves, eye protection, and a respirator or mask when spraying.
•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.
•Do not kink or over-bend the hose.
•Do not expose the hose to temperatures or to pressures in excess of those specified by
Graco.
•Do not use the hose as a strength member to pull or lift the equipment.
•Do not spray with a hose shorter than 25 feet.
•Always replace cracked, broken or missing parts immediately with genuine Graco parts.
See Parts, page 32.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
•Use only in dry locations. Do not expose to water or rain.
•Use in well-lit areas.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Do not operate or clean sprayer with the battery shield open.

Warnings
3A8179C 7
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.
•Do not use chlorine bleach.
•Many other fluids may contain chemicals that can react with aluminum. Contact your
material supplier for compatibility.
BATTERY AND CHARGER COMPATIBILITY HAZARD
•Only use DEWALT brand 54V Max or 60V Max batteries and battery chargers with this tool.
•READ ALL INSTRUCTIONS included with this tool regarding the safety and usage of
DEWALT batteries and battery chargers.
•Do not wash or spray down battery.
•Do not clean the battery with anything other than a cloth moistened with water.
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 Safety Data Sheets (SDSs) 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut, or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
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. 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.

Component Identification
8 3A8179C
Component Identification
Stand Models
A ON/OFF Switch
B Pressure Control
C Prime/Spray Valve
F Tip Guard
G Spray Tip
H Gun
J Airless Hose
K Battery
L Trigger Lock
M Drain Tube
N Siphon Hose
P Pump
R Fluid Outlet
S Grounding Wire and Clamp
U Filter
V Finger Guard / TSL Fill Point
W Ground Outlet Adapter
X Ground Plug Adapter
Y Extension Tube for Stencil Gun
Model/Serial Tag (Not shown, located
on bottom of unit.)

Component Identification
3A8179C 9
Hi-Boy
A ON/OFF Switch
B Pressure Control
C Prime/Spray Valve
F Tip Guard
G Spray Tip
H Gun
J Airless Hose
K Battery
L Trigger Lock
M Drain Tube
N Siphon Hose
P Pump
R Fluid Outlet
S Grounding Wire and Clamp
T Filter
U Finger Guard / TSL Fill Point
V Pail Hook
W Ground Outlet Adapter
Model/Serial Tag (Not shown, located
on bottom of unit.)

Grounding Instructions
10 3A8179C
Grounding Instructions
(Oil-Based and Flammable Materials)
The sprayer is equipped with a grounding
wire and clamp. The clamp must be
connected to a true earth ground when
spraying or flushing oil-based or flammable
materials.
A water pipe can be used as a true earth
ground. Connect the grounding wire and
clamp to a metal water pipe.
A properly grounded electrical outlet can also
be used as a true earth ground. Use the
provided outlet adapter.
Plug the adapter in to a grounded outlet.
Connect the grounding wire and clamp to the
metal stud on the adapter. If the ground wire
is not long enough to reach a grounded
electrical outlet, use a 3-wire grounded
extension cord between the adapter and
outlet.
Fluid hoses: Use only electrically conductive
hoses with a maximum of 300 ft. (91 m)
combined hose length to ensure grounding
continuity.
Spray gun: Grounded through connection to
a properly grounded fluid hose and pump.
The equipment must be grounded to reduce
the risk of static sparking. A static spark can
cause fumes to ignite or explode causing
serious injury. A good ground provides an
escape wire for the electric current.

Grounding Instructions
3A8179C 11
Pails
Solvents and oil-based materials: follow
local codes and regulations. Use only
conductive metal pails, placed on a grounded
surface such as concrete.
Do not place pail on a non-conductive surface
such as paper or cardboard which interrupts
grounding continuity.
Always ground a metal pail: connect a
ground wire to the pail. Clamp one end to the
pail and the other end to a true earth ground
such as a water pipe.
To maintain ground continuity when
sprayer is flushed or pressure is relieved:
hold metal part of spray gun firmly to the side
of a grounded metal pail then trigger the gun.
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Pressure Relief Procedure
12 3A8179C
Pressure Relief Procedure
Follow the Pressure Relief
Procedure whenever you see this
symbol.
1. Engage the trigger lock.
2. Turn the ON/OFF switch to the OFF
position. Power button is illuminated
when ON. Wait 7 seconds for power to
dissipate.
3. Turn pressure control to lowest setting.
Disengage the trigger lock.
4. Hold a metal part of the gun firmly to a
grounded metal pail. Trigger the gun to
relieve pressure.
5. Engage the trigger lock.
This equipment stays pressurized until
pressure is manually relieved. To help
prevent serious injury from pressurized
fluid, such as skin injection, splashed fluid
and moving parts, follow the Pressure
Relief Procedure whenever sprayer is
stopped and before sprayer is cleaned or
checked, and before equipment is
serviced.
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Pressure Relief Procedure
3A8179C 13
6. Put drain tube in a pail. Turn prime/spray
valve down. Leave prime/spray valve in
down (drain) position until you are ready
to spray again.
7. If you suspect the spray tip or hose is
clogged or that pressure has not been
fully relieved:
a. VERY SLOWLY loosen the tip
guard retaining nut or the hose end
coupling to relieve pressure
gradually.
b. Loosen the nut or coupling
completely.
c. Clear hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when sprayer
is stopped to prevent the gun from being
triggered accidentally by hand or if dropped
or bumped.

Setup
14 3A8179C
Setup
When unpacking sprayer for the first time or
after long term storage perform setup
procedure. When first setup is performed
remove shipping plug from fluid outlet.
1. Connect Graco airless hose to fluid
outlet. Use two wrenches to tighten
securely.
2. Connect other end of hose to gun.
3. Use wrenches to tighten securely.
4. Engage trigger lock.
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Setup
3A8179C 15
5. Remove tip guard.
6. When unpacking sprayer for the first
time remove packaging materials from
inlet strainer. After long term storage
check inlet strainer for clogs and debris.
7. Fill throat packing nut with TSL to
prevent premature packing wear. Do this
daily or each time you spray.
a. Place the TSL bottle nozzle into the
top center opening in the grill at the
front of the sprayer.
b. Squeeze bottle to dispense enough
TSL to fill the space between the
pump rod and packing nut seal.
8. Make certain ON/OFF switch is OFF.
Power button is illuminated when it is
ON.
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Setup
16 3A8179C
9. Turn prime/spray valve down.
10. Place fluid intake with drain tube in
grounded metal pail partially filled with
flushing fluid. When spraying oil-based
or flammable, follow Grounding
Instructions, page 10.
11. Turn pressure control to lowest setting.
12. Install battery, see Battery Installation
and Removal, page 17.
13. Turn ON/OFF switch to ON position.
14. Increase pressure 1/2 turn to start motor.
Allow fluid to flush through sprayer for
one minute.
15. Turn prime/spray valve horizontal.
Disengage trigger lock.
16. Hold a metal part of the gun firmly to a
grounded metal pail. Trigger gun and
flush until clean.
17. Turn ON/OFF switch to OFF position.
18. Remove gun and engage trigger lock.
19. If the initial flushing fluid is not
compatible with the material that is to be
sprayed, a second flush is needed.
Repeat steps 11-18.
20. Re-install tip guard, see Spray Tip
Installation, page 20.
21. Sprayer is now ready to start up and
spray.
NOTE: New sprayers are shipped with
storage fluid that must be flushed out with
mineral spirits prior to using the sprayer.
Check flushing fluid for compatibility with
material that is to be sprayed, see Cleaning
Fluid Compatibility, page 26. A secondary
flush with a compatible fluid may be
necessary.
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Setup
3A8179C 17
Battery Installation and
Removal
Always start with a fully charged Battery.
Do not splash or immerse Battery or
charger in water. See Battery and charger
information shipped with the sprayer.
Remove and install Battery into the sprayer
as follows:
1. Remove the used Battery, if in place.
2. Install battery by aligning the battery
pack with the rails inside the sprayer and
sliding it in until the battery pack is firmly
seated. Ensure that it does not
disengage.
Replace and charge Battery only in a
well-ventilated area and away from
flammable or combustible materials,
including paints and solvents.

Startup
18 3A8179C
Startup
1. Perform Pressure Relief Procedure,
page 12.
2. Turn pressure control to lowest
pressure.
3. Install battery, see Battery Installation
and Removal, page 17.
4. When spraying oil-based or flammable
material, follow Grounding
Instructions, page 10.
5. Turn ON/OFF switch to ON position.
Power button is illuminated when it is
ON.
6. Place fluid intake in paint pail. Place
drain tube in waste pail.
7. Increase pressure 1/2 turn to start motor.
Allow paint or other material to circulate
through sprayer until material flows out
the drain tube.
8. Turn prime/spray valve horizontal.
Disengage trigger lock.
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Startup
3A8179C 19
9. Hold gun against grounded metal waste
pail. Trigger gun at least 1 minute until
paint appears.
10. Move gun to paint pail and trigger for 20
seconds. Release trigger and allow
sprayer to build pressure. Engage
trigger lock.
11. Inspect Airless Hose and hose
connections for leaks. If leaks occur,
perform Pressure Relief Procedure ,
page 12, then tighten all fittings and
repeat Startup procedure. If there are no
leaks, continue with Operation , page 20.
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1 m
High-pressure spray is able to inject toxins
into the body and cause serious bodily
injury. Do not stop leaks with hand or rag.

Operation
20 3A8179C
Operation
Spray Tip Installation
1. Perform Pressure Relief Procedure,
page 12.
2. Use spray tip (A) to insert OneSeal™ (B)
into tip guard (C).
3. Insert Spray Tip.
4. Screw assembly onto gun. Tighten.
Spray
NOTE: If spraying oil-based or flammable
material, follow Grounding Instructions,
page 10.
When a RAC X™ FF LP Fine Finish Low
Pressure reversible spray tip is used,
spraying pressure can be lowered. Spraying
at a lower pressure results in less overspray
and reduces spray tip wear. Adjust the
sprayer pressure to minimize overspray.
To avoid serious injury from skin injection,
do not put your hand in front of the Spray
Tip when installing or removing the Spray
Tip and Spray Tip Guard.
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C
B
A
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Atomized, evenly
distributed fan pattern
Tails
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